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W270B
Wheel Loader
Bur 87661531
Use for Service Manual

W270B Wheel Loader
Service Manual
87661531
Table of Contents
Description Section No.
General Tab 1
Section Index - General
Standard Torque Specifications 1001
Fluids and Lubricants 1002
Metric Conversion Chart 1003
Engines Tab 2
Section Index - Engines
Engine and Radiator Removal and Installation 2000
Aftercooler 2003
Fuel System Tab 3

Section Index - Fuel System
For Fuel System Repair, See the Engine Service Manual
Electrical Tab 4
Section Index - Electrical
Removal and Installation of Starter and Alternator 4001
Electrical Specifications and Troubleshooting 4002
Batteries 4003
Instrument Cluster 4005
Copyright © 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia Issued III-2007
W270B Wheel Loader
Service Manual
87661531
Table of Contents
Steering Tab 5
Section Index - Steering
Removal and Installation of Steering Components 5001
Steering Specifications, Pressure Checks, and Troubleshooting 5002
Steering Cylinders 5005
Center Pivot 5006
Auxiliary Steering Motor and Pump 5007
Power Train Tab 6

Section Index - Power Train
Removal and Installation of Power Train Components 6001
Transmission Specifications, Pressure Checks, and Troubleshooting 6002
Transmission 6003
Front and Rear Axle 6004
Drive Shafts, Center Bearing, and Universal Joints 6005
Wheels and Tires 6006
Transmission Control Valve 6007
Brakes Tab 7
Section Index - Brakes
Removal and Installation of Brake Components 7001
Hydraulic Brake Troubleshooting 7002
Brake Accumulators 7004
Parking Brake 7008
Hydraulics Tab 8
Section Index - Hydraulics
Removal and Installation of Hydraulic Components 8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002
Cleaning the Hydraulic System 8003
Hydraulic Pump 8004
Loader Control Valve 8005
Cylinders 8006
Pilot Pressure Accumulator and Ride Control Accumulator 8013
Ride Control Valve 8014
W270B Wheel Loader
Service Manual
87661531
Table of Contents
Mounted Equipment Tab 9
Section Index - Mounted Equipment
Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant 9002
Air Conditioner System Service 9003
Removal and Installation of Air Conditioning and Heater Components 9004
Loader 9006
ROPS Cab and ROPS Canpoy 9007
Cab Glass Installation 9010
Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket

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

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Section
1001
GENERAL TORQUE SPECIFICATIONS

1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
b oth UN C a nd UNF th re ad s as rec eive d fr om
suppliers dry, or when lubricated with engine oil. Not
ap plic able if sp ecial g rap hities , Mo ly disulfid e
greases, or other extreme pressure lubricants are
Pound- Newton
used.
Size Inches metres
1/4 inch 144 to 180 16 to 20
Grade 5 Bolts, Nuts, and Studs
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73
Pound- Newton Pound- Newton

Size Inches metres Size Feet metres
1/4 inch 108 to 132 12 to 15 7/16 inch 70 to 84 95 to 114
5/8 inch 220 to 264 298 to 358
Pound- Newton 3/4 inch 380 to 456 515 to 618
Size Feet metres
7/8 inch 600 to 720 814 to 976
7/16 inch 54 to 64 73 to 87
1.0 inch 900 to 1080 1220 to 1465
1/2 inch 80 to 96 109 to 130
1-1/8 inch 1280 to 1440 1736 to 1953
9/16 inch 110 to 132 149 to 179
1-1/4 inch 1820 to 2000 2468 to 2712
5/8 inch 150 to 180 203 to 244
1-3/8 inch 2380 to 2720 3227 to 3688
3/4 inch 270 to 324 366 to 439
1-1/2 inch 3160 to 3560 4285 to 4827
7/8 inch 400 to 480 542 to 651
NOTE: Use thick nuts with Grade 8 bolts.
1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983
1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

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

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

Size Feet metres M30 1470 to 1770 2000 to 2400
M12 66 to 79 90 to 107 M36 2580 to 3090 3500 to 4200
M14 106 to 127 144 to 172
Grade 12.9 Bolts, Nuts, and Studs
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
12.9
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
Usually the torque values specified for grade 10.9
M36 1600 to 1950 2175 to 2600 fasteners can be used satisfactorily on grade 12.9
fasteners.
1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

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

Pound- Newton
Size Inches metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube OD Size Inches metres Size Inches metres
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
Dash Thread Pound- Newton 1-3/16-12 95 to 100 129 to 136
Size Tube OD Size Inches metres
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
19.0 mm
-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190
31.8 mm
-24 1-1/2 inch 2-12 150 to 180 200 to 254
38.1 mm
Section
1002
FLUIDS AND LUBRICANTS

1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMISSION OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Model W270B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model W270B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1002-3
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change .............................................................................................37 liters (39 U.S. quarts)
Type of oil........................... AMBRA Mastergold HSP SAE 15W-40, see engine oil recommendations on page 4
Engine Cooling System
Capacity...................................................................................................................56.8 liters (15.0 U.S. Gallons)
Type of Coolant ...................................................................AMBRA Agriflù 50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ................................................................................................................. 393.6 liters (104 U.S. Gallons)
Type of Fuel ............................................................................................................. See Diesel fuel specifications
Hydraulic System
Hydraulic Reservoir Refill Capacity with Filter Change ................................................130 liters (34 U.S. Gallons)
Total System Capacity ............................................................................................242 liters (63.93 U.S. Gallons)
Type of Oil .................................................................................................................. AMBRA Hydrosystem 46HV
Transmission
Refill Capacity with Filter Change ...............................................................................22 litres (5.81 U.S. Gallons)
Type of Oil .................................................................................................. AMBRA Supergold HSP SAE 10W-30
Axles
Capacity
Front.................................................................................................................... 47.3 litres (12.50 U.S. Quarts)
Rear ............................................................................................................................. 53 litres (14 U.S. Quarts
Type of Lubricant .....................................................................................AMBRA TRX Transaxle Fluid, 80W-140
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an
alternate oil. Machines are shipped from the factory with break-in oil.
Brake System
Type of Fluid (Same as Hydraulic System) ................................................................ AMBRA Hydrosystem 46HV
ENGINE OIL RECOMMENDATIONS

New Holland AMBRA Engine oil is recommended
See the cha rt below for
for use in your New Holland engine. New Holland
rec ommended visc osity at
AMBRA En g ine O il will lu b rica te y ou r e ng in e
ambie nt air tempe ratu re
correctly under all operating conditions.
ranges.
If New Holland AMBRA Multi-Viscosity Oil is not
NOTE: Do not put performance
available, use only oil meeting API engine oil service
additives or other oil additive
category CH -4 (preferred) or CG-4.
products in the engine crankcase.
The oil change intervals given in this
RH99K130
manual are according to tests with
New Holland AMBRA lubricants.
1002-4
HYDRAULIC OIL TEMPERATURE CHART
BC06B208
TRANSMISSION OIL TEMPERATURE CHART
BC06B209
ENGINE OIL TEMPERATURE CHART
BC06B150
1002-5
DIESEL FUEL SYSTEM

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

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

API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60°C (140°F)
Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above
Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum .................................................................................................... 0.05%
1002-6
MAINTENANCE SCHEDULE
Model W270B
INTERVALS IN HOURS
SERVICE
INTERVALS PAGE SERVICE POINTS
Every 5-16 Engine oil level 10

10 Hours 5-16 Drain fuel filter 10
5-17 Checking the tension of belts 10
5-18 Engine coolant level 50
5-18 Radiator and oil cooler 50
Every 5-19 Transmission oil level 50
50 Hours 5-19 Hydraulic oil level 50
5-20 Bucket/Attachments grease fittings 50
5-20 Grease articulation fittings 50
Every
5-21 Grease points 100
100 Hours
5-23 Recirculation air filter 250
Every 5-23 Engine coolant filter 250

250 Hours 5-24 Tire pressure 250
5-26 Replace fuel filter 250
5-27 Axle oil level 500
Every 5-27 Battery electrolyte level 500

500 Hours 5-28 Change engine oil and filter 500
5-29 Drain fuel tank condensation 500
5-30 Replace hydraulic oil filters 1000
5-31 Grease articulation fittings 1000
Every
5-31 Change front and rear axle oil 1000
1000 Hours
5-32 Replace cab air filters 1000
5-33 Change transmission oil and filters 1000
Every
Check valve adjustment See your New Holland Dealer or refer to Service Manual
1500 Hours
Every 5-34 Change hydraulic oil 2000

2000 Hours 5-35 Change coolant 2000
5-36 Replace engine air cleaner 2000
Every Engine Injectors See your New Holland Dealer or refer to Service Manual
6000 Hours
Fuel pump See your New Holland Dealer or refer to Service Manual
1002-7
MAINTENANCE POINTS
Model W270B
W270M115
See your Operators manual for maintenance of If you operate the machine in severe conditions,
safety related items and for detailed information of lubricate and service the machine more frequently.
the service items on this chart. Operators and service
manuals are available for this machine from your
dealer.
1002-8
NOTES
Section
1003
METRIC CONVERSION CHART

1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot
hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch
meter 3.280 840 foot
kilometer 0.621 371 mile
Mass: kilogram 2.204 622 pound
Mass/Area: kilogram/hectare 0.000 466 ton/acre
Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.
Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.
Power: kilowatt 1.341 02 horsepower
Pressure: kilopascal 0.145 038 lb/sq. inch
bar 14.50385 lb/sq. inch
Temperature: degree C 1.8 x C +32 degree F
Torque: newton meter 8.850 748 lb/inch
newton meter 0.737 562 lb/foot
Velocity: kilometer/hr. 0.621 371 miles/hr.
Volume: cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)
litre/min. 0.219 969 gallon/min. (Imperial)
1003-4
U.S. to Metric
MULTIPLY BY TO OBTAIN
Area: square foot 0.092 903 square meter
acre 0.404 686 hectare
Force: ounce force 0.278 014 newton
pound force 4.448 222 newton
Length: inch 25.4 * millimeter
foot 0.304 8 * meter
mile 1.609 344 * kilometer
Mass: pound 0.453 592 kilogram
ounce 28.35 gram
Mass/Area: ton/acre 2241 702 kilogram/hectare
Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr
Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter
Power: horsepower 0.745 700 kilowatt
Pressure: lbs/sq. in. 6.894 757 kilopascal
lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm
Temperature: degree F 1.8 F - 32 degree C
Torque: pound/inch 0.112 985 newton meter
pound/foot 1.355 818 newton meter
Velocity: miles/hr. 1.609 344 * kilometer/hr.
Volume: cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact
SECTION INDEX
ENGINES
Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000

Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003
FOR THE REMOVAL, INSPECTION, OVERHAUL AND REINSTALLATION OF

THE ENGINE, PLEASE REFER TO THE SPECIFIC MANUALS FOR THIS TYPE
OF ENGINE AVAILABLE FROM THE SERVICE NETWORK.
Section
2000
ENGINE AND RADIATOR REMOVAL AND

INSTALLATION

2000-2
TABLE OF CONTENTS
Engine . . . . . ............................................................................. 4
Removal . ............................................................................. 4
Installation ............................................................................ 14
RADIATOR . ............................................................................ 26
Removal . ............................................................................ 26
Installation ............................................................................ 28
2000-3
39 40
29 37 38
31 32
35
41
36 30
3 35 36 33 34
2
1
5 22 25 21
4
12
14
24 23 18
10
14
26
16 6 12 19 20
13
17 10
27
8
14 28
7
15 6
14 9
10
11
W270-1R003
1. RIGHT AFTERCOOLER TUBE 8. PLATE 15. HOSE 22. TUBE 29. BRACKET 36. BOLT
2. LEFT AFTERCOOLER TUBE 9. BOLT 16. PIPE 23. HOSE 30. MOUNT 37. WASHER
3. HOSE 10. WASHER 17. CLAMP 24. CLAMP 31. WASHER 38. BOLT
4. HOSE 11. BOLT 18. BOLT 25. CLAMPA 32. BOLT 39. WASHER
5. HOSE CLAMP 12. NUT 19. BUSHING 26. TAPE ADESIVE 33. WASHER 40. BOLT
6. WASHER 13. HOSE 20. PIN 27. HOSE 34. NUT 41. SPACER
7. MOUNT 14. CLAMP 21. HOSEE 28. STRAP 35. WASHER
2000-4
ENGINE
Removal STEP 3
STEP 1
W270-1R008
O pen the e ngine hoo d upp er side pan els and

W270-1R006 remove the engine hood lower side panels, by
Park the machine on a flat surface and lower the turning the two p lastic blocks indica ted in the
bucket to the round. Place the articulation block in figure.
BLOCK position.
STEP 4
STEP 2
W270-1R009
W270-1R007 Drain the hydraulic oil from the reservoir using a

hose from the draining valve into a container of
appropriate capacity (130 litres - 34 US Gal) to keep
the liquid drained. To facilitate the operation, loosen
the filler cap on the hydraulic tank.
2000-5
STEP 5 STEP 7
W270-1R010 W270-1R012
Place a container of appropriate capacity under the Sling and hold the left rear mudguard complete with
machine in correspondence with the radiator draining handrail and remove it from the machine by removing
pipe. Open the valve and drain the coolant into the the securing screws (q.ty 6).
container. To facilitate the draining of the coolant Replicate the operation on the right rear mudguard.
loosen the filler cap.
STEP 8
STEP 6
W270-1R013
W270-1R011 Also, sling and hold the cab left side ladder, then
Place a container of about 45 litres - 12 US Gal remove it from the machine removing the relevant
under the transmission oil draining and drain it by screws (q.ty 6).
loosening the securing screws (q.ty 2) indicated in Replicate the operation on the right ladder.
the figure holding the oil filler plug.
2000-6
STEP 9 STEP 12
1�
2�
W270-1R014 W270-1R017
Remove the left side upper door from the relevant Remove dust ejector rubber hose (1) by loosening
hinges indicated in the figure. Replicate the operation the clamps (2).
on the right side upper door.
STEP 13
STEP 10
2�
1�
W270-1R018
W270-1R015 Remove the fumes exhaust pipe from the engine
From the engine upper hood, loosen the clamp (1) upper hood by removing the securing nuts (q.ty 4)
and remove the air cleaner rain guard device (2). under the hood from the studs welded to the pipe
support plate.
STEP 11
1�
2�
W270-1R016
Remove pipe (1) from th e turbo cha rger to the

silencer by loosening the clamps (2).
2000-7
STEP 14 STEP 16
1�
W270-1R019 W270-1R021
Remove the front upper hood by removing the Open the radiator-after cooling rear guard grill by
securing screw s (q.ty 8). Slin g the hood in an unscrewing side screws (1, q.ty 2) to reach the
appropriate manner, lift it and rest it onto the ground. disassembly screws of the rear upper engine hood.
Secure the grill using the rod located on the right side
STEP 15 of the radiator compartment.
2� STEP 17
1�
1�
W270-1R020
Remove silencer (1) from the supports located on the

beams of the engine upper hood by removing the W270-1R022
securing nuts (q.ty 4) from rubber pad blocks (2, q.ty Remove securing screws (1, q.ty 3) of the engine
4). upper rear hood.
STEP 18
W270-1R023
Remove hood (1) from the machine.

2000-8
STEP 19 STEP 22
1�
2�
1�
W270-1R024 W270-1R027
Disconnect hose (1) between the coolant tank and Remove air-cooling steel pipe (1) from the engine to
the radiator. the radiator-after cooler by opening of the clamps (2,
q.ty 2).
STEP 20
STEP 23
1�
W270-1R025
Remove the engine central upper hood by removing W270-1R028
all the securing screws (q.ty 15). Disconnect the air pipe (1) from the turbocharger to
the radiator-aftercooler.
STEP 21
STEP 24
1
W270-1R026
Sling the hood in an appropriate manner, lift it and W270-1R029
rest it onto the ground. Disconnect pipe (1) from the water pump to the
radiator by loosening the clamps (q.ty 3).
2000-9
STEP 25 STEP 28
1�
1�
2�
2�
W270-1R030 W270-1R033
Disconnect the engine air cleaner suction pipe (1) by From the right side of the central sector located
loosening the clamps (2, q.ty 2). between the engine and radiator-after cooler remove
panel (1) by removing the securing screws (q.ty 9) to
STEP 26 reach to the engine air cleaner removing screws.
3� STEP 29
2�
1�
1�
W270-1R031
If the machine is equipped with air conditioner,

recover the gas making reference to section 9003 W270-1R034
then identify tag and disconnect de-hydration filter (1) Remove screws (1, q.ty 4) securing the engine air
electric connection (2) and pipe (3). cleaner to the sector through the opening.
STEP 27 STEP 30
1�
1
W270-1R032 W270-1R035
Tag and disconnect hose (1) from the condenser to Remove engine air cleaner (1).
the cab conditioner compressor.
2000-10
STEP 31 STEP 33
4� 5�
1�
3�
2�
W270-1R036 W270-1R038
Use adequate cables for the weight to be lifted to Identify, tag and disconnect hoses (2,3,4,5) from the
sling the central sector located between the engine radiator liquid tank (1).
and the radiator-after cooler to prevent accidental
falls during the disassembly phase of the machine. STEP 34
STEP 32
2�
1�
1�
3� W270-1R039
From the left side of the engine, shut valve (1) of the
W270-1R037 cab heating pipes.
Free the sector from safety chain (1) of the fuel cap
and engine oil dipstick (2). Remove the sector from STEP 35
engine compartment by removing securing screws
(3, q.ty 4). 1
2�
W270-1R040
If the machine is equipped with air conditioning,

identify, tag and disconnect the refrigerant gas
high-pressure the pipings (2) from compressor (1).
2000-11
STEP 36 STEP 39
1�
1
2�
W270-1R041 W270-1R044
Remove the fuel feeding (1 ) pipe from e ngine Disconnect the two electric connections (1) from the
controller and the piping and filter (2). engine controller by removing the locking screw
using a 4 mm Allen wrench.
STEP 37
STEP 40
2�
1�
3�
W270-1R042
Identify, tag and disconnect the electric connections W270-1R045
indicated from starter motor (1). Remove relay cover Identify, tag and disconnect the electric connections
(2) from the relay box by removing screw (3) to indicated from the alternator.
access the box securing nuts on the hydraulic oil
tank. STEP 41
STEP 38
1�
W270-1R046
Identify, tag and disconnect all the pipes and hoses

W270-1R043 connected to the lower side of the hydraulic oil tank.
Remove nuts (1, q.ty 2) and remove the fuses and
relays box.
2000-12
STEP 42 STEP 44
W270-1R047 W270-1R049
Install two lifting eyes on the upper side of the Using the chains previously installed, lift the tank
hydraulic oil tank then use appropriate chains to sling paying attention to any possible spill of residual oil
and hold the tank to prevent accidental falls during from the tank. Rest the tank on the appropriate
the disassembly phase of the machine. supporting stand.
STEP 43 STEP 45
W270-1R048 W270-1R050
Remove the screws (q.ty 4) securing the hydraulic oil Remove the cab from the machine, making reference
tank to the rear frame of the machine. to section 9007.
STEP 46
Disconnect all hydraulic lines, electric connections
and propeller shafts from the transmission, following
the procedure described in section 6001.
2000-13
STEP 47 STEP 50
W270-1R051 W270-1R054
Remove the screws from the engine front supports Install adjustable chains, as indicated in the figure, to
(q.ty 2). the transmission-torque converter group to make the
performance of the subsequent operations safe.
STEP 48
STEP 51
1�
W270-1R052
Replicate the operation for the engine rear support. W270-1R055
From the right side of the engine-transmission group,

STEP 49 remove panel (1) located on the torque converter
cover by removing screws (2, q.ty 4) to reach the
securing screws engine-converter coupling located
inside.
W270-1R053
2000-14
STEP 52 STEP 54
W270-1R058
Using the adjustable chains previously installed,

remove the transmission group from the engine
group and rest it on an appropriate stand.
Installation
STEP 55
If the rubber pad devices of the engine (7, see figure
at page 3) and transmission (30) must be replaced
and install new rubber pad.
W270-1R056
Remove the inner screws (q.ty 12) turning the engine STEP 56
crankshaft. For this operation, remove two screws
from vibration dumper, insert on the vibration dumper
the tool illustrated on the page, reinstall with the two
s cr e w s r e mo v e d t h e n tu r n slo w ly th e e n g in e
crankshaft by means of a lever.
STEP 53
W270-1R059
Grease the mounting flanges of the transmission

group and the engine group for the subsequent
coupling phase.
W270-1R057
Remove the outer screws (q.ty 12) securing the

torque converter cover to the engine.
2000-15
STEP 57 STEP 59
W270-1R060 W270-1R062
U s in g t h e a dj u st a b le ch a in s in st a lle d o n t h e From the s ide right opening located on the

transmission group, proceed with the coupling with tr an smis sio n co n ve rte r co ve r , in se rt , w it ho u t
the engine group. Pay special attention, during the tightening them, all the inner screws (q.ty 12) turning
lifting of the transmission group, to the perfect p ro gre ss iv ely th e en gin e c ran ks ha ft. For th is
balancing and alignment with the engine group. operation, remove two screws from the vibration
dumper, insert on the vibration dumper the tool
STEP 58 indicated on the page 25, with the two screws
removed, and then turn slowly the crankshaft by
means of a lever.
Tighten all the screws to a torque of 40 lb-ft (55 Nm).
STEP 60
W270-1R061
Insert, at first, two or three outer screws, without

ti g h te n in g t h e m , to tr y a lig n in g p e rf e ct ly t h e
transmission group with the engine group. Then
insert all the outer screws (q.ty 12) tightening them to
a torque of 48 lb-ft (65 Nm). W270-1R063
Insert the closing panel on the access opening of the

inner screws applying first some sealant along the
perimeter of the panel. Secure it using screws (1, q.ty
4).
2000-16
STEP 61 STEP 63
1�
W270-1R053 W270-1R065
Install on the engine-transmission group adjustable Align perfectly the support holes and insert, without
chains of appropriate lifting capacity. These chains tightening them, the securing screws complete with
must be mounted on the three appropriate lifting washers and nuts (1, q.ty 2) on the two engine rear
points provided for such operation. supports to be used as a guide for the correct
positioning of the engine-transmission group on the
STEP 62 rear frame of the machine.
STEP 64
W270-1R064
Lift slowly the e ngine-transmission group an d

position it on the rear frame. Make sure that all W270-1R066
harness and hose connections are not interfering, Insert, without tightening them, securing screws (1,
then lower the group. q.ty 2) complete with washers and nuts on the
transmission supports. Make sure that the
engine-transmission group is properly positioned on
the frame, then tighten to a torque between 685 to
770 lb-ft (929 and 1044 Nm) the front support screws
and a torque of 285 to 320 lb-ft (386 through 434
Nm) the nuts of the rear supports.
STEP 65
C o n n e c t a ll t h e h y d r a u l ic li n e s a n d e l e c t r i c
connections to the transmission, following the
procedures described in section 6001.
2000-17
STEP 66 STEP 68
W270-1R067 W270-1R048
Install lifting eyes on the hydraulic oil tank and, using Tighten the tank securing screws to a torque of 220
chains of appropriate lifting capacity, lift it and lb-ft (300 Nm).
position it on the frame of the machine for the
subsequent securing phases. STEP 69
STEP 67 4� 5�
1
3� 2�
3�
2�
1�
W270-1R038
Connect hoses (2,3,4,5) to radiator liquid tank (1)

W270-1R068 tightening the relatives clamps.
Insert the screws securing the hydraulic oil tank (q.ty
4) to the rear frame of the machine and connect, STEP 70
during this phase, sleeves (1) and hoses (2) to the
relevant connection properly greased. Tighten the
sleeves using the metal clamps tightening device (3).
W270-1R036
Using cables, sling properly the sector, lift it and

position it on the rear frame of the machine, between
engine and radiator-after cooler, for the subsequent
reinstallation phase.
2000-18
STEP 71 STEP 74
1�
2�
2�
1�
W270-1R035 W270-1R072
Prior to securing the sector, install engine air cleaner Secure electric connection (1) on the sector installing
(1) otherwise, its installation could become difficult. screws (2, q.ty 2) on the mounting brackets.
STEP 72 STEP 75
1�
1�
W270-1R034 W270-1R073
Insert screws (1, q.ty 4) securing the air cleaner Secure the sector on the rear frame of the machine
through the right side opening of the sector. tightening screws (1, q.ty 4) to a torque of 80 lb-ft
(110 Nm).
STEP 73
STEP 76
3
2�
1�
1�
W270-1R071
Install the panel on the opening engine wall and W270-1R031
secure it with screws (1, q.ty 9). If the machine is equipped with air conditioner,
connect de-hydration filter (1) electric connection (2),
pipe (3) and the refrigerant gas of the pipings on the
compressor.
2000-19
STEP 77 STEP 80
1
2�
1�
W270-1R029 W270-1R027
Connect engine cooling pipe (1) using by means the Connect air-cooling pipe (1) from the engine to the
clamps. radiator-aftercooler with the clamps (2).
STEP 78 STEP 81
1�
2�
2�
W270-1R030 W270-1R026
Connect engine air cleaner suction pipe (1) with the Use cables to sling appropriately the central upper
clamps (2). engine hood and position it on the machine for the
subsequent reinstallation phase. Secure the hood to
STEP 79 the machine, installing, without tightening them all
the screws (q.ty 15).
1�
W270-1R028
Connect air heating pipe (1) from the engine to the

radiator-aftercooler with the clamps.
2000-20
STEP 82 STEP 85
2�
1�
1�
W270-1R024 W270-1R020
Connect hose (1) between the radiator coolant tank Install silencer (1) on the supports located on the two
and the radiator and secure it in the two points engine upper hood inserting the securing nuts (q.ty
arranged along the right beam of the upper central 4) and the relevant rubber pad (2, q.ty 4).
engine hood.
STEP 86
STEP 83
2�
1�
1�
2�
W270-1R017
W270-1R023 Connect dust ejector rubber hose (1) to the silencer
Position engine rear upper hood (1) on the machine. tightening the two clamps (2).
STEP 84 STEP 87
1� 2�
1�
W270-1R022 W270-1R081
Open the radiator-after cooler rear guard grill by Install pipe (1) from the turbocharger to the silencer
loosening the side screws (q.ty 2) to access the hood tightening holders (2).
securing screws (1, q.ty 3).
Tigh the three srews of the upper rear hood.
2000-21
STEP 88 STEP 90
W270-1R019 W270-1R018
Use lifting cables to sling the engine front upper hood Install the fumes exhaust pipe on the engine upper
and position it on the machine for the securing phase hood, inserting from the lower side of the hood itself,
by inserting the screws (q.ty 8) without tightening the securing nuts (q.ty 4) on the studs welded on the
them. After positioning correctly the three parts of the pipe supporting plate.
engine upper hood, tighten all the screws of the hood
assembly. STEP 91
STEP 89
1�
W270-1R050
Reinstall the cab on the machine referring to the

W270-1R015 procedures described in section 9007.
Install air cleaner rain guard device (1) on the engine
upper hood tightening the clamp (2). STEP 92
W270-1R045
Connect the electric connections indicated on the

alternator.
2000-22
STEP 93 STEP 96
1�
1�
2�
W270-1R044 W270-1R041
Connect the electric connections indicated (1) on the Connect the two fuel feeding hoses on engine
engine controller tightening the securing screw using controller (1) and on filter (2).
a 4 mm Allen wrench.
STEP 97
STEP 94
R e co n n e c t th e t r a n sm iss io n p r o p e lle r s h a ft s
following the procedure described in section 6001.
STEP 98
1�
1
2�
W270-1R043
Install the fuse and relay box on the hydraulic oil tank
using screws (1, q.ty 2).
W270-1R084
STEP 95
Install the left upper side door on the relevant hinges
by inserting screw (1, q.ty 4) and securing nut (2).
2� Replicate the operation on the right upper side door.
1�
3�
W270-1R042
Install cover (2) on the fuse box inserting screw (3)

and connect the electric connections indicated on
starter motor (1).
2000-23
STEP 99 STEP 101
W270-1R013 W270-1R008
Using lifting cables, sling and lift the left cab climbing Secure the engine hood lower side panels turning the
ladder and rest it on the machine, then reinstall it plastic blocks indicated in the figure.
using the securing screws (q.ty 6). Replicate the
operation for the climbing ladder on the right side. STEP 102
STEP 100 1�
W270-1R085
Fill the transmission with oil through filler neck (1)

W270-1R012 monitoring level indicator light (2), since the filling
Again, use lifting cables to sling, lift and rest the left must occur in a progressive manner to prevent
re ar m ud gua rd co mp lete w ith h an dra il o n th e spilling oil from the filler neck.Start the engine and
machine and secure it with the relevant screws (q.ty run at idle speed. Check the engine oil filter and
6). remote drain for leaks. After two minutes stop the
engine. Wait for the engine oil to drain down for an
accurate read on the dipstick. Check the dipstick and
add additional oil, if necessary.
For the specifications, please refer to section 1002.
2000-24
STEP 103 STEP 106
W270-1R086 W270-1R088
Fill the engine cooling system through the filler neck Move the main battery switch onto ON. Start the
located on the upper hood with a 50/50 mixture of engine and idle it. Let the engine run for about five
water and ethylene glycol. For the specifications, minutes at operating temperature to mix thoroughly
please refer to section 1002. Reinstall the radiator the water and the anti freeze. Once the coolant
cap. reaches the operating temperature, cut-off the
engine. Once the engine has cooled-off, check the
STEP 104 level of the coolant in the tank.
WARNING: hot coolant could spill under
pressure when removing the radiator cap. To
remove the radiator cap, let the system cool-off,
turn the cap very slowly, and wait for the
pressure to bleed completely.
W270-1R087
Fill the hydraulic oil tank through the filler neck.

Monitor level the hydraulic oil indicator light, since the
filling must occur in a progressive manner to prevent
spilling oil from the filler neck.
Start the engine and run at 1000 rpm. Check for
leakage around the filter and drain. Operate the
loader controls several times to remove any air in the
lines. Place the bucket/attachment on the ground
and stop the engine. Check the hydraulic oil level
and if it is necessary to top off with more oil.
STEP 105
When the machine is equipped with air conditioner,
charge the cooling gas making reference to the
procedures described in section 9003.
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2000-26
RADIATOR
Removal STEP 3
STEP 1
W270-1R010
Place a container of appropriate capacity under the

W270-1R006 machine in correspondence with the radiator draining
Park the machine on a flat surface and lower the pipe. Open the valve and drain the coolant into the
bucket to the round. Place the articulation block in container. To facilitate the draining of the coolant
BLOCK position. loosen the filler cap.
STEP 2 STEP 4
Remove the left and right panels from the machine
and the engine upper hood assembly following the
procedure described in the chapter relative to the
removal of the engine.
STEP 5
1�
W270-1R007
Cut-off the engine. Actuate the brake pedal a few

times to discharge the brake accumulators. Move the
starter key into "contact" position and move the
loader control lever forward and backward to bleed
2
the pressure from the hydraulic circuit. Move the
battery cut-off switch into position OFF, as indicated W270-1R091
in the figure. Open radiator guard grill (1) by loosening side

screws (2, q.ty 2) and secure the grill using the metal
rod located on the right side.
2000-27
STEP 6 STEP 9
1�
1�
W270-1R093 W270-1R095
Disconnect lights electric connection (1). Remove securing screws (1, q.ty 2).
STEP 7 STEP 10
1� 2�
W270-1R092 W270-1R096
Re move sup ports ( 1, q.ty 2 ) of r ear ligh ts (2) With the cables previously installed, lift the grill and
removing the securing screws (q.ty 3 for each rest it on the ground.
support).
STEP 11
STEP 8
1�
1�
2�
2� 3
W270-1R097
W270-1R094 Remove securing screws (1,q.ty 4) of the radiator
Use lifting cables to sling and hold grill (1) complete fan, remove the fan and disconnect pipes (2,3) from
with frame (2) to prevent accidental falls during the the hydraulic motor.
installation phase of the securing screws.
2000-28
STEP 12 STEP 14
1�
2�
W270-1R098 W270-1R099
Remove the radiator fa n ho using by removing Use adjustable chains to properly sling and hold the
screws (1, q.ty 8) and free electric connection (2) radiator-after cooler group to prevent accidental falls,
attached to it. for the subsequent removal phase from the machine.
STEP 13 STEP 15
1�
1
W270-1R101 W270-1R100
Disconnect all the hoses from the lower side of the Remove from the radiator screws (1, q.ty 4) complete
radiator and the ground cable of the cooling group. with rubber pad devices and the relevant washers
securing it on the machine, then lift it and rest it onto
the ground.
Installation
STEP 16
To install the radiator-after cooler group and fan
guard grill, reverse the removal operation.
2000-29
STEP 17
W270-1R086
Fill the engine cooling system through the filler

located on the upper hood with a mixture of 50 %
water and 50 % glycol ethyl anti freeze. Please refer
to section 1002 for the specifications. Reinstall the
cap on the radiator.
STEP 18
W270-1R088
Move the main battery switch onto ON. Start the

engine and let it idle. Have the engine running for
about five minutes at operating temperature to fully
mix water and anti freeze. Once the coolant reaches
the operating temperature, cut-off the engine. Once
the engine has cooled off, check the coolant level in
the tank.
WARNING: hot coolant could spill under pressure when
removing the radiator cap. To remove the radiator cap, let
the system cool-off, turn the cap very slowly, and wait for
the pressure to bleed completely.
2000-30
NOTES
Section
2003
AFTERCOOLER

2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2003-3
3
2
1
W270-1R004
1. RADIATOR 3. BOLT
2. WASHER 4. BOLT
2003-4
8�
13�
14�
4�
6
7� 1� 18�
22�
2�
21�
4� 11� 11�
11� 8�
10� 21�
9�
5�
8� 16
15�
17�
3� 19�
20
23�
12 11�
W270-1R005
1. FRAME 7. BOLT 13. COOLER, HYDRAULIC 18. TRIM

2. COOLER CHARGE AIR 8. WASHER TRANSMISSION 19. WASHER
3. COOLER FUEL 9. NUT 14. BOLT 20. NUT
4. CENTER BONDED 10. BOLT 15. WASHER 21. NUT
5. BRACKET 11. WASHER 16. BOLT 22. BRACKET
6. WASHER 12. BOLT 17. MOUNT 23. REAR CHASSIS
2003-5
TROUBLESHOOTING AFTERCOOLER
STEP 1 STEP 5
Park machine on level ground, lower the bucket. Put
transmission in neutral, apply the parking brake. Turn
off engine.
STEP 2
BD07B196
Inspect the after cooler inlet flex hose for leaks or

holes and insure that the clamps are tight.
BD07B212
Raise hood. Install ‘T’ fitting in waste gate valve

h os e. Atta ch p re ss ur e ga ug e . In sta ll a no th er
pressure gauge into the intake manifold port.
STEP 3
Have assistant start engine and run at 2000 r/min
(rpm). Record pressure readings for both gauges. If
the pressure difference is greater than 67.6 m Bar
BD07B195
(0.98 psi), inspect cooler components for damaged
Inspect the after cooler outlet flex hose for leaks or
or missing parts.
holes and insure that the clamps are tight.
STEP 4
STEP 6
Visually inspect the after cooler for damage or leaks.
NOTE: If the leak source has not been located,
remove and test the after cooler.
BD07B197
Inspect the intake manifold flex hose for leaks or

holes and insure that the clamps are tight. Inspect
the turbocharger flex hose for leaks or holes and
insure that the clamps are tight.
2003-6
AFTERCOOLER REMOVAL
Removal STEP 5
STEP 1
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 2
Raise the hood and place the master disconnect
switch in the OFF position.
NOTE: Radiator drain is located under the rear
chassis behind the rear axle.
BD07B193
STEP 3 Attach suitable lifting equipment to the after cooler.
STEP 6
BD07B176
Drain 20 liters (5.5 gallons) of coolant from the

BD07B179
engine cooling system.
Loosen and remove the top mounting bolts.
STEP 4
STEP 7
BD07B178
Loosen clamps and remove upper radiator hose and BD07B194
tube. Loosen the clamps and remove the hoses from Loosen and remove the bottom mounting bolts.
the after cooler. Loosen clamps and disconnect
radiator vent hose, disconnect cooling level sensor. STEP 8
Remove the after cooler from the cooling frame.
2003-7
Leak Test STEP 3
BD07B178
Install two top mounting bolts.
BS03B028
STEP 4
Check the core for leaks by closing off the outlet tube
and attaching regulated air pressure 550kPa (80 psi)
to the inlet tube. Submerge the cooler in water and
watch for air leakage.
NOTE: If leakage is detected replace the after
cooler.
Installation
STEP 1
Support after cooler with appropriate lifting device.
Install after cooler in its frame. BD07B178
Install the cooler hoses and upper radiator hose and

STEP 2 tube.
STEP 5
Refill the cooling system.
BD07B194
Install two bottom mounting bolts.

2003-8
NOTES
SECTION INDEX
FUEL SYSTEM
FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL

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

Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005
Section
4001
REMOVAL AND INSTALLATION OF STARTER

AND ALTERNATOR

4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
With Out Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
With Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4001-3
STARTER
Removal Installation
STEP 1 STEP 5
Park machine on a level surface and lower bucket to
ground.
9�
STEP 2
Open the engine compartment panel. Place the
master disconnect switch in the OFF position.
STEP 3
8�
7�
2�
W270-7R006
Position starter motor on machine and insert the three

screws (7) and washers (8) retaining it to engine
4� housing flange (9). Lock the three screws at 210 to
375±14 Nm torque 155 to 275±10 pound-feet).
3� STEP 6
1�
W270-7R004
Place ad identification mark on the battery-starter 11�

motor cable (1), on the frame-ground cable (2), on
negative start-up cable (3), on engine starter motor
ground stranded wire (4) and remove starter motor
cables.
13
STEP 4
12� 10�
W270-7R007
Install and lock the battery-starter motor cable (10),

the frame-ground cable (11), the negative starter
motor cable (12) and engine starter motor ground
stranded wire (13).
STEP 7
5� Place the maste r discon nect switch in the ON
6� position. Close the engine compartment panel.
W270-7R005
Remove setscrews (5, 3 q.ty), washers (6) and

disconnect starter motor.
4001-4
11
15
24
VIEW B-B
B
1 B
18
8 1
11 12
23 20 13
7 3 20 13
4
14 22 16
10 9
A A
3 20 13
21 13
6
17
3 20 13
5 3 13 20
VIEW A-A
2 19
W270-7R008
1. MOTOR STARTER 7. CABLE STARTER NEGATIVE 13. NUT 20. WASHER

2. SWITCH MASTER 8. CABLE STARTER NEGATIVE 14. CABLE BATTERY TO STARTER 21. WASHER
3. CLAMP TO CHASSIS GND. 15. STRAP GROUND 22. HOUSING HOOD
4. CABLE BATTERY POSITIVE 9. WASHER 16. CONDUIT BATTERY CABLES 23. CLAMP
5. CABLE BATTERY NEGATIVE 10. BOLT 17. STRAP CABLE 24. ENGINE BELLHOUSING
6. HARNESS 11. WASHER 18. BOOT ELECTRICAL
12. NUT 19. BOOT ELECTRICAL
4001-5
ALTERNATOR
Removal STEP 4
NOTE: Grill is removed for clarity only, it is not
required for alternator replacement. 1
STEP 1
ground.
STEP 2
Open the left engine compartment panel. Place the
master disconnect switch in the OFF position.
STEP 3 W270-7R012
Use a wrench to move the belt tensioner (1) to

loosen the tension on the belt. Remove the belt.
STEP 5
3
3
2
5
W270-7R010
Disconnect wires from the alternator. 4

W270-7R011
Remove alternator (2) setscrews (3, 2 q.ty) from

cover (4) of belt (5) and take cover out.
4001-6
STEP 6 Installation
NOTE: Grill is removed for clarity only, it is not
required for alternator replacement.
STEP 7
W270-7R013
Remove alternator.
2
2
1
W270-7R015
Position alternator on engine, position belt cover (1)

then fasten alternator and cover by means of screws
(2, 2 q.ty) and lock.
STEP 8
W270-7R014
Position tensioner (3) on alternator (4) and fit belt (5).

NOTE: Belt routing instructions are on belt cover.
4001-7
STEP 9
W270-7R010
Connect wires to the alternator, place rubber boot

over positive post.
STEP 10
Place the master disconnect switch in the ON
position. Close the left engine compartment panel.
4001-8
BELT INSTALLATION
W270-7R017
WITH OUT AIR CONDITIONING
W270-7R016
WITH AIR CONDITIONING
Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING

4002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Voltmeter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Power Relay Module A, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power Relay Module B, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power Relay Module C, For Fuel Filter Heater and Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . 48
Ether Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Voltmeter Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Circuit breaker Cab B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Power Relay Module D, Accessory Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fan Control Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fan Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4002-3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for
Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4002-4
LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Right Hand Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Left Hand Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Diodes Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Power Relay Module E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Blower Fan Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4002-5
STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4002-6
NOTES
4002-7
SPECIFICATIONS
Electrical System ............................................................Two 12 volt batteries connected in series, negative ground

System Voltage .............................................................................................................................................. 24 volts
Batteries
Group Size ..........................................................................................................................................................31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17 C (0 F) for 60 Seconds At 6.0 Volts.................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Alternator ..................................................................................................................................... 24 volt, 95 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20 C (68 F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20 C (68 F) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20 C (68 F) ......................................... 3521 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Set point ............................................................................................................................ 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig)
A/C Trinary Pressure Switch (Closed With Normal System Pressure)
Opens With Pressure ............................................................................ Above 28.5 ± 2.5 bar (413.3 ± 36,25 psi)
Below 2.5 ± 0.25 bar (36.25 ± 3.6 psi)
Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi)
Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi)
Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Set point........................ 5 to 6 bar increasing (75 to 85 psi)
Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi)
Fuel Filters Heater Resistance At 20 C (68 F) (Nominal)............................................................................ 1.9 ohms
Parking Brake Solenoid DC Resistance At 20 C (68 F) (Nominal) ........................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20 C (68 F) (Nominal) ........................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20 C (68 F) (Nominal) ...................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20 C (68 F) (Nominal) .............................................................. 22.7 ohms
Secondary Steering Solenoid DC Resistance At 20 C (68 F) (Nominal) .................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20 C (68 F) (Nominal)........................................................... 39.3 ohms
Fan PWM Solenoid DC Resistance At 20 C (68 F) (Nominal) ............................................................ 26 to 32 ohms
Fuel Temperature Sensor At 20 C (68 F) (Nominal) ................................................................................ 2500 ohms
Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)
Analog Throttle ................................................................................. Idle Validation Switch Closes At 0.775V ± 0.1V
Throttle Position Potentiometer ................................................................................................. 5V Reference ± 0.2V
Low Idle Position .............................................................................................................................. 0.4V ± 0.025V
High Idle Position ................................................................................................................................. 4.0V ± 0.1V
4002-8
ELECTRICAL WIRE IDENTIFICATION
Wire Identification Codes

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

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

Color, Size,
Wire Circuit Connector Cavity Connector Cavity
and Material
14 ALTERNATOR D+ LG1_0-SXL AD, ALTERNATOR D+ 1 ENG, ENGINE-CAB 26
42 WORK LIGHTS SW FSD PWR R2_0-GXL SPL_WL, ULTRASONIC A ECC, ELECT CNTR C A2
44 BRK LT CTRL PWR T1_0-SXL FRONT, CAB-FRNT_CHAS 23 PBL, BRAKE_LT_PRES_SW 2
SPL_BCK_LGT, SPLICE BACK
49 BACK LIGHT POWER DU1_0-GXL D_OR, DIODE OR C A
LGHT PWR
AIC_1, ADV INSTR CLU-
52 FAN REVERSER LSD W0_8-TXL 23 ECB, ELECT CNTR B B8
STER 1
56 FAN CONTROL PWM W0_8-TXL CAB_E, CAB-ENGINE 23 AIC_1, ADV INSTR CLUSTER 1 26
57 PIN ENGAGE SOL PWR W1_0-SXL FRONT, CAB-FRNT_CHAS 20 YPE, PIN_ENGAGE_OPT A
PRBF,
58 RIDE CTRL SOLPWR W1_0-SXL A YRC, RIDE_CONTROL_OPT 1
ROLLBACK_PRES_SW
64 HORN POWER OR1_0-SXL FRONT, CAB-FRNT_CHAS 13 HN1, HORN_PWR 1
SFL, SPL_BCK_LT_GD2, SPL_BACK
0_29 RTT/FLOAT GND BK0_8-GXL 4 K
RETURN_TO_TRAVEL_SW LGT GRND
0_AA PROX SW GND BK1_0-SXL PXH, HGT_CNTRL-RTT B SPL_A2, ULTRASONIC A
0_AB PROX SW GND BK1_0-SXL SPL_A2, ULTRASONIC A GND_FC, GROUND_A 1
0_AC PROX SW GND BK1_0-SXL PXF, RTD B SPL_A2, ULTRASONIC A
0_AD RIDE CONTROL GND BK1_0-SXL YRC, RIDE_CONTROL_OPT 2 SPL_A1, ULTRASONIC A
0_AE PIN ENGAGE GND BK1_0-SXL SPL_A1, ULTRASONIC A YPE, PIN_ENGAGE_OPT B
0_AF HORN GND BK1_0-SXL HN2, HORN_GRND 1 SPL_A1, ULTRASONIC A
0_AG FRONT CHASSIS GND BK2_0-SXL SPL_A1, ULTRASONIC A GND_FC, GROUND_A 1
0_AH RH FRONT LIGHTS GND BK1_0-SXL SPL_A1, ULTRASONIC A LRF, LIGHTS_RH 1
0_AJ LH FRONT LIGHTS GND BK1_0-SXL SPL_A1, ULTRASONIC A LLF, LIGHTS_LH 1
0_AK PARK BRAKE/WARNING GND BK1_0-SXL SPL_A4, ULTRASONIC A GND_FC, GROUND_A 1
0_AL BRK WARN PRES SW GND BK1_0-SXL PBW, BRK_WARN_PR_SW 2 SPL_A4, ULTRASONIC A
0_AM RTD GND BK1_0-SXL PXM, RTD B PXT, RTD B
0_AN PARK BRAKE SOL GND BK1_0-SXL YPB, PARK_BRK_SOL 2 SPL_A4, ULTRASONIC A
FRONT TO REAR CHASSIS
0_AP BK5_0-SXL GND_S1, GROUND_A 1 GND_S2, GROUND_A 1
GND
YCS, COMFORT STEER
0_AQ COMFORT STR SOL GND BK1_0-SXL B SPL_A4, ULTRASONIC A
SOLEROID
0_AR FRONT AX TEMP SENS GND BK1_0-SXL FRONT, CAB-FRNT_CHAS 9 HOT_FA, FRNT_AX_OIL_TEMP 2
SPL_ENG_GRD, GRND SPLICE
0_B FRONT WASHER GND BK1_0-SXL FWW, FRONT_WASHER 2 E
6 PCK
SPC, SPL_PED_BL_GD, SPL BACK
0_B1 BACK LIGHT GND BK0_8-GXL 7 B
PILOT_CONTROL_SWITCH LGT GD 6PCK
SFL, SPL_BCK_LT_GD2, SPL_BACK
0_B2 BACK LIGHT GND BK0_8-GXL 7 B
RETURN_TO_TRAVEL_SW LGT GRND
SHC, HEIGHT CONTROL SPL_BCK_LT_GD2, SPL_BACK
0_B3 BACK LIGHT GND BK0_8-GXL 7 C
SW LGT GRND
4002-9

21C Bk - 1.0


Color, Size,
and Material
SPL_BCK_LT_GD2, SPL_BACK
0_B4 BACK LIGHT GND BK0_8-GXL SRTD, DETENT_SWITCH 7 D
LGT GRND
0_B5 BACK LIGHT GND BK0_8-GXL SPE, PIN_ENGAGE_SW 9 E
LGT GRND
0_B6 CAB2 GND BK1_0-GXL GND_CAB2, GROUND_A 1 F
LGT GRND
0_B7 BACK LIGHT GND BK0_8-GXL SFC, FAN_CONTROL_SW 7 M
LGT GRND
SPL_BCK_LT_GD, SPL
0_B8 FRONT WIPER MOTOR GND BK0_8-GXL H FWMG, WIPER GROUND A
BACK LGHT GD
SPL_PED_BL_GD, SPL BACK
0_B9 BACK LIGHT GND BK0_8-GXL SCS, COMFORT STEER SW 7 A
LGT GD 6PCK
SPL_HOOD_GRND, HOOD
0_B10 HOOD GND BK1_0-GXL E GND_CAB2, GROUND_A 1
GRND 6PCK
SPL_BCK_LT_GD2, SPL_PED_BL_GD, SPL BACK
0_B11 BACK LIGHT GND BK0_8-GXL L F
SPL_BACK LGT GRND LGT GD 6PCK
SPL_HOOD_GRND, HOOD
0_B12 HOOD DOWN RELAY GND BK1_0-GXL A ECC, ELECT CNTR C C4
GRND 6PCK
SPL_BCK_LT_GD, SPL
0_B13 BACK LIGHT GND BK1_0-GXL A GND_CAB2, GROUND_A 1
BACK LGHT GD
SPL_BCK_LT_GD, SPL BACK
0_B14 BACK LIGHT GND BK0_8-GXL SWL, WORK LIGHTS SW 7 B
LGHT GD
0_B15 BACK LIGHT GND BK0_8-GXL SBE, BEACON_SW 7 C
LGHT GD
SPL_HOOD_GRND, HOOD
0_B16 HOOD DOWN CONTROL GND BK1_0-GXL B ECC, ELECT CNTR C B4
GRND 6PCK
0_B17 BACK LIGHT GND BK0_8-GXL STA, TRANS_AUTO_SW 7 E
LGHT GD
0_B18 BACK LIGHT GND BK0_8-GXL SDC, DECLUTCH_SWITCH 7 F
LGHT GD
0_B19 BACK LIGHT GND BK0_8-GXL SDR, DRIVING LIGHTS SW 7 G
LGHT GD
0_B20 BACK LIGHT GND BK0_8-GXL SRC, RIDE_CONTROL_SW 7 J
LGT GRND
SBU, SPL_BCK_LT_GD, SPL BACK
0_B21 BACK LIGHT GND BK1_0-GXL 7 J
BACK-UP_ALRM_DIS_SW LGHT GD
SPL_HOOD_GRND, HOOD
0_B22 HOOD UP RELAY GND BK1_0-GXL C ECC, ELECT CNTR C C2
GRND 6PCK
0_B23 BACK LIGHT GND BK0_8-GXL SRWP, REAR_WIPER_SW 7 L
LGHT GD
0_B24 BACK LIGHT GND BK0_8-GXL SHZ, HAZARD_SWITCH 7 C
LGT GD 6PCK
SPL_HOOD_GRND, HOOD
0_B25 HOOD UP CONTROL GND BK1_0-GXL D ECC, ELECT CNTR C B2
GRND 6PCK
0_B26 BUZZER/SW PAD GND BK0_8-GXL SPL_BUZ, ULTRASONIC A G
LGT GRND
4002-10

21C Bk - 1.0


Color, Size,
and Material
0_B27 BUZZER GND BK0_8-GXL SPL_BUZ, ULTRASONIC A BUZ, AIC_BUZZER 2
0_B28 SW PAD GND BK0_8-TXL SW_PD, SWITCH PAD 10 SPL_BUZ, ULTRASONIC A
SPB, SPL_PED_BL_GD, SPL BACK
0_B29 RTT/FLOAT GND BK0_8-GXL 7 E
PARKING_BRAKE_SWITCH LGT GD 6PCK
0_B30 BACK LIGHT GND BK0_8-GXL SETHR, ETHER SWITCH 7 D
LGT GD 6PCK
0_BA PEDESTAL GND STRAP BK5_0-SXL GND_PDST, GROUND_A 1 GND_PDST2, GROUND_A 1
0_BA
EDC7 GND BK2_0-SXL SPL_EDC1, ULTRASONIC A GND_ENG2, WIF, EDC 1
C
GND_ENG7, TRANNY, COOL
0_BAE EDC7 SENDER GND BK1_0-SXL RECT, ENG_COOL_TEMP B 1
TEMP
CLS_, GND_ENG7, TRANNY, COOL
0_BAF COOL LEVEL SNDR GND BK1_0-SXL B 1
COOL_JUMP-COOL_SEND TEMP
0_BA GND_ENG4, REAR
HOOD GROUNDS(EURO) BK1_0-SXL 1 E_HD, TRANS-HOOD C
G LIGHTING
0_BA
HOOD GROUNDS(NA) BK1_0-SXL ENG_H, ENGINE TO HOOD 1 GND_ENG4, REAR LIGHTING 1
G_N
0_BA
QSM 11 GND BK0_8-GXL SPL_EDC1, ULTRASONIC A QSM11, ENGINE CONTROLLER 29
H
0_BAI QSM 11 GND BK0_8-GXL SPL_EDC1, ULTRASONIC A QSM11, ENGINE CONTROLLER 30
0_BAJ QSM 11 GND BK0_8-GXL SPL_EDC1, ULTRASONIC A QSM11, ENGINE CONTROLLER 39
0_BAK QSM 11 GND BK0_8-GXL SPL_EDC1, ULTRASONIC A QSM11, ENGINE CONTROLLER 40
0_BA
ETHER RLY SGNL GND BK1_0-SXL PRM_C2, PRM SIGNAL B GND_ENG2, WIF, EDC 1
M
0_BA GND_ENG3, SPLC_PK, WSHR
ETHER STRT GRND BK1_0-SXL ETHR, ETHER SOLENOID B 1
N MTR
0_BAP QSM 11 GRND BK0_8-GXL SPL_EDC1, ULTRASONIC A QSM11, ENGINE CONTROLLER 50
0_BA GND_WIF, GRND WIF RING
WIF BODY GRND BK1_0-SXL 1 GND_ENG6, DEDICATED 1
R TERM
HOT_RA, GND_ENG7, TRANNY, COOL
0_BAS REAR AX TEMP SENS GND BK1_0-SXL 2 1
REAR_AX_OIL_TEMP TEMP
0_BB FAN REVERSE SOL GND BK1_0-SXL YFR, FAN_REV_SOL_OPT 2 SPL_FAN, ULTRASONIC A
0_BC EDC7 GND BK1_0-GXL SPL_EDC1, ULTRASONIC A EDC7, ENGINE CONTROLLER 11
0_BD EDC7 GND BK1_0-GXL SPL_EDC1, ULTRASONIC A EDC7, ENGINE CONTROLLER 10
0_BE EDC7 GND BK1_0-GXL SPL_EDC1, ULTRASONIC A EDC7, ENGINE CONTROLLER 5
0_BF EDC7 GND BK1_0-GXL SPL_EDC1, ULTRASONIC A EDC7, ENGINE CONTROLLER 6
0_BG AIC POWER GND BK0_8-GXL ENG, ENGINE-CAB 19 GND_ENG6, DEDICATED 1
0_BH AIC POWER GND RED BK0_8-GXL ENG, ENGINE-CAB 20 GND_ENG6, DEDICATED 1
0_BJ AIC SENSOR GND BK0_8-GXL ENG, ENGINE-CAB 17 GND_ENG6, DEDICATED 1
0_BK TRANS SPLICE GNDS BK1_0-GXL ENG_T, ENGINE TO TRANS 2 1
TEMP
0_BL REAR WASHER GND BK1_0-SXL RWW, REAR_WASHER 2 F
6 PCK
4002-11

21C Bk - 1.0


Color, Size,
and Material
SPL_ENG_GRD, GRND GND_ENG3, SPLC_PK, WSHR
0_BM ENGINE SPLICE GNDS BK1_0-SXL A 1
SPLICE 6 PCK MTR
0_BN FILTER HEATER CONTROL BK0_8-GXL PRM_C2, PRM SIGNAL B EDC7, ENGINE CONTROLLER 13
0_BP WIF SENSOR GND BK1_0-SXL GND_ENG2, WIF, EDC 1 WIF, WATER_IN_FUEL_SNSR 2
0_BQ FAN SPEED PWM SOL GND BK1_0-SXL YFN, FAN_PWM_SOL B SPL_FAN, ULTRASONIC A
LRR_E,
0_BR RH REAR LIGHT GND(EURO) BK1_0-SXL 5 GND_ENG4, REAR LIGHTING 1
RH_REAR_COMB_LT
0_BR_ LLR_N,
LH REAR LIGHT GND(NA) BK1_0-SXL D SPL_J1, ULTRASONIC A
N LH_REAR_COMB_LT
0_BS FAN CONTROL GND BK1_0-SXL SPL_FAN, ULTRASONIC A D
6 PCK
LLR_E,
0_BT LH REAR LIGHT GND(EURO) BK1_0-SXL 5 GND_ENG4, REAR LIGHTING 1
LH_REAR_COMB_LT
0_BT_ LRR_N,
RH REAR LIGHT GND(NA) BK1_0-SXL D SPL_J1, ULTRASONIC A
N RH_REAR_COMB_LT
0_BU FUEL LEVEL SENDER GND BK1_0-SXL RFLG, FUEL_SEND_GRND 1 1
TEMP
0_BV GRID HEATER CTRL GND BK0_8-TXL GHC, GRID_HEATER_REL 2 EDC7, ENGINE CONTROLLER 75
GND_ENG1, STRT, FFH,
0_BW WATER SEP HEATER GND BK2_0-SXL 1 WSH, WATER_SEP_HTR A
WAT_SEP_HTR
0_BX FUEL FILTER HEATER GND BK2_0-SXL FFH, FUEL_FLTR_HTR B 1
WAT_SEP_HTR
SPL_ENG_GRD, GRND
0_BY AIR FILT REST SW GND BK1_0-SXL B PAF, AIR_FILT_RES_SW 2
SPLICE 6 PCK
GND_ENG3, SPLC_PK, WSHR
0_BZ SEC STEERING SPLICE GND BK1_0-SXL ENG_T, ENGINE TO TRANS 1 1
MTR
0_CA SEC STEERING SIGNAL GND BK1_0-SXL SSM, SEC STR MOD 11 SPL_SEC_STR, SEC STR 6PK B
0_CB SEC STEERING SIGNAL GND BK1_0-SXL SSM, SEC STR MOD 12 SPL_SEC_STR, SEC STR 6PK A
SEC STEERING PRESS SW PSS, SEC STR PRES
0_CC BK1_0-SXL B SPL_SEC_STR, SEC STR 6PK C
GND SWITCH
SPL_SEC_STR, SEC STR
0_CD SEC STEERING SPLICE GND BK1_0-SXL F SS_TR, SS_MOD-TRANS D
6PK
SEC STEERING CHASSIS GND_SSMOD, SEC STR CHA-
0_CE BK1_0-SXL SSM, SEC STR MOD 4 1
GND SIS GND
0_CF SEC STEERING SOL GND BK1_0-SXL YSS, SEC_STRG_SOL 2 SPL_SEC_STR, SEC STR 6PK D
0_DA AIC CHASSIS GND BK0_8-TXL GND_PDST1, GROUND_A 1 AIC_2, ADV INSTR CLUSTER 2 22
0_DA SPL_BCK_LT_GD, SPL BACK
BACK LIGHT GND S0_8-GXL STE, TRANS_ENABLE_SW 7 K
P LGHT GD
108F,
0_DAV TECM DIAGNOSTIC GND BK0_8-GXL DIAGNOSTIC_CONNECTO 3 GND_CAB3D, GROUND_A 1
R
0_DB AIC POWER GND RED BK0_8-TXL CAB_E, CAB-ENGINE 20 AIC_2, ADV INSTR CLUSTER 2 15
GND_CAB_SPL2, SPL
0_DC TIME DELAY MOD GND BK0_8-GXL A TDM, TIME_DELAY_MODULE 3
BACK LGHT GD
4002-12

21C Bk - 1.0


Color, Size,
and Material
VOLTMETR RELAY CONTROL GND_CAB_SPL2, SPL
0_DD BK0_8-GXL E ECB, ELECT CNTR B B2
GND BACK LGHT GD
GND_CAB_SPL2, SPL
0_DE NEUT START RLY CTRL GND BK0_8-GXL G ECB, ELECT CNTR B B4
BACK LGHT GD
CRANK REQUEST RLY CTRL GND_CAB_SPL2, SPL
0_DF BK0_8-GXL F ECB, ELECT CNTR B B6
GND BACK LGHT GD
GND_CAB_SPL, CAB GRND
0_DG CAB SPLICE GNDS BK1_0-GXL F GND_CAB3, GROUND_C 1
SPLICE
DIAGNOSTIC CONNECTOR GND_CAB_SPL, CAB GRND
0_DH BK0_8-GXL M DIA, DIAGNOSTIC A
GND SPLICE
0_DJ AC RELAY CONTROL GND BK0_8-GXL K ECD, ELECT CNTR D B10
SPLICE
0_DK SEAT COMP MOTOR GND BK0_8-GXL I SC, SEAT_COMP_MOTOR B
SPLICE
PWR CONVERTER RLY CTRL GND_CAB_SPL, CAB GRND
0_DL BK0_8-GXL H PRM_E2, PRM SIGNAL B
GND SPLICE
CAB_T, CAB-TRANSMIS-
0_DM SPEED SENSOR GNDS BK0_8-TXL 11 TECM, TRANS 3
SION
OUTPUT SPEED SENSOR CAB_T, CAB-TRANSMIS-
0_DN BK0_8-TXL 28 TECM, TRANS 4
GND SION
0_DP DIAG TECM GND BK0_8-TXL GND_CAB3D, GROUND_A 1 TECM, TRANS 1
0_DQ DIAG TECM GND BK0_8-TXL GND_CAB3D, GROUND_A 1 TECM, TRANS 2
CAB_RF, CAB TO ROOF
0_DR ROOF SPLICE GNDS BK1_0-GXL F GND_CAB1, GROUND_A 1
CONNECTION
CAB_RF, CAB TO ROOF
0_DS ROOF SPLICE GNDS BK1_0-GXL G GND_CAB1, GROUND_A 1
CONNECTION
FRONT WIPER/WASHER SW GND_CAB_SPL, CAB GRND SFWW, FRONT
0_DT BK0_8-GXL G 2
GND SPLICE WIPER/WASHER
0_DU PILOT PRESSURE SOL GND BK0_8-GXL L YPP, PILOT_PRES_SOL B
SPLICE
0_DV CIGAR LIGHTER GND BK3_0-SXL CL, CIGAR_LIGHTER 2 GND_CAB3, GROUND_C 1
0_DW AIC POWER GND BK0_8-TXL CAB_E, CAB-ENGINE 19 AIC_1, ADV INSTR CLUSTER 1 12
0_DX AIC SENSOR GND BK0_8-TXL CAB_E, CAB-ENGINE 17 AIC_1, ADV INSTR CLUSTER 1 6
0_DY FRONT AX TEMP SENS GND BK1_0-GXL CAB_F, CAB-FRNT_CHAS 9 GND_CAB3D, GROUND_A 1
GND_CAB_SPL2, SPL
0_EA TIME DELAY RLY CTRL GND BK0_8-GXL B PRM_B2, PRM SIGNAL B
BACK LGHT GD
GND_CAB_SPL2, SPL
0_EB IGNITION RELAY CTRL GND BK0_8-GXL C PRM_A1, PRM SIGNAL B
BACK LGHT GD
GND_CAB_SPL2, SPL
0_EC ACC RELAY CONTROL GND BK0_8-GXL D PRM_D1, PRM SIGNAL B
BACK LGHT GD
0_ED HVAC GNDS BK3_0-SXL HVAC2, HVAC2 2 GND_CAB4, GROUND_C 1
0_EE DIODE SUPRESSION GNDS BK0_8-GXL A 140M, DIODE_MODULE C
SPLICE
GND_CAB_SPL2, SPL
0_EF BRK LTS RLY CTRL GND BK0_8-GXL M ECC, ELECT CNTR C B6
BACK LGHT GD
4002-13

21C Bk - 1.0


Color, Size,
and Material
FLSHR, GND_CAB_SPL2, SPL BACK
0_EG FLASHER MODULE GND BK0_8-GXL 4 L
FLASHER_MODULE LGHT GD
FLSHR, GND_CAB_SPL2, SPL BACK
0_EH FLASHER MODULE GND BK0_8-GXL 3 K
FLASHER_MODULE LGHT GD
CNV, 24V TO 12V PWR
0_EJ POWER CONVERTER GND BK1_0-GXL 3 GND_CAB4, GROUND_C 1
CONVERTER
0_EK AUX POWER OUTLET 1 GND BK1_0-GXL PO1, POWER_OUTLET C GND_CAB5, GROUND_C 1
0_EL AUX POWER OUTLET 2 GND BK1_0-GXL PO2, POWER_OUTLET C GND_CAB5, GROUND_C 1
CAB_RF, CAB TO ROOF GND_CAB_SPL, CAB GRND
0_EM RADIO GND BK0_8-GXL M B
CONNECTION SPLICE
ROOF, ROOF TO CAB CON-
0_EN RADIO GND BK0_8-GXL M RAD, RADIO_POWER 8
NECTION
0_EP HORN SW GND BK0_8-GXL C SRHSTLK, RH STALK SWITCH 31
SPLICE
SPLICE PACK GND_CAB_SPL2, SPL GND_CAB6, STRT, FFH,
0_EQ BK0_8-GXL H 1
GND_CAB_SPL2 GND BACK LGHT GD WAT_SEP_HTR
CNV, 24V TO 12V PWR
0_ER POWER CONVERTER GND BK1_0-GXL 6 GND_CAB4, GROUND_C 1
CONVERTER
GND_GH1, STRT, FFH,
0_ES GRID HTR GND BK19_0-SXL GH_1, GRID_HTR 1 1
WAT_SEP_HTR
0_GB STARTER RLY CTRL GND BK1_0-SXL SRC_1, RELAY 2 1
WAT_SEP_HTR
SPL_TRN_GRD, SPLICE
0_HC TRANS SPLICE GNDS BK1_0-SXL A TRAN_E, TRANS TO ENG 2
TRANS GRND
TRANS, CAB-TRANSMIS-
0_HD SPEED SENSOR GNDS BK1_0-SXL 11 SPL_H2, ULTRASONIC A
SION
OUTPUT SPEED SENSOR TRANS, CAB-TRANSMIS-
0_HE BK1_0-SXL 28 OSS, OUT_SPEED_SENS 1
GND SION
BK0_8_GXL_
0_HF ENGINE SP SENSOR GND ESS, ENG_SPEED_SENS 2 SPL_H2, ULTRASONIC A
TWIST
BK0_8_GXL_
0_HG INT SPEED SENSOR GND ISS, INT_SPEED_SENS 2 SPL_H2, ULTRASONIC A
TWIST
TURBINE SPEED SENSOR BK0_8_GXL_
0_HH TSS, TURB_SPEED_SENS 2 SPL_H2, ULTRASONIC A
GND TWIST
SPL_TRN_GRD, SPLICE
0_HL RED BRAKE SW GND BK1_0-SXL PRB2, RED_BRAKE_SW B E
TRANS GRND
SPL_TRN_GRD SPLICE TRANS
0_HM RED BRAKE SW GND BK1_0-SXL PRB1, RED_BRAKE_SW B F
GRND
0_HP SEC STEERING SPLICE GND BK1_0-SXL TRAN_E, TRANS TO ENG 1 TR_SS, SEC_STR_MOD_OPT D
COOLANT LEVEL SENDER CLS, SPL_TRN_GRD, SPLICE
0_HV BK1_0-SXL B D
GND COOL_JUMP-COOL_SEND TRANS GRND
HOT, SPL_TRN_GRD, SPLICE
0_HW HOT GROUND BK1_0-SXL B C
HYD_OIL_TEMP_SEND TRANS GRND
0_JA HOOD GROUNDS(EURO) BK1_0-SXL HD_E, HOOD-TRANS C SPL_J1, ULTRASONIC A
4002-14

21C Bk - 1.0


Color, Size,
and Material
0_JA_
HOOD GROUNDS(NA) BK1_0-SXL HD_N, HOOD TO ENG 1 SPL_J1, ULTRASONIC A
N
BU1,
0_JB BACKUP ALARM GND BK1_0-SXL 1 SPL_J1, ULTRASONIC A
BACKUP_ALARM_GRND
0_JC LICENSE PLATE LIGHT GND BK1_0-SXL LPL, LIC_PLATE_LIGHT B SPL_J1, ULTRASONIC A
0_LA REAR LIGHT GND BK1_0-SXL HD_9, HOOD TO ENG 1 SPL_B1, ULTRASONIC A
LLR_9,
0_LB REAR LIGHT GND BK1_0-SXL 5 SPL_B1, ULTRASONIC A
LH_REAR_COMB_LT
0_LC REAR LIGHT GND BK1_0-SXL SPL_B1, ULTRASONIC A LRR_9, RH_REAR_COMB_LT 5
0_LD REAR LIGHT GND BK1_0-SXL SPL_B1, ULTRASONIC A E_HD9, TRANS-HOOD C
SPL_ROOF, SPLICE ROOF RWMG,
0_MA REAR WIPER MOTOR GND BK1_0-GXL F A
GROUND REAR_WIPER_MTR_GD
SPL_ROOF, SPLICE ROOF
0_MB DOME LIGHT GND BK0_8-GXL LDM3, DOME_LIGHT_GND 1 B
GROUND
LBEGRD, LIGHT BEACON SPL_ROOF, SPLICE ROOF
0_MC BEACON LIGHT GND BK1_0-GXL 1 A
GRND GROUND
LBEE, LIGHT BEACON
0_MD BEACON LIGHT GND BK1_0-GXL B LBEG, LIGHT BEACON GRND 1
EXTENSION
0_ME LH REAR WORK LIGHT GND BK1_0-GXL LLRW, LH_REAR_WK_LT B D
GROUND
0_MF RH REAR WORK LIGHT GND BK1_0-GXL LRRW, RH_REAR_WK_LT B E
GROUND
0_MJ RH FRONT WORK LIGHT GND BK1_0-GXL LRFW, RH_FRONT_WK_LT B J
GROUND
ROOF, ROOF TO CAB CON- SPL_ROOF, SPLICE ROOF
0_MK ROOF GROUNDS BK1_0-GXL G M
NECTION GROUND
ROOF, ROOF TO CAB CON- SPL_ROOF, SPLICE ROOF
0_MN ROOF GROUNDS BK1_0-GXL F L
NECTION GROUND
0_MU LH FRONT WORK LIGHT GND BK1_0-GXL LLFW, LH_FRONT_WK_LT B C
GROUND
0_NB MASTER DISCONNECT GND BK62_0-SGR DC2, DISCON-BLCK_GRND 1 STTR_GRN, GRID_HTR_FUSE 1
0_NC BATTERY DISCONNECT BK62_0-SGR BT4, DISCON-BLCK_GRND 1 DC1, DISCONECT-BATTERY 1
242F,
GND_SSCHAS,
0_ND SSM GROUND BK62_0-SGR CHAS_GRD-SEC_STRG_M 1 1
SSM_GROUND_CABLE
TR
0_PA LEFT SPEAKER GND BK0_8-GXL LSPK, LEFT_SPEAKER 2 SPK, SPEAKER 8
0_PB RIGHT SPEAKER GND BK0_8-GXL RSPK, RIGHT_SPEAKER 2 SPK, SPEAKER 2
12AC
IGNITION SW ACC POWER W0_8_GXL S_KEY, IGNITION_SWITCH 4 SPL_ACC, ULTRASONIC A
C
12AC
ACC PRM CONTROL POWER W0_8_GXL SPL_ACC, ULTRASONIC A PRM_D1, PRM SIGNAL A
C_B
4002-15

21C Bk - 1.0


Color, Size,
and Material
12AC PWR CONVERTER PRM CTRL
W0_8_GXL SPL_ACC, ULTRASONIC A PRM_E2, PRM SIGNAL A
C_C PWR
12V 12V PWR TO OUTLET 1 OR1_0-GXL PO1, POWER_OUTLET A ECD, ELECT CNTR D AA4
12V_A 12V PWR TO OUTLET 2 OR1_0-GXL PO2, POWER_OUTLET A ECD, ELECT CNTR D AA5
CAB_RF, CAB TO ROOF
12V_B 12V FUSED PWR TO RADIO OR1_0-GXL N ECD, ELECT CNTR D AA6
CONNECTION
CNV, 24V TO 12V PWR
12V_C 12V SWITCHED POWER OR2_0-GXL 5 SPL_12V, ULTRASONIC A
CONVERTER
12V_D PLUG 1 12V SW PWR OR1_0-GXL SPL_12V, ULTRASONIC A ECD, ELECT CNTR D A4
12V_E PLUG 2 12V SW PWR OR1_0-GXL SPL_12V, ULTRASONIC A ECD, ELECT CNTR D A5
12V_F RADIO 12V SW PWR OR1_0-GXL SPL_12V, ULTRASONIC A ECD, ELECT CNTR D A6
12V_G 2 WAY RADIO 12V SW PWR OR1_0-GXL SPL_12V, ULTRASONIC A ECD, ELECT CNTR D A7
12V_H 12V FUSED PWR TO RADIO OR0_8-GXL N SPL_RAD, ULTRASONIC A
NECTION
12V_H
12V FUSED PWR TO RADIO OR0_8-GXL SPL_RAD, ULTRASONIC A RAD, RADIO_POWER 7
A
12V_H
12V FUSED PWR TO RADIO OR0_8-GXL SPL_RAD, ULTRASONIC A RAD, RADIO_POWER 4
B
DC3,
13C FUEL SHUTOFF FUSED PWR OR1_0-SXL 1 DISC, DISCONNECT-ENGINE A
FUEL_SOL_DISCONNECT
13C_A FUEL SHUTOFF FUSED PWR OR1_0-SXL ENG_D, DISC_HARNESS A ENG, ENGINE-CAB 21
13C_B FUEL SHUTOFF FUSED PWR OR1_0-SXL CAB_E, CAB-ENGINE 21 ECA, ELECT CNTR A A9
TDM,
13D TIME DELAY RLY CTRL PWR OR1_0-GXL 1 PRM_B2, PRM SIGNAL A
TIME_DELAY_MODULE
13H TIME DELAY POWER OR3_0-GXL SPL_DLY_RL, ULTRASONIC A PRM_B1, PRM OUTPUT C
13H_B AIC TIME DELAY POWER OR0_8-GXL SPL_DLY_RL, ULTRASONIC A ECD, ELECT CNTR D A3
13H_C TRANS ECM TIME DLY PWR OR0_8-GXL SPL_DLY_RL, ULTRASONIC A ECD, ELECT CNTR D A1
13H_D ENG ECM TIME DLY PWR OR3_0-GXL SPL_DLY_RL, ULTRASONIC A ECD, ELECT CNTR D A2
13K IGNITION SWITCH POWER OR1_0-GXL S_KEY, IGNITION_SWITCH 3 SPL_PK1, SPLICE 3-4WAY E
TDM,
13K_A IGNITION SWITCH POWER OR1_0-GXL 5 SPL_PK1, SPLICE 3-4WAY G
TIME_DELAY_MODULE
13K_B IGNITION SWITCH POWER OR1_0-GXL SPL_PK1, SPLICE 3-4WAY F PRM_A1, PRM SIGNAL A
13K_C IGNITION SWITCH POWER OR1_0-GXL SPL_PK1, SPLICE 3-4WAY H ECB, ELECT CNTR B D1
DC4,
13M FUEL SHUTOFF FUSED PWR OR1_0-SXL 1 DISC, DISCONNECT-ENGINE B
FUEL_SOL_DISCONNECT
13M_
FUEL SHUTOFF FUSED PWR OR0_8-TXL ENG_D, DISC_HARNESS B EDC7, ENGINE CONTROLLER 40
A
13M_
KEY SW PWR DISC SW OR1_0-GXL ENG_D, DISC_HARNESS B QSM11, ENGINE CONTROLLER 38
B
4002-16

21C Bk - 1.0


Color, Size,
and Material
13V VOLTMETER INPUT ANALOG OR0_8-TXL 1 ECB, ELECT CNTR B D2
STER 1
215F,
14_A ALTERNATOR D+ LG0_8-GXL CAB_E, CAB-ENGINE 26 1
ALTERNATOR_RESISTOR
17P_A SW PAD PWR FR0M AIC PWR OR0_8-TXL SW_PD, SWITCH PAD 9 AIC_1, ADV INSTR CLUSTER 1 25
18B LH HIGH BEAM FUSED PWR OR1_0-SXL FRONT, CAB-FRNT_CHAS 7 LLF, LIGHTS_LH 3
18B_A LH HIGH BEAM FUSED PWR OR0_8-GXL CAB_F, CAB-FRNT_CHAS 7 ECB, ELECT CNTR B AA3
18C RH HIGH BEAM FUSED PWR OR1_0-SXL FRONT, CAB-FRNT_CHAS 16 LRF, LIGHTS_RH 3
18C_A RH HIGH BEAM FUSED PWR OR0_8-GXL CAB_F, CAB-FRNT_CHAS 16 ECB, ELECT CNTR B AA4
18D LH LOW BEAM FUSED PWR OR1_0-SXL FRONT, CAB-FRNT_CHAS 14 LLF, LIGHTS_LH 2
18D_A LH LOW BEAM FUSED PWR OR0_8-GXL CAB_F, CAB-FRNT_CHAS 14 ECB, ELECT CNTR B AA6
18E RH LOW BEAM FUSED PWR OR1_0-SXL FRONT, CAB-FRNT_CHAS 15 LRF, LIGHTS_RH 2
18E_A RH LOW BEAM FUSED PWR OR0_8-GXL CAB_F, CAB-FRNT_CHAS 15 ECB, ELECT CNTR B AA5
18F LH POSN/TAIL FUSED PWR OR1_0-SXL FRONT, CAB-FRNT_CHAS 6 LLF, LIGHTS_LH 4
18F_A LH POSN/TAIL FUSED PWR OR0_8-GXL CAB_E, CAB-ENGINE 5 SPL_POS_L, ULTRASONIC
18F_A
LH POSN/TAIL FUSED PWR OR1_0-SXL ENG, ENGINE-CAB 5 ENG_H, ENGINE TO HOOD 6
N
18F_B LH POSN/TAIL FUSED PWR OR1_0-SXL ENG, ENGINE-CAB 5 LLR_E, LH_REAR_COMB_LT 3
18F_B
LH POSN/TAIL FUSED PWR OR1_0-SXL HD_N, HOOD TO ENG 6 LLR_N, LH_REAR_COMB_LT B
N
18F_C LH POSN/TAIL FUSED PWR OR1_0-GXL SPL_POS_L, ULTRASONIC ECB, ELECT CNTR B AA7
18F_E LH POSN/TAIL FUSED PWR OR0_8-GXL CAB_F, CAB-FRNT_CHAS 6 SPL_POS_L, ULTRASONIC
18F_F LH POSN/TAIL FUSED PWR OR1_0-SXL HD_9, HOOD TO ENG 6 LLR_9, LH_REAR_COMB_LT 3
18G RH POSN/TAIL FUSED PWR OR1_0-GXL SPL_POS_R, ULTRASONIC ECB, ELECT CNTR B AA8
18G_A RH POSN/TAIL FUSED PWR OR1_0-SXL FRONT, CAB-FRNT_CHAS 5 LRF, LIGHTS_RH 4
18G_ SPL_POS_NA, ULTRASO-
RH POSN/TAIL FUSED PWR OR1_0-SXL A LRR_N, RH_REAR_COMB_LT B
CN NIC
18G_
LIC PLATE LT FUSED PWR OR1_0-SXL SPL_POS, ULTRASONIC A E_HD, TRANS-HOOD A
D
18G_E LIC PLATE LT FUSED PWR OR0_8-GXL HD_E, HOOD-TRANS A LPL, LIC_PLATE_LIGHT A
18G_E
LIC PLATE LT FUSED PWR OR1_0-SXL LPL, LIC_PLATE_LIGHT A SPL_POS_NA, ULTRASONIC A
N
18G_F RH POSN/TAIL FUSED PWR OR0_8-GXL CAB_E, CAB-ENGINE 9 SPL_POS_R, ULTRASONIC
18G_
RH POSN/TAIL FUSED PWR OR0_8-GXL CAB_F, CAB-FRNT_CHAS 5 SPL_POS_R, ULTRASONIC
G
18G_
RH POSN/TAIL FUSED PWR OR1_0-SXL ENG, ENGINE-CAB 9 SPL_POS, ULTRASONIC A
H
18G_
RH POSN/TAIL FUSED PWR OR1_0-SXL ENG, ENGINE-CAB 9 ENG_H, ENGINE TO HOOD 5
HN
4002-17

21C Bk - 1.0


Color, Size,
and Material
LRR_E,
18G_J RH POSN/TAIL FUSED PWR OR1_0-SXL 3 SPL_POS, ULTRASONIC A
RH_REAR_COMB_LT
18G_J
RH POSN/TAIL FUSED PWR OR1_0-SXL HD_N, HOOD TO ENG 5 SPL_POS_NA, ULTRASONIC A
N
18G_K RH POSN/TAIL FUSED PWR OR1_0-SXL HD_9, HOOD TO ENG 5 SPL_P9, ULTRASONIC A
18G_L RH POSN/TAIL FUSED PWR OR1_0-SXL SPL_P9, ULTRASONIC A E_HD9, TRANS-HOOD A
18G_
RH POSN/TAIL FUSED PWR OR1_0-SXL SPL_P9, ULTRASONIC A LRR_9, RH_REAR_COMB_LT 3
M
18J EDC7 TIME DLY FSD PWR OR2_0-GXL CAB_E, CAB-ENGINE 18 SPL_D2, ULTRASONIC A
18J_A EDC7 TIME DLY FSD PWR OR2_0-SXL ENG, ENGINE-CAB 18 SPL_EDC2, ULTRASONIC A
18J_B EDC7 TIME DLY FSD PWR OR1_0-GXL SPL_EDC2, ULTRASONIC A EDC7, ENGINE CONTROLLER 3
18J_C EDC7 TIME DLY FSD PWR OR1_0-GXL SPL_EDC2, ULTRASONIC A EDC7, ENGINE CONTROLLER 2
18J_D EDC7 TIME DLY FSD PWR OR1_0-GXL SPL_EDC4, ULTRASONIC A EDC7, ENGINE CONTROLLER 8
18J_E EDC7 TIME DLY FSD PWR OR1_0-GXL SPL_EDC4, ULTRASONIC A EDC7, ENGINE CONTROLLER 9
18J_F EDC7 TIME DLY FSD PWR OR2_0-SXL ENG, ENGINE-CAB 14 SPL_EDC4, ULTRASONIC A
18J_G EDC7 TIME DLY FSD PWR OR2_0-GXL CAB_E, CAB-ENGINE 14 SPL_D2, ULTRASONIC A
18J_H WIF SENSOR FUSED PWR OR1_0-GXL SPL_EDC4, ULTRASONIC A WIF, WATER_IN_FUEL_SNSR 3
18J_K EDC7 TIME DLY FSD PWR OR3_0-GXL SPL_D2, ULTRASONIC A ECD, ELECT CNTR D AA2
18J_L QSM11 TIME DELAY PWR OR0_8-GXL SPL_EDC4, ULTRASONIC A QSM11, ENGINE CONTROLLER 17
18J_M QSM11 TIME DELAY PWR OR0_8-GXL SPL_EDC2, ULTRASONIC A QSM11, ENGINE CONTROLLER 7
18J_N QSM11 TIME DELAY PWR OR0_8-GXL SPL_EDC2, ULTRASONIC A QSM11, ENGINE CONTROLLER 8
18J_P QSM11 TIME DELAY PWR OR0_8-GXL SPL_EDC4, ULTRASONIC A QSM11, ENGINE CONTROLLER 18
18J_Q QSM11 TIME DELAY PWR OR0_8-GXL SPL_EDC4, ULTRASONIC A QSM11, ENGINE CONTROLLER 28
18K_A DIAGNOSTIC FUSED PWR OR0_8-GXL DIA, DIAGNOSTIC B ECC, ELECT CNTR C A9
18L_A COMFORT STEER FSD PWR OR0_8-GXL SPL_CSTR, ULTRASONIC A ECA, ELECT CNTR A A2
18L_B COMFORT STEER FSD PWR OR0_8-GXL SPL_CSTR, ULTRASONIC A ECC, ELECT CNTR C D9
18L_C COMFORT STEER FSD PWR OR0_8-GXL SPL_CSTR, ULTRASONIC A ECC, ELECT CNTR C B9
18L_D COMFORT STEER FSD PWR OR0_8-GXL SCS, COMFORT STEER SW 2 SPL_CSTR, ULTRASONIC A
18M AC RELAY FUSED PWR OR0_8-GXL ECA, ELECT CNTR A C5 ECD, ELECT CNTR D B9
BLOWER MOTOR FUSED
18N OR3_0-GXL SPL_BLWR, ULTRASONIC A ECA, ELECT CNTR A C1
PWR
BLOWER MOTOR FUSED
18N_A OR0_8-GXL SPL_BLWR, ULTRASONIC A HVAC1, HVAC1 B
PWR
BLOWER MOTOR FUSED
18N_B OR3_0-GXL SPL_BLWR, ULTRASONIC A HVAC2, HVAC2 1
PWR
18R VOLTMETER RLY FUSED PWR OR2_0-SXL ENG, ENGINE-CAB 13 PRM_C1, PRM OUTPUT A
18R_A VOLTMETER RLY FUSED PWR OR2_0-GXL CAB_E, CAB-ENGINE 13 ECB, ELECT CNTR B B1
OUTPUT SP SENSOR FSD TRANS, CAB-TRANSMIS-
19A OR1_0-SXL 29 OSS, OUT_SPEED_SENS 3
PWR SION
4002-18

21C Bk - 1.0


Color, Size,
and Material
BRAKE DECLUTCH SW FSD
19A_A OR1_0-SXL FRONT, CAB-FRNT_CHAS 27 PBD, DEC_PRESS_SW A
PWR
19A_B FNR SW FUSED PWR OR0_8-GXL 197M, FNR-MAIN_CAB 1 SPL_FNR, ULTRASONIC A
19A_C FNR SW FUSED PWR OR0_8-GXL 197F, MAIN_CAB_FNR 1 SPL_TRNS_PWR, TRANS_PWR F
TRANS ENABLE SW FUSED
19A_D OR0_8-GXL STE, TRANS_ENABLE_SW 2 SPL_D15, ULTRASONIC A
PWR
TRANS ENABLE SW FUSED
19A_E OR0_8-GXL STE, TRANS_ENABLE_SW 10 SPL_D15, ULTRASONIC A
PWR
TRANS ENABLE SW FUSED SPL_TRNS_PWR,
19A_F OR0_8-GXL B SPL_D15, ULTRASONIC A
PWR TRANS_PWR
19A_G FNR SW FUSED PWR OR0_8-GXL SPL_FNR, ULTRASONIC A SFNR, FNR_SWITCH 8
TS1,
19A_H TRANS SHIFTER FUSED PWR OR0_8-GXL A SPL_TRNS_PWR, TRANS_PWR M
TRANSMISSION_SHIFTER
SPC,
19A_J PLOT CTRL SW FUSED PWR OR0_8-GXL 2 SPL_PB1, ULTRASONIC A
PILOT_CONTROL_SWITCH
SPL_TRNS_PWR,
19A_K TECM FUSED PWR OR0_8-TXL J TECM, TRANS 45
TRANS_PWR
SPB,
19A_L PARK BRK SW FUSED PWR OR0_8-GXL 2 SPL_PB1, ULTRASONIC A
PARKING_BRAKE_SWITCH
19A_ OUTPUT SP SNSR FUSED CAB_T, CAB-TRANSMIS-
OR0_8-TXL 29 SPL_TRNS_PWR, TRANS_PWR K
M PWR SION
SPL_TRNS_PWR,
19A_N TRANS FUSE PWR OR1_0-GXL A ECA, ELECT CNTR A A1
TRANS_PWR
BKUP ALM RLY CTRL FSD SPL_TRNS_PWR,
19A_P BK1_0-GXL G ECD, ELECT CNTR D AA10
PWR TRANS_PWR
TRANS/AUTO SW FUSED
19A_Q OR0_8-GXL STA, TRANS_AUTO_SW 2 SPL_TRNS_PWR, TRANS_PWR C
PWR
19A_R DECLUTCH SW FSD PWR OR0_8-GXL SDC, DECLUTCH_SWITCH 2 SPL_TRNS_PWR, TRANS_PWR H
SPL_TRNS_PWR,
19A_S TRANS FUSE PWR OR0_8-GXL L SPL_PB1, ULTRASONIC A
TRANS_PWR
19A_T BRK DECLUTCH SW FSD PWR OR0_8-GXL CAB_F, CAB-FRNT_CHAS 27 SPL_TRNS_PWR, TRANS_PWR D
TRANS KICK DOWN SW FSD
19A_U OR0_8-GXL SPL_FNR, ULTRASONIC A 20M, TRANS_KICK-DOWN 1
PWR
19A_V FNR SW FSD PWR OR0_8-GXL SFNR, FNR_SWITCH 5 SPL_FNR, ULTRASONIC A
108F,
19A_
DIAGNOSTIC CONN FSD PWR OR0_8-GXL DIAGNOSTIC_CONNECTO 1 SPL_TRNS_PWR, TRANS_PWR E
W
R
SRHSTLK, RH STALK
19B TURN SIGNAL FSD PWR OR0_8-GXL 49a ECA, ELECT CNTR A A8
SWITCH
19C_A PILOT CTRL RLY FSD PWR OR1_0-GXL SPL_D24, ULTRASONIC A ECA, ELECT CNTR A A5
19C_B PILOT CTRL RLY FSD PWR OR1_0-GXL SPL_D24, ULTRASONIC A ECD, ELECT CNTR D B5
4002-19

21C Bk - 1.0


Color, Size,
and Material
19C_C PILOT CTRL RLY FSD PWR OR0_8-GXL SPL_D24, ULTRASONIC A ECD, ELECT CNTR D D5
19C_D RIDE CTRL SW FSD PWR OR1_0-GXL SRC, RIDE_CONTROL_SW 2 SPL_D24, ULTRASONIC A
19D_A PARK BRK RLY FSD PWR OR1_0-GXL SPL_PBS, ULTRASONIC A ECA, ELECT CNTR A A6
19D_B PARK BRK RLY FSD PWR OR0_8-GXL SPL_PBS, ULTRASONIC A ECB, ELECT CNTR B D9
19D_C PARK BRK RLY FSD PWR OR1_0-GXL SPL_PBS, ULTRASONIC A ECB, ELECT CNTR B B9
AIC_2, ADV INSTR CLUS-
19E_A AIC WAKE UP IGN OR0_8-TXL 21 ECA, ELECT CNTR A A3
TER 2
19H BKUP ALM RLY FSD PWR OR1_0-GXL ECA, ELECT CNTR A C4 ECD, ELECT CNTR D A10
19J FNT WPR FSD PWR OR0_8-GXL SPL_PK3, SPLICE 3-4WAY K ECA, ELECT CNTR A C2
19J_A FNT WPR MOTOR FSD PWR OR0_8-GXL SPL_PK3, SPLICE 3-4WAY M FWM, FRONT-WIPER_MOTOR C
FNT WPR/ WSHR SW FSD SFWW, FRONT
19J_B OR0_8-GXL 5 SPL_PK3, SPLICE 3-4WAY J
PWR WIPER/WASHER
19J_C FNT WPR RLY FSD PWR OR0_8-GXL SPL_PK3, SPLICE 3-4WAY L SPL_FW, ULTRASONIC A
FNT WPR RLY HS CTRL FSD
19J_D OR0_8-GXL SPL_FW, ULTRASONIC A ECD, ELECT CNTR D D1
PWR
19J_E FNT WPR RLY FSD PWR OR0_8-GXL SPL_FW, ULTRASONIC A ECD, ELECT CNTR D B1
FNT WPR RLY LS CTRL FSD
19J_F OR0_8-GXL SPL_FW, ULTRASONIC A ECD ELECT CNTR D D3
PWR
19J_G WPR CUT OUT RLY FSD PWR OR0_8-GXL SPL_FW, ULTRASONIC A K_WCO, WIPER CUTOUT 86
19K REAR WPR FSD PWR OR1_0-GXL SPL_RWW, ULTRASONIC A ECA, ELECT CNTR A C3
19K_A REAR WPR SW FSD PWR OR1_0-GXL SRWP, REAR_WIPER_SW 3 SPL_RWW, ULTRASONIC A
19K_B REAR WPR SW FSD PWR OR0_8-GXL SRWP, REAR_WIPER_SW 5 SPL_RWW, ULTRASONIC A
CAB_RF, CAB TO ROOF
19K_C REAR WPR MOTOR FSD PWR OR1_0-GXL J SPL_RWW, ULTRASONIC A
CONNECTION
19K_D REAR WPR MOTOR FSD PWR OR1_0-SXL J RWM, REAR_WIPER_MTR C
NECTION
19L PWR CONVERTER FSD PWR OR2_0-GXL PRM_E1, PRM OUTPUT C SPL_CNV, ULTRASONIC A
CNV, 24V TO 12V PWR
19L_A PWR CONVERTER FSD PWR OR2_0-GXL 1 SPL_CNV, ULTRASONIC A
CONVERTER
CNV, 24V TO 12V PWR
19L_B PWR CONVERTER FSD PWR OR2_0-GXL 2 SPL_CNV, ULTRASONIC A
CONVERTER
SEC STR ACCESSORY FSD CAB_T, CAB-TRANSMIS-
19M OR0_8-GXL 3 ECA, ELECT CNTR A C7
PWR SION
19M_ SEC STR ACCESSORY FSD TRANS, CAB-TRANSMIS-
OR1_0-SXL 3 TR_SS, SEC_STR_MOD_OPT A
A PWR SION
19M_ SEC STR ACCESSORY FSD
OR1_0-SXL SSM, SEC STR MOD 7 SS_TR, SS_MOD-TRANS A
C PWR
19N SEAT CPRSR FSD PWR OR1_0-GXL SC, SEAT_COMP_MOTOR A ECA, ELECT CNTR A C6
SPL_PIN, SPL_BACK LGT
19P PIN ENGAGE/FAN FSD PWR OR0_8-GXL B ECA, ELECT CNTR A A7
PWR
19P_A PIN ENGAGE SW FSD PWR OR0_8-GXL SPE, PIN_ENGAGE_SW 2 SPL_PIN, SPL_BACK LGT PWR A
19P_C FAN REV SW FSD PWR OR0_8-GXL SFC, FAN_CONTROL_SW 5 SPL_PIN, SPL_BACK LGT PWR C
4002-20

21C Bk - 1.0


Color, Size,
and Material
19P_D FAN REV RLY FSD PWR OR0_8-GXL E ECB, ELECT CNTR B D7
PWR
19P_E FAN REV RLY FSD PWR OR0_8-GXL F ECB, ELECT CNTR B B7
PWR
19R SEC STR IGN FSD PWR OR0_8-GXL DM, DIODE OR C SPL_2, ULTRASONIC A
19RR SEC STR IGN FSD PWR OR0_8-GXL DM, DIODE OR A ECA, ELECT CNTR A A4
19R_A SEC STR IGN FSD PWR OR1_0-SXL 4 TR_SS, SEC_STR_MOD_OPT B
SION
19R_C SEC STR IGN FSD PWR OR1_0-SXL SSM, SEC STR MOD 1 SS_TR, SS_MOD-TRANS B
216F,
19R_D ALTNR RESISTOR FSD PWR OR0_8-GXL SPL_2, ULTRASONIC A 1
ALTERNATOR_RESISTOR
19R_E SEC STR IGN FSD PWR OR0_8-GXL SPL_2, ULTRASONIC A CAB_T, CAB-TRANSMISSION 4
19S1 SEC STR FSD PWR OR1_0-GXL SS, SEC STR FUSED PWR 1 CAB_T, CAB-TRANSMISSION 26
19S1_ TRANS, CAB-TRANSMIS-
SEC STR FSD PWR OR1_0-SXL 26 TR_SS, SEC_STR_MOD_OPT E
E SION
19S1_
SEC STR FSD PWR R1_0-SXL SSM, SEC STR MOD 3 SS_TR, SS_MOD-TRANS E
X
19S_B AIC DELAY FSD PWR OR0_8-GXL SPL_DLY3, ULTRASONIC A ECD, ELECT CNTR D AA3
19S_C AIC DELAY FSD PWR OR0_8-TXL SPL_DLY3, ULTRASONIC A AIC_2, ADV INSTR CLUSTER 2 20
19S_D AIC DELAY FSD PWR OR0_8-TXL SPL_DLY3, ULTRASONIC A AIC_2, ADV INSTR CLUSTER 2 14
19T_A TECM DELAY FSD PWR OR0_8-TXL TECM, TRANS 23 ECD, ELECT CNTR D AA1
19U HORN RLY FSD PWR OR0_8-GXL SPL_HRN, ULTRASONIC A ECC, ELECT CNTR C A6
19U_A HORN RLY FSD PWR OR0_8-GXL SPL_HRN, ULTRASONIC A ECC, ELECT CNTR C B7
19U_B BEACON DOME LT FSD PWR OR1_0-GXL SPL_LT, ULTRASONIC A ECC, ELECT CNTR C A1
19U_C DOME LT FSD PWR OR0_8-GXL D LDM1, DOME_LIGHT_B+ 1
NECTION
CAB_RF, CAB TO ROOF
19U_D DOME LT FSD PWR OR0_8-GXL D SPL_LT, ULTRASONIC A
CONNECTION
19U_E HORN RLY FSD PWR OR0_8-GXL SPL_HRN, ULTRASONIC A ECC, ELECT CNTR C D7
19U_F DOOR SW FSD PWR BK0_8-GXL S DS, DOOR SWITCH A
NECTION
19U_ CAB_RF, CAB TO ROOF
DOOR SW FSD PWR OR0_8-GXL S SPL_LT, ULTRASONIC A
G CONNECTION
19U_H BEACON SWITCH FSD PWR OR1_0-GXL SBE, BEACON_SW 2 SPL_LT, ULTRASONIC A
19W CIGAR LIGHTER FSD PWR OR3_0-GXL CL, CIGAR_LIGHTER 1 ECC, ELECT CNTR C A8
19Y HOOD CTRL FSD PWR OR1_0-GXL SPL_HOOD, ULTRASONIC A ECC, ELECT CNTR C A7
19Y_A HOOD UP RLY FSD PWR OR1_0-GXL SPL_HOOD, ULTRASONIC A ECC, ELECT CNTR C D2
19Y_B HOOD DOWN RLY FSD PWR OR1_0-GXL SPL_HOOD, ULTRASONIC A ECC, ELECT CNTR C D4
19Y_C HOOD SWITCH FSD PWR OR1_0-GXL CAB_E, CAB-ENGINE 35 SPL_HOOD, ULTRASONIC A
19Y_D HOOD SWITCH FSD PWR OR1_0-GXL ENG, ENGINE-CAB 35 HD, HOOD_SWITCH B
19Z DRIVING LTS SW FSD PWR OR1_0-GXL SPL_PK2, SPLICE 3-4WAY G ECC, ELECT CNTR C A3
19Z_A DRIVING LTS SW FSD PWR OR1_0-GXL SDR, DRIVING LIGHTS SW 2 SPL_PK2, SPLICE 3-4WAY E
19Z_B DRIVING LTS SW FSD PWR OR1_0-GXL SDR, DRIVING LIGHTS SW 5 SPL_PK2, SPLICE 3-4WAY F
4002-21

21C Bk - 1.0


Color, Size,
and Material
SRHSTLK, RH STALK
19Z_C HIGH BEAM FLASH FSD PWR OR1_0-GXL 56d SPL_PK2, SPLICE 3-4WAY H
SWITCH
1A IGN SW FSD PWR R1_0-GXL S_KEY, IGNITION_SWITCH 1 SPL_DLY, ULTRASONIC A
1CB CAB CB PROTECTED PWR R19_0-SXL CB1A, CIRCUIT BRKR 1 CBPW, CAB POWER 1
1CB_
CAB CB PROTECTED PWR R19_0-SXL P_A3, B+ POWER 1 CAB_PW, CAB POWER 1
A
TIME DELAY/IGN SW FSD
1DM R1_0-GXL SPL_DLY, ULTRASONIC A ECC, ELECT CNTR C A5
PWR
TDM,
1DN TIME DELAY FSD PWR R1_0-GXL 2 SPL_DLY, ULTRASONIC A
TIME_DELAY_MODULE
1NC CAB CB PRM PWR R19_0-SXL B1, STARTER PWR STUD 1 CB2B, CAB B+ CB 1
1_AA BRK LT SW PWR R1_0-SXL FRONT, CAB-FRNT_CHAS 22 PBL, BRAKE_LT_PRES_SW 1
1_B9 PRM C PWR R8_0-SXL CB3B, CAB B+ CB 1 P_C5, B+ PWR FRM PRMC 1
1_BA ALTERNATOR B+ R13_0-SXL AB+, ALTERNATOR_B+ 1 B2, STARTER_POWER 1
1_BB STRTR SOL PWR R8_0-SXL 193, STARTER_RELAY 1 194, STARTER_SIGNAL 1
1_BC CAB CB PWR R19_0-SXL P_C3, B+ PWR FRM PRMC 1 CB1B, CAB B+ CB 1
1_BE GRID HTR PWR R19_0-SXL 115, GRID_HTR_PWR 1 GH, GRID_HEATER 1
1_C ECC BAT PWR R8_0-GXL P_A1, B+ POWER 1 L1_ECC, ECC BATT PWR cs01
SPL_FLSHR_PWR, ULTRASO-
1_DR BRK LT SW PWR R1_0-GXL CAB_F, CAB-FRNT_CHAS 22 A
NIC
FLSHR, SPL_FLSHR_PWR, ULTRASO-
1_DU FLASHER MODULE PWR R1_0-GXL 1 A
FLASHER_MODULE NIC
SPL_FLSHR_PWR, ULTRA-
1_DV BRK LTS/FLASHER BAT PWR R2_0-GXL A ECC, ELECT CNTR C A4
SONIC
SPL_FLSHR_PWR, ULTRA-
1_DW BRAKE LT RLY BAT PWR R1_0-GXL A ECC, ELECT CNTR C B5
SONIC
1_E GRID HTR FUSE BAT PWR R19_0-SXL P_C2, B+ PWR FRM PRMC 1 GHF1, GRID HTR FUSE 1
1_GA FLTR HTR PWR R3_0-SXL PRM_C1, PRM OUTPUT C SPL_HTR, ULTRASONIC A
1_GB FUEL FLTR HTR PWR R2_0-SXL SPL_HTR, ULTRASONIC A FFH, FUEL_FLTR_HTR A
1_GC WATER SEP HTR PWR R2_0-SXL SPL_HTR, ULTRASONIC A WSH, WATER_SEP_HTR B
SPL_FLSHR_PWR, ULTRASO-
1_KA HAZARD SW PWR R1_0-GXL SHZ, HAZARD_SWITCH 2 A
NIC
1_NA BATTERY CROSSOVER R62_0-SGR BT3, STARTER-BATTERY 1 BT2, DISCONECT-BATTERY 1
1_NB BATTERY STRTR R62_0-SGR BT1, BATTERY_STARTER 1 B3, STARTER-BATTERY 1
1_NC B+ PWR PRMC R19_0-SXL B1, STARTER PWR STUD 1 P_C1, B+ PWR FRM PRMC 1
244F, STAR-
1_ND SSM PWR R62_0-SGR 1 B4, STARTER_POWER 1
TER-SEC_STRG_MTR
1_Y GRID HTR FSD PWR R19_0-SXL GHF3, GRID_HTR_FUSE 1 GHF4, GRID_HTR 1
1_Z STRTR RLY BAT PWR R8_0-SXL P_C4, B+ PWR FRM PRMC 1 195, STR_REL_PWR 1
20G_A EDC7 ISO-K INTERFACE W0_8-TXL ENG, ENGINE-CAB 31 EDC7, ENGINE CONTROLLER 89
20G_B EDC7 ISO-K INTERFACE W0_8_GXL CAB_E, CAB-ENGINE 31 DIA, DIAGNOSTIC E
21C NEUT START RLY OUTPUT W0_8_GXL SPL_CR, ULTRASONIC A ECB, ELECT CNTR B D4
21C_A NEUT START RLY OUTPUT W0_8_GXL SPL_CR, ULTRASONIC A ECB, ELECT CNTR B D5
4002-22

21C Bk - 1.0


Color, Size,
and Material
21C_B NEUT START RLY OUTPUT W0_8_GXL SPL_CR, ULTRASONIC A ECB, ELECT CNTR B A10
21C_C STRTR RLY SIGNAL W0_8_GXL CAB_E, CAB-ENGINE 1 SPL_CR, ULTRASONIC A
21C_D STRTR RLY SIGNAL W1_0-SXL SR_9, STR_REL_signal 1 ENG, ENGINE-CAB 1
21D STRTR RLY SIGNAL W1_0-SXL SRC_1, RELAY 1 ENG, ENGINE-CAB 15
21D_A STRTR RLY SIGNAL W0_8_GXL SPL_4, ULTRASONIC A ECB, ELECT CNTR B AA9
21D_B STRTR RLY SIGNAL W0_8_GXL 140M, DIODE_MODULE E SPL_4, ULTRASONIC A
21D_C STRTR RLY SIGNAL W0_8_GXL CAB_E, CAB-ENGINE 15 SPL_4, ULTRASONIC A
21E KEY SWITCH CRANK W0_8_GXL CAB_E, CAB-ENGINE 27 ECB, ELECT CNTR B D6
21E_A KEY SWITCH CRANK W0_8-TXL ENG, ENGINE-CAB 27 EDC7, ENGINE CONTROLLER 32
21F EDC7 DIGITAL GND W0_8_GXL CAB_E, CAB-ENGINE 11 ECB, ELECT CNTR B B5
21F_A EDC7 DIGITAL GND W0_8_GXL ENG, ENGINE-CAB 11 SPL_EDC3, ULTRASONIC A
21F_B EDC7 DIGITAL GND W0_8-TXL SPL_EDC3, ULTRASONIC A EDC7, ENGINE CONTROLLER 29
21F_C EDC7 DIGITAL GND W0_8-TXL RTHP, THROTTLE_PEDAL 1 SPL_EDC3, ULTRASONIC A
21G EDC7 CRANK CTRL RLY W0_8_GXL CAB_E, CAB-ENGINE 3 ECB, ELECT CNTR B AA10
21GA EDC7 CRANK CTRL RLY W0_8-TXL ENG, ENGINE-CAB 3 EDC7, ENGINE CONTROLLER 37
21H CRANK CTRL RLY LSD W0_8_GXL CAB_E, CAB-ENGINE 4 ECB, ELECT CNTR B A9
21H_A CRANK CTRL RLY LSD W0_8-TXL ENG, ENGINE-CAB 4 EDC7, ENGINE CONTROLLER 17
21K IGN SW START SIGNAL W0_8_GXL S_KEY, IGNITION_SWITCH 2 SPL_CRK, ULTRASONIC A
21K_A IGN SW START SIGNAL W0_8-TXL SPL_CRK, ULTRASONIC A AIC_2, ADV INSTR CLUSTER 2 17
21K_B IGN SW START SIGNAL W0_8_GXL SPL_CRK, ULTRASONIC A ECB, ELECT CNTR B B3
24B THROT SIGNAL W0_8-TXL RTHP, THROTTLE_PEDAL 3 EDC7, ENGINE CONTROLLER 79
24B_A THROT SIGNAL W0_8-TXL RTHP, THROTTLE_PEDAL 3 QSM11, ENGINE CONTROLLER 47
24L LOW IDLE SWITCH W0_8-TXL RTHP, THROTTLE_PEDAL 6 EDC7, ENGINE CONTROLLER 48
24R THROT GND W0_8-TXL RTHP, THROTTLE_PEDAL 4 EDC7, ENGINE CONTROLLER 78
24R_A THROT GND W0_8-TXL RTHP, THROTTLE_PEDAL 4 QSM11, ENGINE CONTROLLER 49
24S THROT SUPPLY W0_8-TXL RTHP, THROTTLE_PEDAL 5 EDC7, ENGINE CONTROLLER 77
24S_A THROT SUPPLY W0_8-TXL RTHP, THROTTLE_PEDAL 5 QSM11, ENGINE CONTROLLER 48
W0_8_GXL_T TRANS, CAB-TRANSMIS-
25A ENG SP SIGNAL 7 ESS, ENG_SPEED_SENS 1
WIST SION
25A_A ENG SP SIGNAL LU0_8-TXL 7 TECM, TRANS 19
SION
25B INT SP SIGNAL 9 ISS, INT_SPEED_SENS 1
WIST SION
25B_A INT SP SIGNAL LU0_8-TXL 9 TECM, TRANS 42
SION
25C TURBINE SP SIGNAL 8 TSS, TURB_SPEED_SENS 1
WIST SION
25C_A TURBINE SP SIGNAL LU0_8-TXL 8 TECM, TRANS 41
SION
25D OUTPUT SP SIGNAL LU1_0-SXL 10 OSS, OUT_SPEED_SENS 2
SION
4002-23

21C Bk - 1.0


Color, Size,
and Material
25D_A OUTPUT SP SIGNAL LU0_8-TXL 10 TECM, TRANS 62
SION
TS1,
25F FORWARD SIGNAL LU0_8-TXL B TECM, TRANS 43
25G BRK DECLUTCH SW CTRL LU1_0-SXL FRONT, CAB-FRNT_CHAS 28 PBD, DEC_PRESS_SW B
25G_A BRK DECLUTCH SW CTRL LU0_8-GXL CAB_F, CAB-FRNT_CHAS 28 SPL_DC, ULTRASONIC A
25G_B BRK DECLUTCH SW CTRL LU0_8-GXL SDC, DECLUTCH_SWITCH 1 SPL_DC, ULTRASONIC A
25G_
BRK DECLUTCH SW CTRL LU0_8-TXL SPL_DC, ULTRASONIC A TECM, TRANS 66
C
25H TRANS AUTO SIGNAL LU0_8-TXL STA, TRANS_AUTO_SW 3 TECM, TRANS 29
25J TRANS SOL VALVE Y6 LU0_8-TXL 21 TRC, TRANS_CONTROL 6
SION
25J_A TRANS SOL VALVE Y6 LU0_8-TXL 21 TECM, TRANS 51
SION
25K TRANS SOL VALVE Y1 LU0_8-TXL 16 TRC, TRANS_CONTROL 1
SION
25K_9 TRANS SOL VALVE Y2 LU0_8-TXL 16 TRC, TRANS_CONTROL 2
SION
25K_A TRANS SOL VALVE Y1 LU0_8-TXL 16 TECM, TRANS 56
SION
25L TRANS SOL VALVE Y2 LU0_8-TXL 17 TRC, TRANS_CONTROL 2
SION
25L_9 TRANS SOL VALVE Y1 LU0_8-TXL 17 TRC, TRANS_CONTROL 1
SION
25L_A TRANS SOL VALVE Y2 LU0_8-TXL 17 TECM, TRANS 10
SION
25M TRANS SOL VALVE Y3 LU0_8-TXL 18 TRC, TRANS_CONTROL 3
SION
25M_ CAB_T, CAB-TRANSMIS-
TRANS SOL VALVE Y3 LU0_8-TXL 18 TECM, TRANS 32
A SION
25N TRANS SOL VALVE Y4 LU0_8-TXL 19 TRC, TRANS_CONTROL 4
SION
25N_A TRANS SOL VALVE Y4 LU0_8-TXL 19 TECM, TRANS 55
SION
25P TRANS SOL VALVE Y5 LU0_8-TXL 20 TRC, TRANS_CONTROL 5
SION
25P_A TRANS SOL VALVE Y5 LU0_8-TXL 20 TECM, TRANS 9
SION
TS1,
25R REVERSE SIGNAL LU0_8-TXL C TECM, TRANS 64
25S OUTPUT SW PWR VPS1 LU0_8-TXL 22 TRC, TRANS_CONTROL 7
SION
25S_A OUTPUT SW PWR VPS1 LU0_8-TXL 22 SPL_D12, ULTRASONIC A
SION
25S_B OUTPUT SW PWR VPS1 LU0_8-TXL SPL_D12, ULTRASONIC A TECM, TRANS 12
4002-24

21C Bk - 1.0


Color, Size,
and Material
25S_C OUTPUT SW PWR VPS1 LU0_8-TXL SPL_D12, ULTRASONIC A TECM, TRANS 13
25T NEUTRAL SIGNAL LU0_8-GXL SPL_NEU, ULTRASONIC A ECB, ELECT CNTR B D3
TS1,
25T_B NEUTRAL SIGNAL LU0_8-GXL D SPL_NEU, ULTRASONIC A
25T_C NEUTRAL SIGNAL LU0_8-TXL SPL_NEU, ULTRASONIC A TECM, TRANS 67
TS2,
25W 3RD AND 4TH GEAR SIGNAL LU0_8-TXL B TECM, TRANS 65
TS2,
25Y TRANS KICK DOWN SIGNAL LU0_8-GXL D SPL_D11, ULTRASONIC A
25Y_A TRANS KICK DOWN SIGNAL LU0_8-TXL SPL_D11, ULTRASONIC A TECM, TRANS 22
25Y_B TRANS KICK DOWN SIGNAL LU0_8-GXL 197F, MAIN_CAB_FNR 6 SPL_D11, ULTRASONIC A
25Y_C TRANS KICK DOWN SIGNAL LU0_8-GXL 20M, TRANS_KICK-DOWN 2 197M, FNR-MAIN_CAB 6
TS2,
25Z 1ST AND 4TH GEAR SIGNAL LU0_8-TXL C TECM, TRANS 63
26E TRANS ENABLE SIGNAL LU0_8-TXL STE, TRANS_ENABLE_SW 3 TECM, TRANS 31
26F_A FNR FORWARD SIGNAL LU0_8-GXL 197M, FNR-MAIN_CAB 2 SFNR FNR_SWITCH 6
26F_B FNR FORWARD SIGNAL LU0_8-TXL 197F, MAIN_CAB_FNR 2 TECM, TRANS 20
26J FNR SWITCH JUMPER LU0_8-GXL SFNR, FNR_SWITCH 2 SFNR, FNR_SWITCH 4
26N_A FNR NEUT SIGNAL LU0_8-GXL SFNR, FNR_SWITCH 3 197M, FNR-MAIN_CAB 3
26N_B FNR NEUT SIGNAL LU0_8-TXL 197F, MAIN_CAB_FNR 3 TECM, TRANS 44
26R_A FNR REVERSE SIGNAL LU0_8-GXL SFNR, FNR_SWITCH 1 197M, FNR-MAIN_CAB 4
26R_B FNR REVERSE SIGNAL LU0_8-TXL 197F, MAIN_CAB_FNR 4 TECM, TRANS 30
28E ETHER RLY SGNL W1_0-SXL PRM_C2, PRM SIGNAL A ENG, ENGINE-CAB 16
28F FUEL FLTR HTR RLY CTRL W0_8-TXL PRM_C2, PRM SIGNAL A EDC7, ENGINE CONTROLLER 36
28G GRID HTR SOURCE DR W1_0-GXL GHC, GRID_HEATER_REL 1 EDC7, ENGINE CONTROLLER 12
28H ETHER SW SIGNAL W0_8_GXL CAB_E, CAB-ENGINE 16 SETHR, ETHER SWITCH 3
28J ETHER AIC OK SIG W0_8_GXL SETHR, ETHER SWITCH 2 AIC_1, ADV INSTR CLUSTER 1 19
28P ETHER SOL PWR W1_0-SXL PRM_C1, PRM OUTPUT C ETHR, ETHER SOLENOID A
TRANS, CAB-TRANSMIS- CLS,
31D COOLANT LEVEL SIGNAL Y1_0-SXL 2 A
SION COOL_JUMP-COOL_SEND
31D_A COOLANT LEVEL SIGNAL Y0_8-TXL 2 AIC_2, ADV INSTR CLUSTER 2 26
SION
31D_B COOL LVL SNDR ENG TRNS Y1_0-SXL 2 TRAN_E, TRANS TO ENG 3
SION
CLS_,
31D_C COOL LVL SNDR ENG TRNS Y1_0-SXL A ENG_T, ENGINE TO TRANS 3
COOL_JUMP-COOL_SEND
31F AIR FLTR REST SW SGNL Y1_0-SXL ENG, ENGINE-CAB 28 PAF, AIR_FILT_RES_SW 1
31F_A AIR FLTR REST SW SGNL Y0_8-TXL CAB_E, CAB-ENGINE 28 SW_PD, SWITCH PAD 5
31H HYD FLTR REST SW SGNL Y1_0-SXL 23 PHF, HYD_OIL_FILT_RES_SW 1
SION
31H_A HYD FLTR REST SW SGNL Y0_8-GXL SW_PD, SWITCH PAD 4 CAB_T, CAB-TRANSMISSION 23
4002-25

21C Bk - 1.0


Color, Size,
and Material
SPC,
31L PILOT CTRL SW HIGH Y0_8-TXL 3 AIC_2, ADV INSTR CLUSTER 2 18
PILOT_CONTROL_SWITCH
32F TRANS FLTR MAINT SW Y1_0-SXL 31 FM, FILT_MAINT_SW 1
SION
32F_A TRANS FLTR MAINT SW Y0_8-TXL 31 TECM, TRANS 17
SION
32J_A TRANS ENABLE INDICTION Y0_8-GXL SFNR, FNR_SWITCH 7 197M, FNR-MAIN_CAB 5
32J_C TRANS ENABLE INDICTION Y0_8-GXL STE, TRANS_ENABLE_SW 9 SPL_D16, ULTRASONIC A
32J_D TRANS ENABLE INDICTION Y0_8-TXL SPL_D16, ULTRASONIC A TECM, TRANS 5
32J_E TRANS ENABLE INDICTION Y0_8-GXL 197F, MAIN_CAB_FNR 5 SPL_D16, ULTRASONIC A
33P BRK WARNING PRESS LOW Y1_0-SXL FRONT, CAB-FRNT_CHAS 26 PBW, BRK_WARN_PR_SW 1
33P_A BRK WARN PRESS LOW Y0_8-TXL CAB_F, CAB-FRNT_CHAS 26 AIC_2, ADV INSTR CLUSTER 2 5
RDNT BRK ACCUM PRESS CAB_T, CAB-TRANSMIS-
33R Y0_8-TXL 1 AIC_2, ADV INSTR CLUSTER 2 4
LOW SION
RDNT BRK ACCUM PRESS TRANS, CAB-TRANSMIS-
33R_A Y1_0-SXL 1 SPL_RD, ULTRASONIC A
LOW SION
RDNT BRK ACCUM PRESS
33R_B Y1_0-SXL SPL_RD, ULTRASONIC A PRB2, RED_BRAKE_SW A
LOW
RDNT BRK ACUCM PRESS
33R_C Y1_0-SXL SPL_RD, ULTRASONIC A PRB1, RED_BRAKE_SW A
LOW
SPB,
33U PARK BRK SWITCH Y0_8-TXL 3 AIC_2, ADV INSTR CLUSTER 2 6
PARKING_BRAKE_SWITCH
35A_9 BACKUP ALARM PWR Y1_0-SXL HD_9, HOOD TO ENG 7 E_HD9, TRANS-HOOD B
35A_A BKUP ALM RLY OUT Y0_8-GXL SPL_PK1, SPLICE 3-4WAY L ECD, ELECT CNTR D AA9
SBU,
35A_B BKUP ALM DISABLE SW Y0_8-GXL 2 SPL_PK1, SPLICE 3-4WAY K
BACK-UP_ALRM_DIS_SW
35A_C BKUP ALM RLY OUT Y0_8-GXL CAB_E, CAB-ENGINE 7 SPL_PK1, SPLICE 3-4WAY M
209M,
35A_D BKUP ALM RLY OUT Y0_8-GXL BACK-UP_ALRM_DISA_JM A SPL_PK1, SPLICE 3-4WAY J
P
209F,
35A_E BKUP ALM RLY OUT Y0_8-SXL BACK-UP_ALRM_DISA_JM A SPL_D8_C1, ULTRASONIC A
P
35A_F BKUP ALM RLY OUT Y0_8-SXL CAB_E, CAB-ENGINE 40 SPL_D8_C1, ULTRASONIC A
35A_G BKUP ALM RLY OUT Y1_0-SXL ENG, ENGINE-CAB 40 E_HD, TRANS-HOOD B
35A_G
BKUP ALM RLY OUT Y1_0-SXL ENG, ENGINE-CAB 40 ENG_H, ENGINE TO HOOD 7
N
35A_H BKUP ALM RLY OUT Y1_0-SXL HD_E, HOOD-TRANS B BU2, BACKUP_ALARM 1
35A_H
BKUP ALM RLY OUT Y1_0-SXL HD_N, HOOD TO ENG 7 BU2, BACKUP_ALARM 1
N
35A_J REVERSE LT K1_0-SXL ENG, ENGINE-CAB 7 SPL_A1A, ULTRASONIC A
4002-26

21C Bk - 1.0


Color, Size,
and Material
35A_K REVERSE LT K1_0-SXL SPL_A1A, ULTRASONIC A LRR_E, RH_REAR_COMB_LT 4
35A_L REVERSE LT K1_0-SXL SPL_A1A, ULTRASONIC A LLR_E, LH_REAR_COMB_LT 4
35A_
REVERSE LIGHT K1_0-SXL SPL_REV, ULTRASONIC A HD_9, HOOD TO ENG 8
M
35A_N REVERSE LIGHT K1_0-SXL SPL_REV, ULTRASONIC A LLR_9, LH_REAR_COMB_LT 4
LRR_9,
35A_P REVERSE LIGHT K1_0-SXL 4 SPL_REV, ULTRASONIC A
RH_REAR_COMB_LT
35A_R BKUP ALM RLY OUT Y1_0-SXL ENG, ENGINE-CAB 7 ENG_H, ENGINE TO HOOD 8
35B AIC BUZZER HSD W0_8-TXL BUZ, AIC_BUZZER 1 AIC_1, ADV INSTR CLUSTER 1 13
35C BKUP ALM RLY CTRL Y0_8-TXL TECM, TRANS 7 ECD, ELECT CNTR D A9
SBU,
35R_C BKUP ALM SW Y0_8-GXL 1 SPL_D8_C1, ULTRASONIC A
BACK-UP_ALRM_DIS_SW
WIF,
35W WIF INDICATOR W0_8-TXL 1 EDC7, ENGINE CONTROLLER 42
WATER_IN_FUEL_SNSR
35X SEC STR LOW PRESS SGNL Y0_8-TXL 6 AIC_2, ADV INSTR CLUSTER 2 11
SION
35X_A SEC STR LOW PRESS SGNL Y1_0-SXL SPL_C3, ULTRASONIC A PSS, SEC STR PRES SWITCH C
35X_B SEC STR LOW PRESS SGNL Y1_0-SXL 6 TR_SS, SEC_STR_MOD_OPT C
SION
35X_C SEC STR LOW PRESS SGNL Y1_0-SXL SPL_C3, ULTRASONIC A SS_TR, SS_MOD-TRANS C
35X_D SEC STR LOW PRESS SGNL Y1_0-SXL SSM, SEC STR MOD 8 SPL_C3, ULTRASONIC A
36A REAR AXLE TEMP P0_8-TXL CAB_E, CAB-ENGINE 32 AIC_1, ADV INSTR CLUSTER 1 5
36A_A REAR AXLE TEMP P1_0-SXL ENG, ENGINE-CAB 32 HOT_RA, REAR_AX_OIL_TEMP 1
36B FRONT AXLE TEMP P0_8-TXL 8 CAB_F, CAB-FRNT_CHAS 8
TER 1
36B_A FRONT AXLE TEMP P1_0-SXL FRONT, CAB-FRNT_CHAS 8 HOT_FA, FRNT_AX_OIL_TEMP 1
36C RADIATOR COOL TEMP SGNL P1_0-SXL ENG, ENGINE-CAB 34 RECT, ENG_COOL_TEMP A
36C_A RADITAOR COOL TEMP SGNL W0_8-TXL CAB_E, CAB-ENGINE 34 AIC_1, ADV INSTR CLUSTER 1 11
36D AXLE FILTER RES SENSOR P0_8-GXL CAB_F, CAB-FRNT_CHAS 10
TER 1
36D_A AXLE FILTER RES SENSOR P1_0-SXL SPL_FHR, ULTRASONIC A FRONT, CAB-FRNT_CHAS 10
36D_B REAR AXLE FLTR SNSR P1_0-SXL PFA, FRONT AXLE FILTER 1 SPL_FHR, ULTRASONIC A
36D_C FRONT AXLE FLTR SNSR P1_0-SXL PRA, REAR AXLE FILTER 1 SPL_FHR, ULTRASONIC A
36F FUEL LEVEL ANALOG P1_0-SXL ENG, ENGINE-CAB 33 RFL, FUEL_SENDER 1
36F_A FUEL LEVEL ANALOG P0_8-TXL CAB_E, CAB-ENGINE 33 AIC_1, ADV INSTR CLUSTER 1 2
36G TCO TEMP SIGNAL P1_0-SXL 13 TCOT, TCO_SENDER 1
SION
36G_A TCO TEMP SIGNAL P0_8-TXL 13 TECM, TRANS 49
SION
4002-27

21C Bk - 1.0


Color, Size,
and Material
36H HYDRAULIC OIL TEMP P1_0-SXL 30 HOT, HYD_OIL_TEMP_SEND A
SION
36H_A HYDRAULIC OIL TEMP P0_8-TXL 30 AIC_1, ADV INSTR CLUSTER 1 9
SION
36R_A TRANS TEMPS/FLTR RETURN P1_0-SXL 12 SPL_H1, ULTRASONIC A
SION
TRANS FLTR MAINT SW
36R_B P1_0-SXL SPL_H1, ULTRASONIC A FM, FILT_MAINT_SW 2
RETURN
36R_C VALVE BODY TEMP RETURN P0_8-TXL SPL_H1, ULTRASONIC A TRC, TRANS_CONTROL 9
36R_D TCO TEMP RETURN P1_0-SXL SPL_H1, ULTRASONIC A TCOT, TCO_SENDER 2
36R_E TRANS TEMPS/FLTR RETURN P0_8-TXL 12 TECM, TRANS 46
SION
36T VALVE BODY TEMP SGNL P0_8-TXL 5 TRC, TRANS_CONTROL 8
SION
36T_A VALVE BODY TEMP SGNL P0_8-TXL 5 TECM, TRANS 39
SION
108F,
37D_A DIAGNOSTIC SGNL P0_8-TXL DIAGNOSTIC_CONNECTO 2 TECM, TRANS 15
R
108F,
DIAGNOSTIC SGNL
37E P0_8-TXL DIAGNOSTIC_CONNECTO 4 TECM, TRANS 18
SWITCHED
R
SRHSTLK, RH STALK
41H_A HIGH BEAM PWR OR1_0-GXL 56a SPL_PK2, SPLICE 3-4WAY L
SWITCH
41H_B HIGH BEAM LH PWR OR0_8-GXL SPL_PK2, SPLICE 3-4WAY K ECB, ELECT CNTR B A3
41H_C HIGH BEAM RH PWR OR0_8-GXL SPL_PK2, SPLICE 3-4WAY J ECB, ELECT CNTR B A4
41H_D HIGH BEAM PWR OR0_8-TXL SW_PD, SWITCH PAD 1 SPL_PK2, SPLICE 3-4WAY M
41J DR LTS PWR OR1_0-GXL SDR, DRIVING LIGHTS SW 6 SRHSTLK, RH STALK SWITCH 56
SRHSTLK, RH STALK
41L_A LOW BEAM PWR OR1_0-GXL 56b SPL_LB, ULTRASONIC
SWITCH
41L_B LOW BEAM LH PWR OR0_8-GXL SPL_LB, ULTRASONIC ECB, ELECT CNTR B A6
41L_C LOW BEAM RH PWR OR0_8-GXL SPL_LB, ULTRASONIC ECB, ELECT CNTR B A5
41T POSN LIGHTS SW PWR K1_0-GXL SDR, DRIVING LIGHTS SW 3 SPL_PK2, SPLICE 3-4WAY C
41T_A POSN LIGHTS RH SW PWR K1_0-GXL SPL_PK2, SPLICE 3-4WAY D ECB, ELECT CNTR B A8
41T_B POSN LIGHTS LH SW PWR K1_0-GXL SPL_PK2, SPLICE 3-4WAY A ECB, ELECT CNTR B A7
41T_C POSN LIGHTS SW PWR K1_0-GXL D_OR, DIODE OR B SPL_D, ULTRASONIC
41T_D POSN LIGHTS SW PWR K0_8-TXL SW_PD, SWITCH PAD 2 SPL_D, ULTRASONIC
41T_E POSN LIGHTS SW PWR K1_0-SXL SPL_PK2, SPLICE 3-4WAY B SPL_D, ULTRASONIC
CAB_RF, CAB TO ROOF
42C_A FNT WRK LTS FUSE PWR DU1_0-GXL C SPL_PK1, SPLICE 3-4WAY A
CONNECTION
42C_C FNT WRK LTS FUSE PWR DU1_0-GXL SPL_PK1, SPLICE 3-4WAY D ECB, ELECT CNTR B AA1
4002-28

21C Bk - 1.0


Color, Size,
and Material
42C_D FNT WRK LTS FUSE PWR DU1_0-GXL SPL_PK1, SPLICE 3-4WAY C D_OR, DIODE OR A
42C_E FNT WRK LTS FUSE PWR DU0_8-TXL SW_PD, SWITCH PAD 3 SPL_PK1, SPLICE 3-4WAY B
42C_F FNT WRK LTS FUSE PWR DU1_0-GXL C SPL_WRKF, ULTRASONIC A
NECTION
42C_
RH FNT WRK LTS FUSE PWR DU1_0-GXL SPL_WRKF, ULTRASONIC A LRFW, RH_FRONT_WK_LT A
G
42C_H LH FNT WRK LTS FUSE PWR DU1_0-GXL SPL_WRKF, ULTRASONIC A LLFW, LH_FRONT_WK_LT A
42FS FNT WRK LTS SW PWR DU1_0-GXL SWL, WORK LIGHTS SW 3 ECB, ELECT CNTR B A1
42RS REAR WRK LTS SW PWR DU1_0-GXL SWL, WORK LIGHTS SW 6 ECB, ELECT CNTR B A2
CAB_RF, CAB TO ROOF
42R_C REAR WRK LTS FUSE PWR DU1_0-GXL B ECB, ELECT CNTR B AA2
CONNECTION
42R_F REAR WRK LTS FUSE PWR DU1_0-GXL B SPL_WRKR, ULTRASONIC A
NECTION
42R_ RH REAR WRK LTS FUSE
DU1_0-GXL SPL_WRKR, ULTRASONIC A LRRW, RH_REAR_WK_LT A
G PWR
42R_H LH REAR WRK LTS FUSE PWR DU1_0-GXL SPL_WRKR, ULTRASONIC A LLRW, LH_REAR_WK_LT A
42_A WRK LTS FUSED PWR R2_0-GXL SWL, WORK LIGHTS SW 2 SPL_WL, ULTRASONIC A
42_B WRK LTS FUSED PWR R2_0-GXL SWL, WORK LIGHTS SW 5 SPL_WL, ULTRASONIC A
CAB_RF, CAB TO ROOF
43S_A DOOR OPEN SGNL W0_8_GXL R SPL_DS, ULTRASONIC A
CONNECTION
43S_B DOOR OPEN SGNL W0_8_GXL R DS, DOOR SWITCH B
NECTION
43S_C DOOR OPEN SGNL W0_8-TXL SPL_DS, ULTRASONIC A AIC_2, ADV INSTR CLUSTER 2 2
TIME DELAY MOD DOOR SW TDM,
43S_D W0_8-TXL 4 SPL_DS, ULTRASONIC A
RESET TIME_DELAY_MODULE
CAB_RF, CAB TO ROOF
43_A DOME LT AUTO MODE DU0_8-TXL A AIC_1, ADV INSTR CLUSTER 1 7
CONNECTION
43_B DOME LT AUTO MODE DU0_8-GXL A LDM2, DOME_LIGHT_AUTO 1
NECTION
44A_A BRK LT RLY OUT T0_8-GXL SPL_BRK, ULTRASONIC A ECC, ELECT CNTR C D6
44A_B BRK LT RLY OUT T0_8-TXL SPL_BRK, ULTRASONIC A AIC_1, ADV INSTR CLUSTER 1 15
44A_C BRK LT RLY OUT T0_8-GXL CAB_E, CAB-ENGINE 8 SPL_BRK, ULTRASONIC A
44A_D BRK LT RLY OUT T1_0-SXL ENG, ENGINE-CAB 8 SPL_B8, ULTRASONIC A
44A_D
BRK LT RLY OUT T1_0-SXL ENG, ENGINE-CAB 8 ENG_H, ENGINE TO HOOD 2
N
LLR_E,
44A_E BRK LT RLY OUT T1_0-SXL 1 SPL_B8, ULTRASONIC A
LH_REAR_COMB_LT
44A_E
BRK LT RLY OUT T1_0-SXL HD_N, HOOD TO ENG 2 SPL_J2_N, ULTRASONIC A
N
LRR_E,
44A_F BRK LT RLY OUT T1_0-SXL 1 SPL_B8, ULTRASONIC A
RH_REAR_COMB_LT
4002-29

21C Bk - 1.0


Color, Size,
and Material
44A_F LLR_N,
BRK LT RLY OUT T1_0-SXL A SPL_J2_N, ULTRASONIC A
N LH_REAR_COMB_LT
44A_G LRR_N,
BRK LT RLY OUT T1_0-SXL A SPL_J2_N, ULTRASONIC A
N RH_REAR_COMB_LT
44A_J BRAKE LIGHT PWR T1_0-SXL SPL_L1, ULTRASONIC A HD_9, HOOD TO ENG 2
44A_K BRAKE LIGHT PWR T1_0-SXL SPL_L1, ULTRASONIC A LRR_9, RH_REAR_COMB_LT 1
LLR_9,
44A_L BRAKE LIGHT PWR T1_0-SXL 1 SPL_L1, ULTRASONIC A
LH_REAR_COMB_LT
44_A BRK LT CTRL PWR T0_8-GXL CAB_F, CAB-FRNT_CHAS 23 ECC, ELECT CNTR C D5
FLSHR,
45A_A LEFT TURN SWITCH PWR N0_8-GXL 9 SRHSTLK, RH STALK SWITCH L
FLASHER_MODULE
FLSHR,
45B_A RIGHT TURN SWITCH PWR N0_8-GXL 10 SRHSTLK, RH STALK SWITCH R
FLASHER_MODULE
FLSHR,
45H HAZARD SWITCH PWR N0_8-GXL 11 SHZ, HAZARD_SWITCH 3
FLASHER_MODULE
45L LEFT TURN SGNL N1_0-SXL FRONT, CAB-FRNT_CHAS 1 LLF, LIGHTS_LH 5
45L_9 LEFT TURN SGNL N1_0-SXL HD_9, HOOD TO ENG 3 LLR_9, LH_REAR_COMB_LT 2
45L_A LEFT TURN SGNL N1_0-SXL ENG, ENGINE-CAB 10 LLR_E, LH_REAR_COMB_LT 2
45L_A
LEFT TURN SGNL N1_0-SXL ENG, ENGINE-CAB 10 ENG_H, ENGINE TO HOOD 3
N
45L_B LEFT TURN SGNL N0_8-GXL CAB_E, CAB-ENGINE 10 SPL_PK3, SPLICE 3-4WAY D
45L_B
LEFT TURN SGNL N1_0-SXL HD_N, HOOD TO ENG 3 LLR_N, LH_REAR_COMB_LT C
N
45L_C LEFT TURN SGNL N0_8-GXL CAB_F, CAB-FRNT_CHAS 1 SPL_PK3, SPLICE 3-4WAY C
FLSHR,
45L_D LEFT TURN SGNL N0_8-GXL 8 SPL_PK, SPLICE 3-4WAY B
FLASHER_MODULE
45L_E LEFT TURN SGNL N0_8-TXL SPL_PK3, SPLICE 3-4WAY A AIC_2, ADV INSTR CLUSTER 2 9
FLSHR,
45N_A FLASHER OPP SIDE CTRL N0_8-GXL 2 64F, FLASHER_CONNECTOR 1
FLASHER_MODULE
FLSHR,
45N_B FLASHER OPP SIDE CTRL N0_8-GXL 12 64M, FLASHER_CONNECTOR 1
FLASHER_MODULE
45R RIGHT TURN SGNL N1_0-SXL FRONT, CAB-FRNT_CHAS 3 LRF, LIGHTS_RH 5
45R_9 RIGHT TURN SGNL N1_0-SXL HD_9, HOOD TO ENG 4 LRR_9, RH_REAR_COMB_LT 2
45R_A RIGHT TURN SGNL N1_0-SXL ENG, ENGINE-CAB 12 LRR_E, RH_REAR_COMB_LT 2
45R_A
RIGHT TURN SGNL N1_0-SXL ENG, ENGINE-CAB 12 ENG_H, ENGINE TO HOOD 4
N
45R_B RIGHT TURN SGNL N0_8-GXL CAB_E, CAB-ENGINE 12 SPL_PK3 SPLICE 3-4WAYH
45R_B
RIGHT TURN SGNL N1_0-SXL HD_N, HOOD TO ENG 4 LRR_N, RH_REAR_COMB_LT C
N
45R_C RIGHT TURN SGNL N0_8-TXL SPL_PK3, SPLICE 3-4WAY E AIC_2, ADV INSTR CLUSTER 2 10
45R_D RIGHT TURN SGNL N0_8-GXL CAB_F, CAB-FRNT_CHAS 3 SPL_PK3, SPLICE 3-4WAY G
4002-30

21C Bk - 1.0


Color, Size,
and Material
FLSHR,
45R_E RIGHT TURN SGNL N0_8-GXL 7 SPL_PK3, SPLICE 3-4WAY F
FLASHER_MODULE
CAB_RF, CAB TO ROOF
46_C BEACON SW PWR K1_0-GXL E SBE, BEACON_SW 3
CONNECTION
46_D BEACON SW PWR K1_0-GXL E LBEPWR, LIGHT BEACON PWR 1
NECTION
LBEE, LIGHT BEACON
46_E BEACON LIGHT PWR K1_0-GXL A LBEP, LIGHT BEACON PWR 1
EXTENSION
49A BACK LIGHT POWER S0_8-GXL HVAC1, HVAC1 C F
LGHT PWR
49S BACK LIGHT POWER S0_8-GXL STA, TRANS_AUTO_SW 8 J
LGHT PWR
SPL_PED_BL, SPL BACK LGT
49U BACK LIGHT POWER S0_8-GXL SETHR, ETHER SWITCH 8 D
PWR 6 PCK
49_A BACK LIGHT POWER S0_8-GXL SWL, WORK LIGHTS SW 8 M
LGHT PWR
49_B BACK LIGHT POWER S0_8-GXL SBE, BEACON_SW 8 L
LGHT PWR
49_C BACK LIGHT POWER S0_8-GXL SRWP, REAR_WIPER_SW 8 C
LGHT PWR
49_D BACK LIGHT POWER S0_8-GXL SHZ, HAZARD_SWITCH 8 C
PWR 6 PCK
SPL_BCK_LGT2, SPL_BCK_LGT, SPLICE BACK
49_E BACK LIGHT POWER S0_8-GXL A K
SPL_BACK LGT PWR LGHT PWR
SPL_BCK_LGT2, SPL_BACK
49_F BACK LIGHT POWER S0_8-GXL SPE, PIN_ENGAGE_SW 10 F
LGT PWR
49_G BACK LIGHT POWER S0_8-GXL SRC, RIDE_CONTROL_SW 8 K
LGT PWR
49_H BACK LIGHT POWER S0_8-GXL STE, TRANS_ENABLE_SW 8 D
LGHT PWR
49_J BACK LIGHT POWER S0_8-GXL SRTD, DETENT_SWITCH 8 C
LGT PWR
SFL, SPL_BCK_LGT2, SPL_BACK
49_K BACK LIGHT POWER S0_8-GXL 8 E
RETURN_TO_TRAVEL_SW LGT PWR
SBU, SPL_BCK_LGT, SPLICE BACK
49_L BACK LIGHT POWER S0_8-GXL 8 E
BACK-UP_ALRM_DIS_SW LGHT PWR
SHC, HEIGHT CONTROL SPL_BCK_LGT2, SPL_BACK
49_M BACK LIGHT POWER S0_8-GXL 8 D
SW LGT PWR
SPC, SPL_PED_BL, SPL BACK LGT
49_N BACK LIGHT POWER S0_8-GXL 8 B
PILOT_CONTROL_SWITCH PWR 6 PCK
49_P BACK LIGHT POWER S0_8-GXL SDR, DRIVING LIGHTS SW 8 G
LGHT PWR
49_Q BACK LIGHT POWER S0_8-GXL SFC, FAN_CONTROL_SW 8 G
LGT PWR
49_R BACK LIGHT POWER S0_8-GXL SDC, DECLUTCH_SWITCH 8 H
LGHT PWR
4002-31

21C Bk - 1.0


Color, Size,
and Material
SPL_PED_BL, SPL BACK SPL_BCK_LGT2, SPL_BACK
49_S BACK LIGHT POWER S0_8-GXL F M
LGT PWR 6 PCK LGT PWR
SFWW, FRONT SPL_BCK_LGT2, SPL_BACK
49_T BACK LIGHT POWER S0_8-GXL 8 H
WIPER/WASHER LGT PWR
49_U BACK LIGHT POWER S0_8-GXL SCS, COMFORT STEER SW 8 A
PWR 6 PCK
SPB, SPL_PED_BL, SPL BACK LGT
49_V BACK LIGHT POWER S0_8-GXL 8 E
PARKING_BRAKE_SWITCH PWR 6 PCK
51B_A COMFORT STR SOL PWR W0_8_GXL SCS, COMFORT STEER SW 6 SPL_CSS, ULTRASONIC A
51B_B COMFORT STR SOL PWR W0_8_GXL SPL_CSS, ULTRASONIC A ECC, ELECT CNTR C D10
51B_C COMFORT STR SOL PWR W0_8_GXL SPL_CSS, ULTRASONIC A CAB_F, CAB-FRNT_CHAS 2
YCS, COMFORT STEER SOLE-
51B_D COMFORT STR SOL PWR W1_0-SXL FRONT, CAB-FRNT_CHAS 2 A
ROID
51C COMFORT STEER CTRL W0_8-TXL 21 ECC, ELECT CNTR C B10
STER 1
51CS COMFORT STR SWITCH W0_8-TXL SCS, COMFORT STEER SW 3 AIC_1, ADV INSTR CLUSTER 1 17
51P_A SEC STR HIGH PRESS W1_0-SXL SSM, SEC STR MOD 9 PSS, SEC STR PRES SWITCH A
51S STANDARD STR SIG W0_8-TXL SCS, COMFORT STEER SW 1 AIC_1, ADV INSTR CLUSTER 1 16
51_A SEC STR MOTOR CTRL W1_0-SXL SSM, SEC STR MOD 2 SPL_SS, ULTRASONIC A
51_B SEC STR MOTOR CTRL W1_0-SXL SPL_SS, ULTRASONIC A SSS, SS MAG SWITCH 1
51_C SEC STR SOL CTRL W1_0-SXL SPL_SS, ULTRASONIC A YSS, SEC_STRG_SOL 1
52AU FAN REVERSE AUTO W0_8-TXL SFC, FAN_CONTROL_SW 3 AIC_2, ADV INSTR CLUSTER 2 8
52A_A FAN REVERSE RLY OUT W1_0-GXL CAB_E, CAB-ENGINE 22 ECB, ELECT CNTR B D8
52A_B FAN REVERSE RLY OUT W1_0-SXL ENG, ENGINE-CAB 22 YFR, FAN_REV_SOL_OPT 1
52C PARK BRAKE SOL LSD W0_8-TXL 14 ECB, ELECT CNTR B B10
STER 1
52J FAN CTRL SW JUMPER W0_8_GXL SFC, FAN_CONTROL_SW 4 SFC, FAN_CONTROL_SW 2
52M FAN REVERSE MAN W0_8-TXL SFC, FAN_CONTROL_SW 6 AIC_2, ADV INSTR CLUSTER 2 7
52P PARK BRK RLY OUT W1_0-SXL FRONT, CAB-FRNT_CHAS 24 YPB, PARK_BRK_SOL 1
52P_A PARK BRK RLY OUT W0_8_GXL CAB_F, CAB-FRNT_CHAS 24 SPL_PB, ULTRASONIC A
52P_B PARK BRK RLY OUT W0_8_GXL SPL_PB, ULTRASONIC A ECB, ELECT CNTR B D10
52P_C PARK BRK RLY OUT W0_8-TXL SPL_PB, ULTRASONIC A TECM, TRANS 21
53A RTD SW PWR W0_8_GXL SRTD, DETENT_SWITCH 3 EM, RTD_HEIGHT_CONT_RTT 3
53B RTD CTRL SIGNAL W1_0-SXL FRONT, CAB-FRNT_CHAS 12 PXF, RTD A
53B_A RTD CTRL SIGNAL W1_0-SXL PXM, RTD A PXT, RTD A
EM,
53B_B RTD CTRL SIGNAL W0_8_GXL 4 CAB_F, CAB-FRNT_CHAS 12
RTD_HEIGHT_CONT_RTT
53C_A PILOT CTRL SOL LSD W0_8-TXL 20 ECD, ELECT CNTR D B6
STER 1
53P_A PILOT CTRL RLY OUT W0_8_GXL SPL_D25, ULTRASONIC A YPP, PILOT_PRES_SOL A
SFL,
53P_B PILOT CTRL RLY OUT W0_8_GXL 2 SPL_D25, ULTRASONIC A
RETURN_TO_TRAVEL_SW
53P_C PILOT CTRL RLY OUT W1_0-GXL SPL_D25, ULTRASONIC A ECD, ELECT CNTR D D6
4002-32

21C Bk - 1.0


Color, Size,
and Material
SHC, HEIGHT CONTROL
53P_D PILOT CTRL RLY OUT W0_8_GXL 2 SPL_D25, ULTRASONIC A
SW
53P_E PILOT CTRL RLY OUT W0_8_GXL SRTD, DETENT_SWITCH 2 SPL_D25, ULTRASONIC A
53P_F PILOT CTRL RLY OUT W0_8_GXL CAB_F, CAB-FRNT_CHAS 19 SPL_D25, ULTRASONIC A
53P_G PILOT CTRL RLY OUT W1_0-SXL FRONT, CAB-FRNT_CHAS 19 SPL_A3, ULTRASONIC A
53P_H PILOT CTRL RLY OUT W1_0-SXL SPL_A3, ULTRASONIC A PXF, RTD C
53P_I PILOT CTRL RLY OUT W1_0-SXL PXM, RTD C PXT, RTD C
53P_J PILOT CTRL RLY OUT W1_0-SXL SPL_A3, ULTRASONIC A PXH, HGT_CNTRL-RTT C
SHC, HEIGHT CONTROL
54A HEIGHT CTRL SW PWR W0_8_GXL 6 EM, RTD_HEIGHT_CONT_RTT 2
SW
54B HC-RTT CTRL SGNL W1_0-SXL FRONT, CAB-FRNT_CHAS 11 PXH, HGT_CNTRL-RTT A
54B_A HC-RTT CTRL SGNL W0_8_GXL CAB_F, CAB-FRNT_CHAS 11 SPL_D1, ULTRASONIC A
EM,
54B_B HC-RTT CTRL SGNL W0_8_GXL 5 SPL_D1, ULTRASONIC A
RTD_HEIGHT_CONT_RTT
SFL,
54B_C HC-RTT CTRL SGNL W0_8_GXL 6 SPL_D1, ULTRASONIC A
RETURN_TO_TRAVEL_SW
EM,
55A_A RTT/FLOAT SW PWR W0_8_GXL 1 SPL_RTT, ULTRASONIC A
RTD_HEIGHT_CONT_RTT
SFL,
55A_B RTT/FLOAT SW PWR W0_8_GXL 1 SPL_RTT, ULTRASONIC A
RETURN_TO_TRAVEL_SW
SFL,
55A_C RTT/FLOAT SW PWR W0_8_GXL 3 SPL_RTT, ULTRASONIC A
RETURN_TO_TRAVEL_SW
SFL,
55B RTT FLOAT SW CTRL W0_8_GXL 5 EM, RTD_HEIGHT_CONT_RTT 6
RETURN_TO_TRAVEL_SW
56_A FAN CONTROL PWM W1_0-SXL ENG, ENGINE-CAB 23 YFN, FAN_PWM_SOL A
57_A PIN ENGAGE SOL PWR W0_8_GXL CAB_F, CAB-FRNT_CHAS 20 SPL_PINE, ULTRASONIC A
57_B PIN ENGAGE SOL PWR W0_8_GXL SPE, PIN_ENGAGE_SW 1 SPL_PINE, ULTRASONIC A
57_C PIN ENGAGE SOL PWR W0_8-TXL SPL_PINE, ULTRASONIC A AIC_2, ADV INSTR CLUSTER 2 16
58C RIDE CTRL SW JUMPER W0_8_GXL SRC, RIDE_CONTROL_SW 5 SRC, RIDE_CONTROL_SW 3
58H_A RIDE CNTL SW PWR VPS2 W0_8-TXL TECM, TRANS 8 ECD, ELECT CNTR D D7
58L RIDE CTRL RLY LSD BK0_8-TXL TECM, TRANS 57 ECD, ELECT CNTR D B8
58S_E RIDE CTRL SOL TO FRNT CAB W1_0-SXL FRONT, CAB-FRNT_CHAS 21 YRC, RIDE_CONTROL_OPT 1
58T RIDE CTRL RLY SW PWR W0_8_GXL SRC, RIDE_CONTROL_SW 4 ECD, ELECT CNTR D B7
58_A RIDE CTRL SOL PWR W1_0-SXL 202M, ROLLBACK_JUMPER A 202M, ROLLBACK_JUMPER B
58_B RIDE CONTROL SOL PWR W1_0-SXL FRONT, CAB-FRNT_CHAS 21 PRBF, ROLLBACK_PRES_SW B
58_C RIDE CTRL SOL PWR W0_8_GXL CAB_F, CAB-FRNT_CHAS 21 SPL_D26, ULTRASONIC A
58_D RIDE CTRL SOL PWR W0_8_GXL 140M, DIODE_MODULE D SPL_D26, ULTRASONIC A
58_E RIDE CTRL SOL PWR W0_8_GXL SPL_D26, ULTRASONIC A ECD, ELECT CNTR D D8
58_F RIDE CTRL SOL PWR W0_8_GXL SRC, RIDE_CONTROL_SW 6 SPL_D26, ULTRASONIC A
59D HOOD DOWN RLY CTRL W1_0-GXL CAB_E, CAB-ENGINE 37 ECC, ELECT CNTR C D3
59D_A HOOD DOWN RLY CTRL W1_0-SXL ENG, ENGINE-CAB 37 HD, HOOD_SWITCH A
59U HOOD UP RLY CTRL W1_0-GXL CAB_E, CAB-ENGINE 39 ECC, ELECT CNTR C D1
4002-33

21C Bk - 1.0


Color, Size,
and Material
59U_A HOOD UP RLY CTRL W1_0-SXL ENG, ENGINE-CAB 39 HD, HOOD_SWITCH C
60D HOOD DOWN RLY OUT W1_0-GXL CAB_E, CAB-ENGINE 36 ECC, ELECT CNTR C B3
60D_A HOOD DOWN RLY OUT W1_0-SXL ENG, ENGINE-CAB 36 HDM, HOOD_LIFT_MOTOR 2
60U HOOD UP RLY OUT W1_0-GXL CAB_E, CAB-ENGINE 38 ECC, ELECT CNTR C B1
60U_A HOOD UP RLY OUT W1_0-SXL ENG, ENGINE-CAB 38 HDM, HOOD_LIFT_MOTOR 1
61A TRINARY PRESS SW INPUT W1_0-SXL ENG, ENGINE-CAB 30 PR, TRINARY PRESS SW A
61A_B TRINARY PRESS SW INPUT W0_8_GXL CAB_E, CAB-ENGINE 30 HVAC1, HVAC1 A
61C AC RELAY OUT OR0_8-GXL CAB_E, CAB-ENGINE 2 ECD, ELECT CNTR D D10
61C_A AC RELAY OUT OR1_0-SXL ENG, ENGINE-CAB 2 ACT, AC_COMP_CLUTCH 1
61C_B AC RELAY OUT OR1_0-SXL ENG, ENGINE-CAB 2 ACT_9, AC_COMP_CLUTCH 1
61R AC RELAY CONTROL W1_0-SXL ENG, ENGINE-CAB 29 PR, TRINARY PRESS SW B
61R_B AC RELAY CONTROL W0_8_GXL CAB_E, CAB-ENGINE 29 ECD, ELECT CNTR D D9
FWM,
63C FNT WPR PARK CTRL W0_8_GXL D ECD, ELECT CNTR D C4
FRONT-WIPER_MOTOR
63C2 FNT WPR PARK CTRL W0_8_GXL ECD, ELECT CNTR D D4 ECD, ELECT CNTR D C2
63C3 FNT WPR PARK CTRL W0_8_GXL K_WCO, WIPER CUTOUT 87A ECD, ELECT CNTR D B3
SFWW, FRONT
63HC FNT WPR HS RLY CTRL W0_8_GXL 9 SPL_HC, ULTRASONIC A
WIPER/WASHER
63HC_
WPR CUT OUT RLY CTRL W0_8_GXL SPL_HC, ULTRASONIC A K_WCO, WIPER CUTOUT 85
A
63HC_
FNT WPR HS RLY CTRL W0_8_GXL SPL_HC, ULTRASONIC A ECD, ELECT CNTR D B2
B
FWM,
63H_A FNT WPR HS RLY OUT W0_8_GXL A SPL_WHS, ULTRASONIC A
FRONT-WIPER_MOTOR
63H_B FNT WPR HS RLY OUT W0_8_GXL SPL_WHS, ULTRASONIC A ECD, ELECT CNTR D D2
63H_C FNT WPR HS RLY OUT W0_8_GXL 140M, DIODE_MODULE A SPL_WHS, ULTRASONIC A
SFWW, FRONT
63LC FNT WPR LS RLY CTRL W0_8_GXL 3 ECD, ELECT CNTR D B4
WIPER/WASHER
FWM,
63L_A FNT WPR LS RLY OUT W0_8_GXL B SPL_WLS, ULTRASONIC A
FRONT-WIPER_MOTOR
63L_B FNT WPR LS RLY OUT W0_8_GXL K_WCO, WIPER CUTOUT 30 SPL_WLS, ULTRASONIC A
63L_C FNT WPR LS RLY OUT W0_8_GXL 140M, DIODE_MODULE B SPL_WLS, ULTRASONIC A
SFWW, FRONT
63W FNT WASHER PUMP W0_8_GXL CAB_E, CAB-ENGINE 25 7
WIPER/WASHER
63W_
FNT WASHER PUMP W1_0-SXL ENG, ENGINE-CAB 25 FWW, FRONT_WASHER 1
A
SRHSTLK, RH STALK
64C HORN RLY CTRL OR0_8-GXL 31b ECC, ELECT CNTR C B8
SWITCH
64_A HORN POWER OR0_8-GXL CAB_F, CAB-FRNT_CHAS 13 ECC, ELECT CNTR C D8
65L LEFT SPEAKER OR0_8-GXL LSPK, LEFT_SPEAKER 1 SPK, SPEAKER 7
65R RIGHT SPEAKER OR0_8-GXL RSPK, RIGHT_SPEAKER 1 SPK, SPEAKER 1
CAB_RF, CAB TO ROOF
68C REAR WPR PARK CTRL OR1_0-GXL K SRWP, REAR_WIPER_SW 1
CONNECTION
4002-34

21C Bk - 1.0


Color, Size,
and Material
68C_A REAR WPR PARK CTRL OR1_0-GXL K RWM, REAR_WIPER_MTR D
NECTION
68L REAR WPR SW PWR OR1_0-GXL SRWP, REAR_WIPER_SW 2 SPL_3, ULTRASONIC A
68L_A REAR WPR SW PWR OR1_0-GXL L RWM, REAR_WIPER_MTR B
NECTION
CAB_RF, CAB TO ROOF
68L_B REAR WPR SW PWR OR1_0-GXL L SPL_3, ULTRASONIC A
CONNECTION
68L_C REAR WPR SW PWR OR1_0-GXL 140M, DIODE_MODULE F SPL_3, ULTRASONIC A
68W REAR WSHR PUMP W0_8_GXL CAB_E, CAB-ENGINE 24 SRWP, REAR_WIPER_SW 6
68W_
REAR WSHR PUMP W1_0-SXL ENG, ENGINE-CAB 24 RWW, REAR_WASHER 1
A
CAN_ Y0_8-TXL_TW
CAN HIGH CAN2, CAN BULK HEAD A EDC7, ENGINE CONTROLLER 35
H IST
CAN_ Y0_8-TXL_TW SPL_CAN_HVAC, ULTRA-
CAN HIGH A CAN, CAN BULK HEAD A
HA IST SONIC
CAN_ Y0_8-TXL_TW SPL_CAN_DIAG, ULTRASO-
CAN HIGH A DIA, DIAGNOSTIC C
HB IST NIC
CAN_ Y0_8-TXL_TW SPL_CAN_TRANS, ULTRA-
CAN HIGH A SPL_CAN_DIAG, ULTRASONIC A
HC IST SONIC
CAN_ Y0_8-TXL_TW SPL_CAN_TRANS, ULTRA-
CAN HIGH A TECM, TRANS 25
HD IST SONIC
CAN_ Y0_8-TXL_TW SPL_CAN_TRANS, ULTRASO-
CAN HIGH SPL_CAN, ULTRASONIC A A
HE IST NIC
CAN_ Y0_8-TXL_TW
CAN HIGH SW_PD, SWITCH PAD 7 SPL_CAN, ULTRASONIC A
HF IST
CAN_ Y0_8-TXL_TW
CAN HIGH SPL_CAN, ULTRASONIC A AIC_1, ADV INSTR CLUSTER 1 3
HG IST
CAN_ Y0_8-TXL_TW
CAN HIGH FROM ENG CAN2, CAN BULK HEAD A QSM11, ENGINE CONTROLLER 46
HJ IST
CAN HIGH A HVAC_CAN1, CAN_HVAC_ATC A
HK IST SONIC
CAN HIGH A SPL_CAN_DIAG, ULTRASONIC A
HM IST SONIC
CAN_ G0_8-TXL_T
CAN LOW CAN2, CAN BULK HEAD B EDC7, ENGINE CONTROLLER 34
L WIST
CAN_ G0_8-TXL_T SPL_CAN_HVAC_L, ULTRA-
CAN LOW A CAN, CAN BULK HEAD B
LA WIST SONIC
CAN_ G0_8-TXL_T SPL_CAN_DIAG_L, ULTRA-
CAN LOW A DIA, DIAGNOSTIC D
LB WIST SONIC
CAN_ G0_8-TXL_T SPL_CAN_TRANS_L, SPL_CAN_DIAG_L, ULTRASO-
CAN LOW A A
LC WIST ULTRASONIC NIC
CAN_ G0_8-TXL_T SPL_CAN_TRANS_L, ULTRA-
CAN LOW SPL_D5, ULTRASONIC A A
LD WIST SONIC
CAN_ G0_8-TXL_T SPL_CAN_TRANS_L, ULTRA-
CAN LOW SPL_CAN_L, ULTRASONIC A A
LE WIST SONIC
4002-35

21C Bk - 1.0


Color, Size,
and Material
CAN_ G0_8-TXL_T
CAN LOW SW_PD, SWITCH PAD 8 SPL_CAN_L, ULTRASONIC A
LF WIST
CAN_ G0_8-TXL_T
CAN LOW SPL_CAN_L, ULTRASONIC A AIC_1, ADV INSTR CLUSTER 1 4
LG WIST
CAN_ G0_8-TXL_T
CAN LOW SPL_D5, ULTRASONIC A TECM, TRANS 27
LJ WIST
CAN_ G0_8-TXL_T
CAN LOW SPL_D5, ULTRASONIC A TECM, TRANS 26
LK WIST
CAN_ G0_8-TXL_T SPL_CAN_HVAC_L, ULTRA-
CAN LOW A HVAC_CAN1, CAN_HVAC_ATC B
LL WIST SONIC
CAN_ G0_8-TXL_T
CAN LOW FROM ENG CAN2, CAN BULK HEAD B QSM11, ENGINE CONTROLLER 37
LM WIST
CAN_ G0_8-TXL_T SPL_CAN_HVAC_L, ULTRA- SPL_CAN_DIAG_L, ULTRASO-
CAN LOW A A
LN WIST SONIC NIC
ECC_
BEACON/DOME LT LI ECC BUSS L1_ECC, ECC BATT PWR cs01 ECC, ELECT CNTR C L1_1
L1
J1 TRANS ECM PWR ECA_BUSS ECA_L1, B+ POWER cs01 ECA, ELECT CNTR A L1
TRANS ECM COMFORT
J2 ECA_BUSS ECA, ELECT CNTR A L1 ECA, ELECT CNTR A L1
STEER
J3 COMFORT STEER AIC PWR ECA_BUSS ECA, ELECT CNTR A L1 ECA, ELECT CNTR A L1
J4 EMG STR AIC PWR ECA_BUSS ECA, ELECT CNTR A L1 ECA, ELECT CNTR A L1
J5 EMG STRG PLT EM DTNTS ECA_BUSS ECA, ELECT CNTR A L1 ECA, ELECT CNTR A L1
J6 PLTEM DTNTS PRK BRK SOL ECA_BUSS ECA, ELECT CNTR A L1 ECA, ELECT CNTR A L1
J7 PRK BRK SOL HRN ECA_BUSS ECA, ELECT CNTR A L1 ECA, ELECT CNTR A L1
J8 FAN RVSR TURN SGNL ECA_BUSS ECA, ELECT CNTR A L1 ECA, ELECT CNTR A L1
J9 TURN SGNL ENG SHTDWN. ECA_BUSS ECA, ELECT CNTR A L1 ECA, ELECT CNTR A L1
J11 BLWR MOTOR PWR ECA_BUSS ECA_L2, B+ POWER cs01 ECA, ELECT CNTR A L2
J12 BLWR MTR FRNT WIPR WASH ECA_BUSS ECA, ELECT CNTR A L2 ECA, ELECT CNTR A L2
J13 FRNT WIPR RER WIPR WSH ECA_BUSS ECA, ELECT CNTR A L2 ECA, ELECT CNTR A L2
J14 RER WIPR WSH BACKUP ECA_BUSS ECA, ELECT CNTR A L2 ECA, ELECT CNTR A L2
J15 BKUP A/C ECA_BUSS ECA, ELECT CNTR A L2 ECA, ELECT CNTR A L2
J16 A/C SEAT COMP ECA_BUSS ECA, ELECT CNTR A L2 ECA, ELECT CNTR A L2
J18 SEAT COMP EMG STRTR ECA_BUSS ECA, ELECT CNTR A L2 ECA, ELECT CNTR A L2
J2_EC
BEACON/DOME LT WORK LTS ECC_BUSS ECC, ELECT CNTR C L1_1 ECC, ELECT CNTR C L1_2
C
J3_EC
WORK LTS DRIVING LTS ECC_BUSS ECC, ELECT CNTR C L1_2 ECC, ELECT CNTR C L1_3
C
J4_EC
DRIVING LTS BRK LTS ECC_BUSS ECC, ELECT CNTR C L1_3 ECC, ELECT CNTR C L1_4
C
J5_EC
BRK LTS DLY PWR ECC_BUSS ECC, ELECT CNTR C L1_4 ECC, ELECT CNTR C L1_5
C
4002-36

21C Bk - 1.0


Color, Size,
and Material
J6_EC
DLY PWR HRN ECC_BUSS ECC, ELECT CNTR C L1_5 ECC, ELECT CNTR C L1_6
C
J7_EC
HRN HOD CTRL ECC_BUSS ECC, ELECT CNTR C L1_6 ECC, ELECT CNTR C L1_7
C
J8_EC
HOD CTRL CIGAR LITR ECC_BUSS ECC, ELECT CNTR C L1_7 ECC, ELECT CNTR C L1_8
C
J9_EC
DIAGNOSTIC PWR ECC_BUSS ECC, ELECT CNTR C L1_9 ECC, ELECT CNTR C L1_8
C
PRM_
IGN PWR FUSE SEC STRG BUSS PRM_A, PWR RLY MOD A PRM_A, PWR RLY MOD A
A
PRM_
TIM DLY FUSE IGN PWR FUSE BUSS, PRM_A, PWR RLY MOD A
B
PRM_
ACC PWR FUSE SPARE BUSS PRM_D, PWR RLY MOD D PRM_D, PWR RLY MOD D
D
PRM_ IGN PWR FUSE ACC PWR
BUSS PRM_A, PWR RLY MOD A PRM_D, PWR RLY MOD D
PWR FUSE
RAD1 RADIO GND W0_8_GXL RAD_J3, RADIO_JUMPER 5 RAD_J1, RADIO_POWER 8
RAD2 12V FSD PWR TO RADIO W0_8_GXL RAD_J3, RADIO_JUMPER 12 RAD_J1, RADIO_POWER 7
RAD3 12V FSD PWR TO RADIO W0_8_GXL RAD_J3, RADIO_JUMPER 7 RAD_J1, RADIO_POWER 4
RAD4 LEFT SPEAKER GND W0_8_GXL RAD_J3, RADIO_JUMPER 3 RAD_J2, SPEAKER 8
RAD5 LEFT SPEAKER W0_8_GXL RAD_J3, RADIO_JUMPER 10 RAD_J2, SPEAKER 7
RAD6 NOT USED W0_8_GXL RAD_J3, RADIO_JUMPER 4 RAD_J2, SPEAKER 6
RAD1
RIGHT SPEAKER GND W0_8_GXL RAD_J3, RADIO_JUMPER 1 RAD_J2, SPEAKER 2
0
RAD11 RIGHT SPEAKER W0_8_GXL RAD_J3, RADIO_JUMPER 8 RAD_J2 SPEAKER 1
4002-37
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Alternator 1�
Correct
Check Points 2� Possible Cause of Bad Reading
Reading
3� 4
Check the 10 ampere fuse at
Good Bad fuse.
location 3 and 4C in the fuse block.
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter. 5�
6�
1. This title is the number and component name on the Electrical Schematic.
2. This column shows the location of the check point.
3. This column shows the indication of the check.
4. This column shows the possible cause of a bad test indication.
5. The numbers in the parentheses show the number of the component on the Electrical Schematic.
6. This statement assumes that all other problems are solved at this point in the test.
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS

NOTE: For the System Electrical Schematic refer to the Schematic Posters located at the rear of this manual.
Components ca n be located on the Electr ical
Schematic posters (rear pocket) by item number
using the key at the bottom of the posters. Use the
following index to find the sheet a component is
located on.
COMPONENT SCHEMATIC
COMPONENT
NUMBER SHEET
12 Volt Radio (Option) 123 8
Actuator 143 9
Air Conditioning High Pressure Switch 129 8
Air Conditioning Low Pressure Switch 129 8
Air Filter Restriction Switch 66 5
Air Seat Compressor 126 8
Alternator 3 1
Back-up Alarm 103 2
Backup Alarm Disable Switch 79 2
Back-up Alarm Relay 78 2

4002-38
COMPONENT SCHEMATIC
COMPONENT
NUMBER SHEET
Batteries 5 1
Beacon Switch (Option) 82 3
Blower Motor 136-147 8-9
Blower Motor Speed Resistors with Thermal Fuse 135-146 8-9
Brake Declutch Pressure Switch 59 4
Brake Lamp Pressure Switch 90 2
Brake Lamps Relay 91 2
Brake Warning Pressure Switch 69 5
Bucket Control Valves Electromagnetic Detents 27 6
Cigar Lighter (Option) 127 8
Comfort Steer Fuse (Option) 70 6
Comfort Steer Relay (Option) 20 6
Comfort Steer Solenoid (Option) 21 6
Comfort Steer Switch (Option) 42 6
Compressor Clutch 130 8
Compressor Clutch Relay 139 9
Converter (24 Volts to 12 Volts) 142 9
Coolant Level Sender 77 5
Crank Control Relay 4 1
Declutch Switch 60 4
Diagnostic Connector 61-119 4-8
Dome Lamp 83 3
Electronic Panel 131 9
Engine Controller (QSM11) 24 1
Engine Speed Sensor 49 4
Ether Solenoid 16 1
Fan PWM Solenoid 43 6
Fan Reverse Relay (Option) 38 6
Fan Reverser Switch (Option) 37 6
Fan Reversing Solenoid (Option) 44 6

4002-39
COMPONENT SCHEMATIC
COMPONENT
NUMBER SHEET
Filter Maintenance Switch 47 4
Flasher Module 92 2
FNR Switch 55-57 4
Front Axle Oil Temperature Sender 22 5
Front Washer Pump Motor 111 7
Front Wiper and Washer Switch 108 7
Front Wiper High Speed Relay 104 7
Front Wiper Low Speed Relay 106 7
Front Wiper Motor 109 7
Fuel Level Sender 65 5
Hazard Switch 93 2
Height Control Switch 26 6
Height Control/Return-To-Travel Proximity Switch 30 6
Horn 99 6
Horn Relay 98 6
Hydraulic Filter Restriction Switch 72 5
Hydraulic Oil Temperature Sender 73 5
Ignition Switch 10 1
Intermediate Speed Sensor 50 4
Internal Air Temperature Sensor 133 9
Left Hand Front Combination Lamp 96 2
Left Hand Front Work Lamp 85 3
Left Hand Rear Combination Lamp 101 2
Left Hand Rear Work Lamp 87 3
Left Speaker 125 8
License Plate Lamp 102 2
Master Disconnect Switch 8 1
Mixed Air Sensor 138 9
Neutral Start Relay 11 1
Output Speed Sensor 45 4

4002-40
COMPONENT SCHEMATIC
COMPONENT
NUMBER SHEET
Parking Brake Fuse 71 5
Parking Brake Relay 64 5
Parking Brake Solenoid 67 5
Pilot Control Relay 29 6
Pilot Control Switch 39 6
Pilot Pressure Solenoid 33 6
Pin Engage Switch (Option) 32 6
Power Converter (24 Volts to 12 Volts) 121 8
Power Outlet (Option) 122 8
Power Relay Module A 13 1
Power Relay Module B 14 1
Power Relay Module C 15 1
Power Relay Module D 18 1
Power Relay Module E 120 8
Radio Fuse (Option) 62 8
Rear Axle Oil Temperature Sender 34 5
Rear Washer Pump Motor 112 7
Rear Wiper and Washer Switch 107 7
Rear Wiper Motor 110 7
Redundant Brake Pressure Switches 75-76 5
Return-To-Dig Proximity Switch 28 6
Return-To-Travel/Float Switch 25 6
RH Front Combination Lamp 97 2
RH Front Work Lamp 86 3
RH Rear Combination Lamp 100 2
RH Rear Work Lamp 88 3
Ride Control Relay (Option) 36 6
Ride Control Solenoid (Option) 40 6
Ride Control Switch (Option) 35 6
Right Speaker 124 8

4002-41
COMPONENT SCHEMATIC
COMPONENT
NUMBER SHEET
Rollback Pressure Switch (Option) 41 6
Rotating Beacon (Option) 82 3
Secondary Steering Module (Option) 116 7
Secondary Steering Motor (Option) 117 7
Secondary Steering Pressure Switch (Option) 118 7
Secondary Steering Solenoid (Option) 115 7
Starter Motor 9 1
Starting Relay 1 1
Thermostat 148 9
Throttle Pedal 23 1
Time Delay Module 7 1
Torque Converter Output Temperature Sensor 48 4
Transmission Auto Switch 58 4
Transmission Electronic Control Module 53 4
Transmission Enable Switch 54 4
Transmission Kick-Down Switch 56 4
Transmission Shifter 52 4
Transmission Solenoid Valve and Temperature Sensor 46 4
Turbine Speed Sensor 51 2
Turn Signal, High/Low Beam, and Horn Switch 94 2
Voltmeter Fuse 17 1
Voltmeter Relay 12 1
Warning Buzzer 63 5
Work Lamps Switch 80 3

4002-42
STARTING AND CHARGING SYSTEMS
10
5 2 7
8
1 9 4 11
6 12
W270-7R020
1. STARTING RELAY 7. TIME DELAY MODULE

2. RESISTOR 75 OHM 8. MASTER DISCONNECT SWITCH
3. ALTERNATOR 9. STARTER
4. CRANK CONTROL RELAY 10. IGNITION SWITCH
5. BATTERIES 11. NEUTRAL START RELAY
6. CRANK REQUEST RELAY 12. VOLT METER RELAY
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-43
1 – Starting Relay
Located in the right side of the engine compartment on starter motor, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading
Relay housing to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position.
Terminal 87, battery hot lead (black

24 volts Check circuit to batteries.
w/white stripe), to ground
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Terminal for wire 21C-D to ground 24 volts Check crank control relay (4), also check circuit 21.
Terminal 30, lead from relay to

24 volts Bad starting relay.
starter solenoid, to ground
2 – Resistor
Located in the cab access panel for fuses and relays.
NOTE: Turn master disconnect switch off, disconnect terminals from resistor.
Correct
Reading
Between terminals of resistor 75 ohms Bad resistor.
3 – Alternator
Located on left side of engine, open engine compartment to gain access.
Correct
Reading
Between housing of alternator and

Continuity Bad ground connection.
ground
Between the B+ terminal of 24 volts Check circuit to positive post of left battery. Bad master
alternator and ground disconnect switch. Bad wire 1-BA.
NOTE: Put the ignition switch in the ON position.
Check circuit 14, 75 ohm resistor (2), and diode module. Bad
Terminal for wire 14 to ground 20 volts fuse ECA-F4. Check power relay module A (13), and 105
ampere circuit breaker (19) in engine compartment of machine.
NOTE: If the readings are good, repair or replace the alternator.
4 – Crank Control Relay

Correct
Reading
NOTE: No information at time of print.

4002-44
5 – Batteries
Located on right and left rear sides of the machine.
NOTE: See Section 4003 and check the batteries.
6 – Crank Request Relay

Correct
Reading
7 – Time Delay Module

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

Terminal for wire 1DN to ground 24 volts
and wire 1DM to fuse ECC F5.
NOTE: Put the ignition switch in the ON position.
Terminal for wire 13K-A to ground 24 volts Bad ignition switch (10), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 30 seconds time
delay an audible click will be heard.
24 volts
Bad time delay module.
Key OFF
After 30 seconds of turning ignition

switch to the OFF position, check 0 volt Bad time delay module.
terminal for wire 13D to ground
8 – Master Disconnect Switch

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

Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
NOTE: Put the master disconnect switch in the OFF position.
Between terminals of master

Open Circuit If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
4002-45
9 – Starter Motor
Located on left side of engine, open engine compartment to gain access.
Correct
Reading
Between housing of starter and

Continuity Bad ground connection.
ground
Starter B+ stud to ground 24 volts Check circuit to batteries.
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
24 volts Bad starting relay (1). Also check wire 1-BB between starter
Terminal S to ground
and starting relay (1).
NOTE: If the readings are good, repair or replace the starter.
10 – Ignition Switch
Located on steering column.
Correct
Reading
Terminal for wire 1A to ground 24 volts Bad 10 ampere fuse in ECC F5. Check circuit 1A.
NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON.
Between Bat and Ign Continuity Bad ignition switch.
Between Bat and Accessory Continuity Bad ignition switch.
NOTE: Hold the ignition switch in the START position.
Between Bat and Starter Continuity Bad ignition switch.
Between Bat and Ign Continuity Bad ignition switch.
NOTE: Put the switch in the Accessory position.
Between Bat and Accessory Continuity Bad ignition switch.

4002-46
11 – Neutral Start Relay

Correct
Reading
Terminal for wire 0-DE to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 25T to ground 24 volts Check circuit 25T, check FNR switch (50).
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21K-B to ground 24 volts Check circuit 21K-B and ignition switch (10).
Terminal for wire 21C to ground 24 volts Bad neutral start relay.
12 – Voltmeter Relay
Correct
Reading
Terminal for wire 0-DD to ground Continuity Bad ground circuit.
Check circuit 18R to power relay module C in engine

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

4002-47
POWER RELAY MODULES AND COLD STARTING SYSTEMS
16
13
15 19 14
18
W270-7R021
13. POWER RLEAY MODULE A 18. POWER RELAY MODULE D

14. POWER RELAY MODULE B 19. CIRCUIT BREAKER CAB +
15. POWER RELAY MODULE C 20. COMFORT STEER RELAY (OPTION)
16. ETHER SOLENOID 21. COMFORT STEER SOLENOID (OPTION)
17. VOLTMETER FUSE
4002-48
13 – Power Relay Module A, Ignition Power

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

Terminal for wire 1CB-A to ground 24 volts
compartment, check circuit breaker.
Terminal for wire 13K-B to ground 24 volts Check circuit 13K and check ignition switch (10).
Terminal for wire J1 BUSS to ground 24 volts Bad power relay module A.
14 – Power Relay Module B, Ignition Power

Correct
Reading
Terminal for wire 0-EA to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire PRM-B BUSS to 24 volts Check circuit 1CB to 105 Amp circuit breaker in engine
ground compartment, check circuit breaker.
Check circuit 13 to Time Delay Module, check TDM (7), check

Terminal for wire 13D to ground 24 volts
ignition switch (10).
Terminal for wire 13H to ground 24 volts Bad power relay module B.
15 – Power Relay Module C, For Ether Solenoid

Located in the right side of the engine compartment, open engine compartment to gain access.
Correct
Reading
Terminal for wire 0-BAM to ground Continuity Bad ground circuit.
NOTE: Turn master disconnect switch to the ON position.
Terminal for wire 1-B9 to ground 24 volts Check circuit 1 to starter B+.
NOTE: Remove the ether bottle from the machine. Make sure engine temperature is below -0° C (32° F). Put the
ignition switch in the ON position, have an assistant press and hold the ether switch to the inject position.
Terminal for wire 28E to ground 24 volts Check Ether switch.
Terminal for wires 28P ground 24 volts Bad power relay module C.
4002-49
16 – Ether Solenoid
Located in the right side of the engine compartment.
Correct
Reading
Terminal for wire 0-BAN to ground Continuity Bad ground circuit.
NOTE: Disconnect connector ETHR from ether solenoid.
Between terminals A and B of 28.8 ohm @

Bad solenoid.
solenoid. 20° C (68° F)
NOTE: If the readings are good, check circuit 28P between solenoid connector ETHR and power relay module C
connector PRM-C1. Check Power Relay Module C (15).
17 – Voltmeter Fuse
Correct
Reading
18 – Power Relay Module D, Accessory Power

Correct
Reading
Terminal for wire 0-EC to ground Continuity Bad ground circuit.
NOTE: Turn master disconnect switch to the ON position.
Terminal for wire PRM-D BUSS to Check circuit 1CB to 105 Amp circuit breaker in engine
24 volts
NOTE: Put the ignition switch in the ACC position.
Terminal for wire 12ACC-B to 24 volts Check ignition switch (10).

ground
Terminal for wire BUSS-J11 ground 24 volts Bad power relay module D.
19 – Circuit breaker Cab B+

Located in the right side of the engine compartment, open engine compartment to gain access.
Correct
Reading
Between terminal A and B on circuit

Continuity Bad circuit breaker
breaker
4002-50
20 – Comfort Steer Relay (option)

Correct
Reading
21 – Comfort Steer Solenoid (option)

Correct
Reading

4002-51
ENGINE CONTROLLER
24
23
22
W270-7R022
22. FRONT AXLE OIL TEMPERATURE SENDER

23. THROTTLE POTENTIOMETER
24. ENGINE CONTROLLER
4002-52
22 – Front Axle Oil Temperature Sender

Correct
Reading
23 – Throttle Potentiomer
Located below cab under throttle pedal.
Correct
Reading
NOTE: Use the Electronic Service Tool to test the throttle sensor.
24 – Engine Controller
Located on right side of engine, open engine compartment to gain access.
Correct
Reading
NOTE: Put the ignition switch in the OFF position. Put the master disconnect switch in the OFF position.
Disconnect connector QSM 11.
Terminal for wire 0-BAH pin 29 to

Continuity Bad ground circuit.
ground
Terminal for wire 0-BAI pin 30 to Continuity Bad ground circuit.

ground
Terminal for wire 0-BAJ pin 39 to Continuity Bad ground circuit.

ground
Terminal for wire 0-BAK pin 40 to

ground
Terminal for wire 0-BAP pin 50 to Continuity Bad ground circuit.

ground
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position.
Terminal for wire 18J-M pin 7 to

24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-N pin 8 to

ground
Terminal for wire 18J-L pin 17 to

ground
Terminal for wire 18J-P pin 18 to

ground
Terminal for wire 18J-Q pin 28 to

ground
NOTE: Use diagnostic service tool for additional tests on QSM 11.
4002-53
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE
28 30
25 26 31
34 29 27
33
W270-7R023
25. RETURN TO TRAVEL FLOAT SWITCH 30. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH
26. HEIGHT CONTROL SWITCH 31. RETRUN TO DIG SWITCH
27. ELETROMAGNETIC DETENTS 32. PIN ENGAGE SWITCH (OPTION)
28. RETURN TO DIG PROXIMITY SWITCH 33. PILOT PRESSURE SOLENOID
29. PILOT CONTROL RELAY ECD-K3 34. REAR AXLE OIL TEMPERATURE SENDER
4002-54
25 – Return-To-Travel/Float Switch
Located on right side console.
Correct
Reading
Terminal for wire 0-B2 to ground Continuity Bad ground circuit.
Terminal for wire 0-29 to ground Continuity Bad ground circuit.
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch. Put the return-to-
travel/float switch in FLOAT position.
Between switch terminals 1 and 2 Continuity Bad return-to-travel/float switch.
NOTE: Put the return-to-travel/float switch in the TRAVEL position.
Between switch terminals 2 and 3 Continuity Bad return-to-travel/float switch.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch. Put
ignition switch in ON position. Put driving lamp switch (95) in position 3.
Bad circuit 49-K. Also check driving lamp switch (95). If

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

Correct
Reading
Terminals for wire 0-B3 to ground Continuity Bad ground circuit.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-D to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
NOTE: Turn the height control switch to the ON position.
Terminal for wire 54A to ground. 24 volts Bad height control switch.
4002-55
27 – Electromagnetic Detents
Located under right side console.
Correct
Reading
NOTE: For joystick controller.
74 ohms @
Between pins 3 and 4 Bad electromagnetic detent
20° C (68° F)
74 ohms @
20° C (68° F)
74 ohms @
20° C (68° F)
NOTE: For single axis controller.
328 ohms @
20° C (68° F)
328 ohms @
20° C (68° F)
328 ohms @
20° C (68° F)
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (36) in OFF
position and return to travel/float switch (22) in ON position.
Wiring harness connector EM, pin 1 24 volts Bad return to travel/float switch (22). Also check wires 55A.
to ground
NOTE: Place the height control switch in the ON position.
Wiring harness connector EM, pin 2

24 volts Bad height control switch. Also check wires 54A.
to ground
NOTE: Place the return to dig switch in the ON position.
Wiring harness connector EM, pin 3

24 volts Bad return to dig switch. Also check wires 53A.
to ground
28 – Return-To-Dig Proximity Switch

Located on bucket cylinder.
Correct
Reading
NOTE: Disconnect the connector from the return-to-dig proximity switch. Put the master disconnect switch and
the ignition switch in the ON position. Put the pilot control switch (36) in the OFF position and the return to dig
switch in the ON position.
Terminal B for wire 0-AC to ground Continuity Bad ground circuit.
24 volts Bad bucket control valve detent electromagnets (24) or return

Terminal A for wire 53B to ground
to dig switch. Also check circuit 53B.
Terminal C for wire 53P-H to ground 24 volts Bad pilot relay (26), also check circuit 53P.
NOTE: If the readings are good, replace the return-to-dig proximity switch.
4002-56
29 – Pilot Control Relay

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(36) is OFF.
Terminal for wire 19C-C to ground 24 volts Bad fuse ECA-F5, also check circuit 19C.
Terminal for wire 53C-A to ground 0 volt Bad instrument cluster (57). Also check circuit 53C.
Terminal for wire 53P-A to ground 24 volts Bad pilot control relay.
NOTE: Put the pilot control switch in ON position.
Terminal for wire 53C-A to ground 24 volts Bad instrument cluster (57). Also check circuit 53C.
30 – Height Control/Return-To-Travel Proximity Switch

Located on left front frame at lift arm pivot.
Correct
Reading
NOTE: Disconnect the connector from the height control/return-to-travel proximity switch. Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (36) in the OFF position
and the return to travel switch in the ON position.
Terminal B for wire 0-AA to ground Continuity Bad ground circuit.
Bad bucket control valve detent electromagnets (24) or return

Terminal A for wire 54B to ground 24 volts
to travel switch. Also check circuit 54B.
Terminal C for wire 53P-J to ground 24 volts Bad pilot relay (26), also check circuit 53P.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch.
31 – Return to Dig Switch

Correct
Reading
Terminals for wire 0-B4 to ground Continuity Bad ground circuit.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-E to ground. 24 volts Bad pilot control relay (26), check fuse ECA-F5.
NOTE: Turn the height control switch to the ON position.
Terminal for wire 53A to ground. 24 volts Bad return to dig switch.
4002-57
32 – Pin Engage Switch (option)

Correct
Reading
33 – Pilot Pressure Solenoid

Located on bottom side of pilot controls.
Correct
Reading
Terminal for wire 0-DU to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control
switch (36) is OFF.
Terminal A for wire 53P-A to ground 24 volts Bad pilot control relay (26), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid.
34 – Rear Axle Oil Temperature Sender

Correct
Reading

4002-58
PILOT CONTROL - RIDE CONTROL - FAN CONTROL
35 37 39
43 36 40
44 38
W270-7R024
35. RIDE CONTROL SWITCH (OPTION) 40. RIDE CONTROL SOLENOID (OPTION)
36. RIDE CONTROL RELAY (OPTION) 41. ROLLBACK PRESSURE SWITCH (OPTION)
37. FAN CONTROL SWITCH (OPTION) 42. COMFORT STEER SWITCH
38. FAN REVERSE RELAY (OPTION) 43. FAN PWM SOLENOID
39. PILOT CONTROL SWITCH 44. FAN REVERSE SOLENOID (OPTION)
4002-59
35 – Ride Control Switch (Option)

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

Continuity Bad ride control switch.
(positive) to terminal 7 (negative)
NOTE: Connect connector SRC to ride control switch. Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
Check fuse ECA-F5 and power relay module A. Also check

Terminal for wire 19C-D to ground 24 volts
circuit 19C.
Terminal for wire 58C to ground 0 volt Bad ride control switch.
NOTE: Put the ride control switch in the ON position.
Terminal for wire 58C to ground 24 volts Bad ride control switch.
NOTE: Put the driving light switch (95) in position 3.
Check driving lamp switch (95). Also check circuit 49. If LED in
Terminal for wire 49-G to ground 24 volts ride control switch is not ON with 24 volts at check point,
replace ride control switch.
36 – Ride Control Relay (Option)

Correct
Reading
Terminal 85 for wire 58L to

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

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

control switch (32) pin 6
NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position.
Terminal for wire 58T to ground 24 volts Bad ride control switch. Also check wire 58T.
NOTE: If readings are normal, replace ride control relay.

4002-60
37 – Fan Control Switch (Option)

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Check fuse ECA-F7, power relay module A (13), also check

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

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

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

24 volts Check fuse ECA-F7 and circuit 19P.
to ground
NOTE: Put the fan reverse switch in the manual reverse position.
Bad fan reverse solenoid, bad fan reverse switch (34), bad
Terminals for wire 52A-A to ground 24 volts
advanced instrument cluster (57).
4002-61
39 – Pilot Control Switch

Located on steering column pedestal.
Correct
Reading
Terminal for wire 0B1 to ground Continuity Bad ground circuit.
Terminal for wire 19A-J to ground 24 volts Bad fuse ECA-F1, also check circuit 19C.
NOTE: Press pilot control switch to turn ON switch LED.
Terminal for wire 31L to ground 24 volts Bad pilot control switch.
NOTE: Put the driving lamp switch (95) in position 3.
Check driving lamp switch (95) and fuse ECC-F3. Also check
Terminal for wire 49-N to ground 24 volts
circuit 49.
NOTE: If the readings are correct replace the pilot control switch.
40 – Ride Control Solenoid (Option)

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

Bad ride control solenoid.
control solenoid 20° C (68° F)
41 – Rollback Pressure Switch (Option)

Correct
Reading
42 – Comfort Steer Switch

Correct
Reading

4002-62
43 – Fan PWM Solenoid (Option)

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

Bad fan reversing solenoid.
solenoid 20° C (68° F)
Pin 2 of wiring harness connector

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

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

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

Bad fan reversing solenoid.
reversing solenoid 20° C (68° F)

YFR to ground
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ON
position (hold rocker in momentary position).
Pin 1 of wiring harness connector Bad fan reversing switch (34), reverse relay (35). Also check wire
24 volts 52-A.
YFR to ground
4002-63
TRANSMISSION
52
59 47 46
48
61
55 56 57
49 50 45 53 54
51 60 58
W270-7R025
45. OUTPUT SPEED SENSOR 54. TRANSMISSION ENABLE SWITCH

46. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 55. FNR SWITCH FOR JOYSTICK CONTROLS
47. FILTER MAINTENANCE SWITCH 56. TRANSMISSION KICK-DOWN SWITCH
48. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 57. FNR SWITCH FOR SINGLE AXIS CONTROLS
49. ENGINE SPEED SENSOR 58. TRANSMISSION AUTO SWITCH
50. INTERMEDIATE SPEED SENSOR 59. BRAKE DECLUTCH PRESSURE SWITCH
51. TURBINE SPEED SENSOR 60. DECLUTCH SWITCH
52. TRANSMISSION SHIFTER 61. DIAGNOSTIC CONNECTOR
53. TRANSMISSION ELECTRONIC CONTROL MODULE
4002-64
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 45 through 61.
45 – Output Speed Sensor

46 – Transmission Solenoid Valve and Temperature Sensors
47 – Filter Maintenance Switch
48 – Torque Converter Output Temperature Sender
49 – Engine Speed Sensor
50 – Intermediate Speed Sensor
51 – Turbine Speed Sensor
52 – Transmission Shifter
53 – Transmission Electronic Control Module
54 – Transmission Enable Switch
55 – FNR Switch for Joystick Controls
56 – Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick
Option; Next to Hydraulic Levers for Single Axis Controls)
57 – FNR Switch for Single Axis Controls
58 – Transmission Auto Switch
59 – Brake Declutch Pressure Switch
60 – Declutch Switch
61 – Diagnostic Connector
4002-65
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE
63
67 69 68
66
65
64
W270-7R026
62. FUSE RADIO (OPTION) 66. AIR FILTER RESTRICTION SWITCH

63. WARNING BUZZER 67. PARKING BRAKE SOLENOID
64. PARKING BRAKE RELAY 68. RADIATOR COOLANT TEMPERATURE SENDER
65. FUEL LEVEL SENDER 69. BRAKE PRESSURE WARNING SWITCH
4002-66
62 – Fuse Radio (Option)

Correct
Reading
63 – Warning Buzzer
Located on steering column under instrument cluster.
Correct
Reading
NOTE: Buzzer sounds for five seconds during self test when ignition switch is turned on.
Terminal for wire 0_B27 to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the ON position
Terminal for wire 35B to ground 24 volts Bad instrument cluster
NOTE: If all readings are good, replace buzzer.
64 – Parking Brake Relay

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (74) is OFF.
Terminal for wire 19D-B and 19D-C

24 volts Bad fuse ECA-F6, also check circuit 19D.
to ground
Terminal for wire 52C to ground 0 volt Bad instrument cluster. Also check circuit 52C.
Terminal for wire 52P-B to ground 24 volts Bad parking brake relay.
NOTE: Put the parking brake switch in the ON position.
Terminal for wire 52C to ground 24 volts Bad instrument cluster. Also check wire 52C.
4002-67
65 – Fuel Level Sender

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

Bad fuel level sender.
sender
66 – Air Filter Restriction Switch

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

Located on the foot brake valve.
Correct
Reading
Terminal for wire 0-AN to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF
position. Have assistant press and hold foot brake and place FNR switch either in F or R position.
Terminal 1 for wire 52P to ground 24 volts Bad parking brake relay (64). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid.
4002-68
68 – Radiator Coolant Temperature Sender

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

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

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

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

Between terminals 1 and 2 of the
Open Circuit 110.3 bar (1600 psi). Refer to Section 7002 to check brake
switch
pressure.
4002-69
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE
77
74
72 73
75
76
W270-7R027
70. FUSE COMFORT STEER 74. PARK BRAKE SWITCH

71. FUSE PARK BRAKE 75. REDUNDANT BRAKE PRESSURE SWITCH 1
72. HYDRAULIC FILTER RESTRICTION SWITCH 76. REDUNDANT BRAKE PRESSURE SWITCH 2
73. HYDRAULIC OIL TEMPERATURE SENDER 77. COOLANT LEVEL SENDER
4002-70
70 – Fuse Comfort Steer

Correct
Reading
71 – Fuse Park Brake

Correct
Reading
72 – Hydraulic Filter Restriction Switch

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

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

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

at 20° C (68° F) Replace hydraulic oil temperature sender.
temperature sender
Approximately
Terminal A for wire 36H to ground Check the instrument cluster.
5 volts
4002-71
74 – Parking Brake Switch

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

Located on steel lines at accumulators.
Correct
Reading
NOTE: Redundant brake switch close at 62 bar (900 psi).
Terminal for wireS 0-HM to ground Continuity Bad ground circuit.
Approximately
Terminal A for wire 33R-C to ground 11.5 volts Bad instrument cluster, also check circuit 33R.
NOTE: If the readings are good, replace the redundant brake pressure switch(es).
76 – Redundant Brake Pressure Switch 2

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

11.5 volts Bad instrument cluster, also check circuit 33R.
ground
NOTE: If the readings are good, replace the redundant brake pressure switch(es).
4002-72
77 – Coolant Level Sender

Located on radiator top tank.
Correct
Reading
Terminal for wire 0-BAF to ground Continuity Bad ground circuit.
Approximately
Terminal A for wire 31D-C to ground Check circuit 31D, also check the instrument cluster.
1.6 volts AC
NOTE: If the readings are correct replace the coolant level sender.
4002-73
BACK UP ALARM CONTROLS
79
78
W270-7R028
78. BACK UP ALARM RELAY 79. BACK UP ALARM DISABLE SWITCH

4002-74
78 – Back-up Alarm Relay

Correct
Reading
NOTE: Disconnect the transmission electronic control module (53) connector TECM.
Terminal for wire 35C to terminal 7 of

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

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
Terminal for wire 35A-B to ground 24 volts Bad back-up alarm relay (78), also check circuit 35A-B.
NOTE: Wires 35A-E and 35A-D are connected together, connectors 209F and 209M, and switch is removed in
North American models. The connectors are disconnected and the switch is installed in TUV road approved
(Germany) models.
Terminal for wire 35R-C to ground 24 volts Bad back-up alarm disable switch.
4002-75
LIGHTS - 01
85
87
82 81
86
88
83
80 84
89
W270-7R029
80. WORK LIGHTS SWITCH 85. LEFT HAND FRONT WORK LAMP
81. DOOR SWITCH 86. RIGHT HAND FRONT WORK LAMP
82. ROTATING BEACON (OPTIONAL) 87. LEFT HAND REAR WORK LAMP
83. DOME LIGHT 88. RIGHT HAND REAR WORK LAMP
84. ROTATING BEACON SWITCH (OPTIONAL) 89. DIODES
4002-76
80 – Work Lamps Switch

Correct
Reading
Terminal for wire 0-B14 to ground Continuity Bad ground circuit
NOTE: Put master disconnect witch in the ON position.
Terminal for wire 42-A and 42-B to

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

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

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

4002-77
83 – Dome Lamp
Located in top of cab.
Correct
Reading
Terminal for wire 0-MB to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put dome lamp switch in ON position.
Terminal for wire 19U-C to ground 24 volts Check fuse ECC-F1, also check circuit 19U.
24 volts Check circuit 43, also check advanced instrument cluster and
Terminal for wire 43-B to ground
3 to 5 seconds time delay module (7).
NOTE: If readings are good, replace dome lamp.
84 – Beacon Switch (Option)

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

Located on left front side of cab.
Correct
Reading
NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector.
Flood lamp connector pin A to pin B Continuity Bad lamp bulb.
NOTE: Connect wiring harness connector LLFW to LH front work lamp connector.
Terminal for wire 0-MU to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
Check fuse ECB-F1 and driving lamp switch (95). Also check
Terminal for wire 42C-H to ground 24 volts circuit 42C from flood lamp to lamp switch (95) and wire 42-A
to fuse ECC-F2.
4002-78
86 – Right Hand Front Work Lamp

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

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

Located on right rear side of cab.
Correct
Reading
NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector.
NOTE: Connect wiring harness connector LRRW to RH rear work lamp connector.
Terminal for wire 0-MF to ground Continuity Bad ground circuit.
Terminal for wire 42R-G to ground 24 volts circuit 42R from flood lamp to lamp switch (95) and wire 42-B
to fuse ECC-F2.
4002-79
89 – Lights Diodes
Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Reading
NOTE: Disconnect wiring harness connector D-OR from diode connector.
Multimeter positive on pin A to pin C None Bad diode.
Multimeter positive on pin B to pin C None Bad diode.
Multimeter positive on pin C to pin A Continuity Bad diode.
Multimeter positive on pin C to pin B Continuity Bad diode.

4002-80
LIGHTS - 02
93 94
95
92 91 90
W270-7R030
90. BRAKE LIGHTS SWITCH 93. HAZARD SWITCH

91. BRAKE LIGHTS RELAY 94. TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH
92. FLASHER MODULE 95. DRIVING LIGHTS SWITCH
4002-81
90 – Brake Lamp Pressure Switch

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

Correct
Reading
Terminal for wire 0-EF to ground Continuity Bad ground circuit.
Terminal for wire 1-DW to ground 24 volts Check fuse ECC-F4 and wires 1-DW and 1-DV.
Terminal for wire 44A to ground 0 volt Bad brake lamp pressure switch (90).
Terminal for wire 44A-A to ground 0 volt Bad brake lamps relay.
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44A to ground 24 volts Bad brake lamp pressure switch (90).
Terminal for wire 44A-A to ground 24 volts Bad brake lamps relay.
4002-82
92 – Flasher Module
Correct
Reading
NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite
side steady on operation and disconnected for European machines for opposite side off operation.
Terminal for wire 0-EG to ground Continuity Bad ground circuit.
Terminal for wire 0-EH to ground Continuity Bad ground circuit.
Terminal for wire 45N-A to terminal

for wire 45N-B (North American Continuity Bad 45N circuit.
machines only)
Terminal for wire 1-DU to ground 24 volts Check fuse ECC-F4. Also check wires 1-DU and 1-DV.
NOTE: Put ignition switch in the ON position. Put the hazard switch (93) ON.
Terminal for wire 45H to ground 24 volts Bad hazard switch (93). Also check wire 45H.
Intermittent 24
Terminal for wire 45L-D to ground Bad flasher module.
volts
Intermittent 24
Terminal for wire 45R-E to ground Bad flasher module.
volts
NOTE: Put hazard switch (93) in OFF position. Put turn signal switch (94) in RIGHT turn position.
24 volts Bad turn signal switch (94) or fuse ECA-F8. Also check wires
Terminal for wire 45B-A to ground
45B-A and 45B.
Intermittent 24
Terminal for wire 45R-E to ground volts Bad flasher module.
NOTE: Put turn signal switch (94) in LEFT turn position.
Bad turn signal switch (94) or fuse ECA-F8. Also check wire
Terminal for wire 45A-A to ground 24 volts
45A-A.
Intermittent 24
Terminal for wire 45L-D to ground Bad flasher module.
volts
4002-83
93 – Hazard Switch
Correct
Reading
Terminal for wire 1-KA to ground 24 volts Check fuse ECC-F4. Also check wires 1-KA and 1-DV.
NOTE: Put hazard switch in ON position.
Bad hazard switch. If hazard switch LED is not ON with 24 volts

Terminal for wire 45H to ground 24 volts
at check point, replace hazard switch.
NOTE: Put driving lamp switch (95) in position 2 or 3.
Check driving lamp switch (95). Also check circuit 49 to lamp

Terminal for wire 49-D to ground 24 volts switch (95). If hazard switch LED is not ON with 24 volts at
check point, replace hazard switch.
4002-84
94 – Turn Signal, High-Low Beam, and Horn Switch

Correct
Reading
HORN SWITCH
Terminal for wire 0-EP to ground Continuity Bad ground circuit.
24 volts Check fuse ECC-F6 and horn relay (98). Also check wires 64C
Terminal for wire 64C to ground
and circuit 19U.
NOTE: Press horn switch.
Terminal for wire 64C to ground 0 volts Bad horn switch.
NOTE: If readings are good, replace the switch.
TURN SIGNAL
Check fuse ECA-F8 and power relay module A (13). Also check
Terminal for wire 19B to ground 24 volts
wire 19B.
NOTE: Move turn signal lever to RIGHT turn position.
Terminal for wire 45B-A to ground 24 volts Bad turn signal switch.
NOTE: Move turn signal lever to LEFT turn position.
Terminal for wire 45A-A to ground 24 volts Bad turn signal switch.
HIGH-LOW BEAM SWITCH
Terminal for wire 19Z-C to ground 24 volts Bad 19Z-C circuit, check fuse ECC-F3.
NOTE: Pull on high beam flash lever.
Terminal for wire 41H_A to ground 24 volts Bad high beam flash switch.
95 – Driving Lamp Switch

Correct
Reading
Terminal for wire 19Z-A to ground 24 volts Check fuse ECC-F3, also check circuit 19Z.
NOTE: Put the driving lamp switch in position 2.
Terminal for wire 41T to ground 24 volts Bad driving lamp switch.
Terminal for wire 41J to ground 24 volts Bad driving lamp switch.
4002-85
LIGHTS - 03 AND HORN
96
99
97
98
W270-7R031
96. LEFT HAND FRONT COMBINATION LAMPS 98. HORN RELAY

97. RIGHT HAND FRONT COMBINATION LAMPS 99. HORN
4002-86
96 – Left Hand Front Combination Lamp

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

Continuity Bad high beam lamp bulb or internal connection.
pin 1

Continuity Bad position lamp bulb or internal connection.
pin 1

Continuity Bad low beam lamp bulb or internal connection.
pin 1

Continuity Bad turn signal lamp bulb or internal connection.
pin 1
NOTE: Connect wiring harness connector LLF to LH front combination lamp connector. Put master disconnect
switch in ON position and driving lamp switch (95) in position 2.
Terminal for wire 0-AJ to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 2.
Connector LLF terminal for wire 0-AJ

to ground
Terminal for wire 18F to ground 24 volts
circuit 18F.
NOTE: Put driving lamp switch (95) in position 3, and high/low beam lever (94) in HIGH beam position.
Check fuse ECB-F3, high/low beam relay, driving lamp switch

Terminal for wire 18B to ground 24 volts (95), and high/low beam switch (94). Also check circuit 18B and
wire 41H.
NOTE: Put high/low beam lever (94) in LOW beam position.
Check fuse ECB-F6, driving lamp switch (95), and high/low

Terminal for wire 18D to ground 24 volts
beam switch (94). Also check circuit 18D and wire 41L-A.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
Terminal for wire 45L to ground
volts check circuit 45L to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp.
4002-87
97 – Right Hand Front Combination Lamp

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

Continuity Bad high beam lamp bulb or internal connection.
pin 1

Continuity Bad position lamp bulb or internal connection.
pin 1

Continuity Bad low beam lamp bulb or internal connection.
pin 1

Continuity Bad turn signal lamp bulb or internal connection.
pin 1
NOTE: Connect wiring harness connector LRF to RH front combination lamp connector. Put master disconnect
switch in ON position and driving lamp switch (95) in position 3.
Terminal for wire 0-AH to ground Continuity Bad ground circuit.
Terminal for wire 18G-A to ground 24 volts
circuit 18G and wire 41T-A.
NOTE: Put high/low beam lever (94) in HIGH beam position.
24 volts Check fuse ECB-F4, driving lamp switch (95), and high/low
Terminal for wire 18C to ground
beam switch (94). Also check circuit 18C and wire 41H.
NOTE: Put high/low beam lever (94) in LOW beam position.
Check fuse ECB-F5, driving lamp switch (95), and high/low

Terminal for wire 18E to ground 24 volts
beam switch (94). Also check circuit 18E and wire 41L-C.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R to ground
volts check circuit 45R to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp.
98 – Horn Relay
Correct
Reading
Terminal for wire 19U-A to ground 24 volts Check fuse ECC-F6, also check wire 19U and 190U-A.
Terminal for wire 19U-E to ground 24 volts Check wire 19U and 19U-E.
Terminal for wire 64C to ground 24 volts Bad horn relay.
NOTE: Have another person push and hold the horn switch.
Terminal for wire 64C to ground 0 volt Bad horn switch.
Terminal for wire 64-A to ground 24 volts Bad horn relay.

4002-88
99 – Horn
Located on the left front of the machine with combination lamps.
Correct
Reading
Terminal for wire 0-AF to ground Continuity Bad ground circuit.
NOTE: Disconnect the wire 64 from the horn. Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground. 24 volts Check the horn relay (98). Also check wires 64 and 64-A.
NOTE: If the readings are good replace the horn.

4002-89
LIGHTS - 04 AND BACK UP ALARM
101
103
100
102
W270-7R032
100.RIGHT HAND REAR COMBINATION LAMPS 102.LICENSE PLATE LAMP

101.LEFT HAND REAR COMBINATION LAMPS 103.BACK UP ALARM
4002-90
100 – Right Hand Rear Combination Lamp

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

Continuity Bad stop lamp bulb.
pin 5

Continuity Bad turn lamp bulb.
pin 5

Continuity Bad tail lamp bulb.
pin 5

Continuity Bad reverse lamp bulb.
pin 5
NOTE: Connect wiring harness connector LRR-E to RH rear combination lamp connector.
Terminal for wire 0-BR to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
Check brake lamps relay (91). Also check circuit 44 to brake

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

Terminal for wire 35A-K to ground 24 volts
backup alarm relay (78).
NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R-A to ground
volts check circuit 45R to flasher module.
NOTE: Put driving lamp switch (95) in position 2 or 3.
24 volts Check fuse ECB-F8 and lamp switch (95). Also check circuit
Terminal for wire 18G-A to ground
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.
4002-91
101 – Left Hand Rear Combination Lamp

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

Continuity Bad stop lamp bulb.
pin 5

Continuity Bad turn lamp bulb.
pin 5

Continuity Bad tail lamp bulb.
pin 5

Continuity Bad reverse lamp bulb.
pin 5
NOTE: Connect wiring harness connector LLR-E to LH rear combination lamp connector.
Terminal for wire 0-BT to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
24 volts Check brake lamps relay (91). Also check circuit 44 to brake
Terminal for wire 44A-E to ground
lamps relay (91).
NOTE: Have assistant put transmission in reverse.
Check backup alarm relay (78). Also check circuit 35A to

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

Located on the right rear of the machine with combination lamp.
Correct
Reading
Terminal for wire 0-JC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2.
Check fuse ECB-F8 and five driving lamp switch (95). Also
Terminal for wire 18G-E to ground 24 volts
check circuit 18G.
4002-92
103 – Back-up Alarm

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

Terminal for wire 35A to ground 24 volts
model, check connector 209F and 209M is connected.
NOTE: If the readings are good, replace the back-up alarm.

4002-93
CAB WINDOW WASHER AND WIPER SYSTEM
110
109
107 108
113 111 104 106

112 105
W270-7R033
104.FRONT WIPER HIGH SPEED RELAY 109.FRONT WIPER MOTOR

105.WIPER CUT OUT RELAY 110.REAR WIPER MOTOR
106.FRONT WIPER LOW SPEED RELAY 111.FRONT WASHER MOTOR
107.REAR WIPER/WASHER SWITCH 112.REAR WASHER MOTOR
108.FRONT WIPER/WASHER SWITCH 113.DIODES
4002-94
104 – Front Wiper High Speed Relay

Correct
Reading
Terminal for wire 19J-D and 19J-E to Bad fuse ECA-F12, check circuit 19J, also check power relay
24 volts
ground module D (18).
NOTE: Put the front wiper switch in the HIGH position.
Terminals for wire 63HC-B to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63HC-B to ground 24 volts Bad wiper high speed relay.
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C2 to ground 24 volts Bad wiper high speed relay.
105 – Front Wiper Cut Out Relay

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position, front wiper switch in the low
position.
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-G to ground 24 volts
module D (18).
Terminal for wire 63L-B to ground 24 volts Bad wiper cut out relay.
NOTE: Put the front wiper switch in the HIGH position.
Terminals for wire 63HC-A to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63L-B to ground 0 volts Bad wiper cut out relay.
4002-95
106 – Front Wiper Low Speed Relay

Correct
Reading
Bad fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-F to ground 24 volts
module D (18).
NOTE: Put the front wiper switch in the LOW position.
Intermittent
Terminals for wire 63C to ground Bad wiper low speed relay.
24 volts
Terminals for wire 63LC to ground 0 volts Bad front wiper and washer switch (108).
Terminal for wire 63Cw to ground 24 volts Bad circuit 63Cw, check front wiper high speed relay (104).
Bad wiper low speed relay, also check high speed wiper relay
Terminals for wire 63C3 to ground 24 volts
(104).
107 – Rear Wiper and Washer Switch

Correct
Reading
Bad fuse ECA-F13 or power relay module D (18). Also check

Terminal for wire 19K-B to ground 24 volts
circuit 19K.
Bad fuse ECA-F13 or power relay module D (18). Also check

Terminal for wire 19K-A to ground 24 volts
circuit 19K.
NOTE: Put the rear wiper and washer switch in the ON position.
Terminal for wire 68L to ground 24 volts Bad rear wiper and washer switch.
NOTE: Press and hold the rear wiper and washer switch in the WASH position.
Terminal for wire 68W to ground 24 volts Bad rear wiper and washer switch.
Check rotary lamp switch (95) and circuit 49. If LEDs in rear
Terminal for wire 49-C to ground 24 volts wiper and washer switch are not ON with 24 volts at check
point, replace rear wiper and washer switch.
4002-96
108 – Front Wiper and Washer Switch

Correct
Reading
Terminal for wire 0-DT to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch is in the OFF position.
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-B to ground 24 volts
module D (18).
NOTE: Put the front wiper and washer switch in the LOW position.
Bad front wiper and washer switch also check grounding

Terminal for wire 63LC to ground Continuity
circuit.
NOTE: Put the front wiper and washer switch in the HIGH position.
Bad front wiper and washer switch also check grounding

Terminal for wire 63HC to ground 0 volts
circuit.
NOTE: Put the front wiper and washer switch in the wash position.
Terminal for wire 63W to ground 24 volts Bad front wiper and washer switch.
NOTE: Put the driving lamp switch in position 2 or 3.
Check driving lamp switch (95) and circuit 49. If LEDs in rear
Terminal for wire 49-T to ground 24 volts wiper and washer switch are not ON with 24 volts at check
point, replace rear wiper and washer switch.
4002-97
109 – Front Wiper Motor

Located in front of steering column.
Correct
Reading
NOTE: Make sure the front wiper and washer switch (108) is in the OFF position, disconnect connector FWM.
Between terminals B and D for wires Bad front wiper motor. Confirm with ohm meter, this may be
Continuity
63H and 63L-A open when motor is parked.
NOTE: Connect connector FWM. Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J to ground 24 volts Check fuse ECA-F12, also check circuit 19J.
NOTE: Put the front wiper and washer switch (108) in the LOW position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63L-A to ground 24 volts
and washer switch (108), low speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (108)
NOTE: Put the front wiper and washer switch (108) in the HIGH position.
24 volts Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63H-A to ground
and washer switch (108), high speed relay or cut out relay.
Terminal for wire 63C to ground 24 volts Bad front wiper and washer switch (108).
NOTE: Put the front wiper and washer switch in the intermittent position.
Intermittent
Terminal for wire 63L-A to ground Bad front wiper and washer switch (108).
24 volts
Intermittent
Terminal for wire 63C to ground Bad front wiper park contact.
24 volts
NOTE: If the readings are good, replace the front wiper motor.
4002-98
110 – Rear Wiper Motor

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

connector to motor for wires 19K-D Continuity Bad rear wiper and washer switch (107).
and 68L-A.
NOTE: Connect connector RWM. Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19K-C to ground 24 volts Check fuse ECA-F13, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (107) in the ON position.
Terminal for wire 68L-A to ground 24 volts Bad rear wiper and washer switch (107).
Intermittent
Terminal for wire 68C-A to ground Bad rear wiper and washer switch (107).
24 volts
NOTE: If the readings are good, replace the rear wiper motor.
111 – Front Washer Pump Motor

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

Located on right side under steps.
Correct
Reading
Terminal for wire 0-B to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (108).
Bad front wiper and washer switch (108), also check circuit
Terminal for wire 63W-A to ground 24 volts
63W.
NOTE: If the readings are good, replace the front washer pump motor.
4002-99
113 – Diode Module

Correct
Reading
NOTE: Disconnect wiring harness connector 140M from diode connector. Set multi meter to Diode check mode.
Multimeter positive on pin A to pin C Open Bad diode.
Multimeter positive on pin B to pin C Open Bad diode.
Multimeter positive on pin D to pin C Open Bad diode.
Multimeter positive on pin E to pin C Open Bad diode.
Multimeter positive on pin F to pin C Open Bad diode.
Multimeter positive on pin C to pin A Continuity Bad diode.
Multimeter positive on pin C to pin B Continuity Bad diode.
Multimeter positive on pin C to pin D Continuity Bad diode.
Multimeter positive on pin C to pin E Continuity Bad diode.
Multimeter positive on pin C to pin F Continuity Bad diode.
NOTE: If one or more of the diodes are bad, replace the diode module.
4002-100
SECONDARY STEERING
115
117
116 118
114
W270-7R034
114.SECONDARY STEERING DIODES 117.SECONDARY STEERING MOTOR

115.SECONDARY STEERING SOLENOID 118.SECONDARY STEERING PRESSUR SWITCH
116.SECONDARY STEERING MODULE
4002-101
114 – Secondary Steering Diodes

Located in the cab access panel for fuses and relays, rear of compartment. Set multi meter to Diode check mode.
Correct
Reading
NOTE: Disconnect wiring harness connector DM from diode connector.
Multimeter positive on pin A to pin C Continuity Bad diode.
Multimeter positive on pin B to pin C Continuity Bad diode.
Multimeter positive on pin C to pin A Open Bad diode.
Multimeter positive on pin C to pin B Open Bad diode.
NOTE: If one or more of the diodes are bad, replace the diode module.
115 – Secondary Steering Solenoid (Option)

Located in the rear frame of the machine.
Correct
Reading
NOTE: Disconnect connector YSS from secondary steering solenoid.
Between pins A and B of secondary 36 to 42 ohms

20° c (68° f) Bad secondary steering solenoid.
steering solenoid
Between pin 2 of connector YSS and

ground
NOTE: Disconnect wire 51-B from secondary steering motor relay; make sure that wire does not touch any metal
part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and
run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN
STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately
to ON position.
Between pin 1 of connector YSS and Check secondary steering module (116) and secondary
24 volts
ground steering pressure switch (118).
4002-102
116 – Secondary Steering Module (Option)

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

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

Pin 8 of connector SSM to ground Continuity
wires 35X-D, 35X-C, and 35X-A.
Bad secondary steering pressure switch (118). Also check wire

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

Pin 1 of connector SSM to ground 24 volts
switch, and diode module. Also check circuit 19R.
21 to 22 volts Check circuit 35X to instrument cluster. If circuit 35X okay,

Pin 8 of connector SSM to ground
problem is bad instrument cluster.
NOTE: Start and run engine at idle speed.
Pin 9 of connector SSM to ground Continuity Bad secondary steering pressure switch.
Check circuit 35X to instrument cluster. If circuit 35X okay,

Pin 8 of connector SSM to ground 0 volts
problem is bad instrument cluster.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector SSM to secondary
steering module. Disconnect wire 51-B from secondary steering motor (117) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector PSS from secondary steering pressure switch (118). Apply a
ground to pin C of connector PSS. Emergency steering indicator lamp should illuminate in the cluster.
Terminal for wire 51-A to ground 24 volts Bad secondary steering module.
4002-103
117 – Secondary Steering Motor (Option)

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

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

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

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

Correct
Reading
NOTE: Engine must be off. Disconnect wiring harness connector PSS from secondary steering pressure switch.
Pressure switch pin B to pin C Continuity Bad secondary steering pressure switch.
Pressure switch pin B to pin A Open Circuit Bad secondary steering pressure switch.
Pressure switch pin A to pin C Open Circuit Bad secondary steering pressure switch.
NOTE: Start and run engine at idle speed.
Pressure switch pin B to pin A Continuity Bad secondary steering pressure switch.
Pressure switch pin B to pin C Open Circuit Bad secondary steering pressure switch.
NOTE: If continuity is not correct, check pressure at PSS port to confirm pressure drops below 2.5 bar (35 psi)
with engine off before replacing pressure switch.
4002-104
CAN COMMUNICATION
119
W270-7R035
119.DIAGNOSTIC CONNECTOR
4002-105
119 – CAN Communication Diagnostics Connector

Correct
Reading
Terminal A for wire 0-DH to ground Continuity Bad ground circuit.
Terminal B for wire 18K-A to ground 24 volts Check fuse ECC-F9, check circuit 18K.
4002-106
RADIO AND POWER CONVERTER
125
124
122 123
120 121
W270-7R036
120.POWER RELAY MODULE E 123.RADIO

121.POWER CONVERTER 24 TO 12 VOLT 124.RIGHT SPEAKER
122.12 VOLT POWER OUTLETS (OPTION) 125.LEFT SPEAKER
4002-107
120 – Power Relay Module E

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

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

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

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

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

4002-108
123 – 12 Volt Radio Ready (Option)

Located in the cab.
Correct
Reading
Terminal in radio connector for wire

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

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

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

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

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

4002-109
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR
126
130
129 127
128
W270-7R037
126.AIR SEAT 129.HIGH/LOW SWITCH

127.CIGAR LIGHTER 130.AIR CONDITIONING COMPRESSOR CLUTCH
128.AIR CONDITIONING CLUTCH REALY
4002-110
126 – Seat Compressor and Switch (Option)

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

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

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

Correct
Reading
Terminal for wire 0-DJ to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch in position 1, 2, 3 or 4
and push AC switch to ON.
Check thermostat switch, AC trinary switch, AC switch, and

Terminal for wire 61R-B to ground 24 volts
check wire 61R-B.
Terminal for wire 18M to ground 24 volts Check fuse ECA-F15, also check wire 18M.
Terminal for wire 61C to ground 24 volts Bad compressor clutch relay.
4002-111
129 – A/C High/Low Pressure Switch

Located on the top of the engine air filter bracket.
Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (137) in position 1,
2, 3 or 4 and push AC switch to ON.
Terminal B for wire 61A to ground 24 volts Check the thermostat switch, AC switch, and check circuit 61A.
NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch.
Bad A/C low pressure switch, also check refrigerant charge

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

Located on the left side of the engine.
Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (137) in position 1, 2,
3 or 4 and push AC switch to ON.
Check the compressor clutch relay (128), also check circuit

Terminals for wire 61C-B to ground 24 volts
61C.
4002-112
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL
138 134
135 136 137
133
140 141
137
131 139
142 132
W270-7R038
131.ELECTRONIC PANEL 137.THERMOCOUPLE SENSOR

132.EXTERNAL AIR TEMPERATURE SENSOR 138.MIXED AIR SENSOR
133.INTERNAL AIR TEMPERATURE SENSOR 139.COMPRESSOR RELAY
134.SUN SENSOR 140.RECYCLING MOTOR
135.BLOWER FAN RESISTOR 141.ELETRONIC WATER VALVE
136.BLOWER MOTORS 142.24 TO 12 VOLT CONVERTER
4002-113
131 – Electronic Panel

Correct
Reading
132 – External Air Temperature Sensor

Correct
Reading
133 – Internal Air Temperature Sensor

Correct
Reading
134 – Sun Sensor

Correct
Reading
135 – Blower Fan Resistor

Correct
Reading
136 – Blower Motors

Correct
Reading
137 – Thermocouple Sensor

Correct
Reading
138 – Mixed Air Sensor

Correct
Reading

4002-114
139 – Compressor Relay

Correct
Reading
140 – Recycling Motor

Correct
Reading
141 – Electronic Water Valve

Correct
Reading
142 – 24 to 12 Volt Converter

Correct
Reading

4002-115
STANDARD CLIMATE CONTROL
144 145
146 147 148
149 150 151

152 153
W270-7R039
143.ACTUATOR 151.CONTROL PANEL LIGHTS

144.DRIVER 152.WATER VALVE POTENTIOMETER
145.ELETRONIC WATER VALVE 153.AIR RECIRCULATING SWITCH
146.BLOWER FAN RESISTOR
147.BLOWER MOTOR
148.THERMOSTAT
149.FAN SPEED SWITCH
150.AIR CONDITIONING SWITCH
4002-116
143 – Actuator
Correct
Reading
144 – Driver
Correct
Reading
145 – Electronic Water Valve

Correct
Reading
146 – Blower Fan Resistor

Correct
Reading
147 – Blower Motor

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

Correct
Reading

4002-117
150 – Air Conditioning Switch

Correct
Reading
151 – Control Panel Lights

Correct
Reading
152 – Water Valve Potentiometer

Correct
Reading
153 – Air Recirculating Switch

Correct
Reading

4002-118
CONNECTORS
CONNECTOR 108F - DIAGNOSTIC CONNECTOR CONNECTOR 197F - MAIN CAB FNR
291663A1 225350C1
CAV WIRE IDENT CIRCUIT CAV WIRE IDENT CIRCUIT

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

CAV WIRE IDENT CIRCUIT 1 19A-B FNR Switched Fused Power
A 63H-C Front Wiper High Speed 2 26F-A FNR Forward Signal
B 63L-C Front Wiper Low Speed 3 26N-A FNR Neutral Signal
C 0-EE Diode Suppression Grounds 4 26R-A FNR Reverse Signal
D 58-D Ride Control Solenoid Power 5 32J-A Trans Enable Indication Lamp
E 21D-B Starter Relay Signal 6 25Y-C Trans Kick Down Signal
F 68L-C Rear Wiper Switch Power
4002-119
CONNECTOR 209F - BACKUP ALARM DISABLE CONNECTOR 215F - ALTERNATOR RESISTOR
JUMPER
199436A1
CAV WIRE IDENT CIRCUIT 1 14-A Alternator D+

A 35A-E Backup Alarm Relay Out
CONNECTOR 216F - ALTERNATOR RESISTOR

CONNECTOR 209M - BACKUP ALARM DISABLE
JUMPER
199436A1
CAV WIRE IDENT CIRCUIT

1 19R-D Alternator Resistor Fused Pwr
245480C1

A 35A-D Backup Alarm Relay Out CONNECTOR 242F-CHAS GRD SEC STRG MTR
B Not Used
1 0-ND SSM Ground
CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH
CONNECTOR 244F-STARTER SEC STRG MTR

1 1-ND SSM PWR
225316C1

1 19A-U Trans Kick Down Switched Pwr
2 25Y-C Trans Kick Down Signal
4002-120
CONNECTOR 64F - FLASHER CONNECTOR CONNECTOR AD-ALTERNATOR-D+

1 14 Alternator D+
CONNECTOR AIC1 - ADV INSTRUMENT

CLUSTER 1
245481C1

1 45N-A Flasher Optional Side Control
CONNECTOR 64M - FLASHER CONNECTOR
87419488

1 13V Voltmeter Input ANALOG
2 36F-A Fuel Level ANALOG
3 CAN-HG CAN High
4 CAN-LG CAN Low
245480C1
5 36A Rear Axle Temperature
6 0-DX AIC Sensor Ground
1 45N-B Flasher Optional Side Control
7 43-A Dome Light Auto Mode
8 36B Front Axle Temperature
CONNECTOR AB-ALTERNATOR-B+ 9 36H-A Hydraulic Oil Temperature
10 Not Used
CAV WIRE IDENT CIRCUIT 11 36C-A Radiator Coolant Temp Signal
1 1-BA Alternator B+ 12 0-DW AIC Power Ground
13 35B AIC Buzzer HSD
14 52C Park Brake Solenoid LSD
CONNECTOR ACT 9 - AIR CONDITIONING
15 44A-B Brake Light Relay Out
COMPRESSOR CLUTCH
16 51S Standard Steering Signal
17 51CS Comfort Steering Switch
18 Not Used
19 28J Ether AIC OK Signal
20 53C-A Pilot Control Solenoid LSD
21 51C Comfort Steering Control
22 Not Used
23 52 Fan Reverser LSD
24 Not Used
245480C1
25 17P-A Switch Pad Pwr From AIC Pwr
26 56 Fan Control PWM
1 61C-B AC relay out
4002-121
CONNECTOR AIC2 - ADV INSTRUMENT CONNECTOR B1-STARTER PWR STUD
CLUSTER 2
1 1-NC B+ PWR PRMC
1 1-NC CAB CB PRM PWR
CONNECTOR B2-STARTER-POWER

1 1-BA Alternator B+
87410948
CAV WIRE IDENT CIRCUIT CONNECTOR B3-STARTER-BATTERY

1 Not Used
2 43S-C Door Open Signal CAV WIRE IDENT CIRCUIT
3 Not Used 1 1-NB Battery STRTR
4 33R Redundant Brk Accm Press Low

5 33P-A Brake Low Pressure Warning
CONNECTOR B4-STARTER-POWER
6 33U Park Brake Switch
7 52M Fan Reverse Manual
8 52AU Fan Reverse Auto
1 1-ND SSM PWR
9 45L-E Left Turn Signal
10 45R-C Right Turn Signal
11 35X Sec. Steering Low Press Signal CONNECTOR BT1-BATTERY-STARTER
12 Not Used
13 Not Used CAV WIRE IDENT CIRCUIT
14 19S-D AIC Delay Fused Power 1 1-NB Battery STRTR
15 0-DB AIC Power Ground Red
16 57-C Pin Engage Solenoid Power
CONNECTOR BT2-DISCONNECT-BATTERY
17 21K-A Ignition Switch Start Signal
18 31L Pilot Control Switch High
19 Not Used
1 1-NA Battery Crossover
20 19S-C AIC Delay Fused Power
21 19E-A AIC Wake Up Ignition
22 0-DA AIC Chassis Ground CONNECTOR BT3-STARTER-BATTERY
23 Not Used
24 Not Used CAV WIRE IDENT CIRCUIT
25 Not Used 1 1-NA Battery Crossover
26 31D-A Coolant Level Signal
CONNECTOR BT4-DISCON-BLCK-GRND

1 0-NC Battery Disconnect
4002-122
CONNECTOR BU1-BACKUP-ALARM-GRND CAV WIRE IDENT CIRCUIT
9 18G-F RH Position/Tail Fused Power
CAV WIRE IDENT CIRCUIT 10 45L-B Left Turn Signal
1 0-JB Backup Alarm GND 11 21F EDC7 Digital Ground
12 45R-B Right Turn Signal
13 18R-A Voltmeter Relay Fused Power
CONNECTOR BU2-BACKUP-ALARM
14 18J-G EDC7 Time Delay Fused Power
15 21D-C Starter Relay Signal
16 28H Ether Switch Signal
1 35A-H BKUP ALM RLY OUT
17 0-DX AIC Sensor Ground
1 35A-HN BKUP ALM RLY OUT
18 18J EDC7 Time Delay Fused Power
19 0-DW AIC Power Ground
CONNECTOR BUZ - AIC BUZZER 20 0-DB AIC Power Ground Red
21 13C-B Fuel Shutoff Fused Power
22 52A-A Fan Reverse Relay Out
23 56 Fan Control PWM
24 68W Rear Washer Pump
25 63W Front Washer Pump
26 14-A Alternator D+
27 21E Key Switch Crank
28 31F-A Air Filter Restriction Sw Signal
29 61R-B AC Relay Control
30 61A-B Trinary Pressure Switch Input
222136A1
31 20G-B EDC7 ISO-K Interface
32 36A Rear Axle Temperature
1 35B AIC Buzzer HSD
33 36F-A Fuel Level ANALOG
2 0-B27 Buzzer Ground
34 36C-A Radiator Coolant Temp Signal
35 19Y-C Hood Switch Fused Power
CONNECTOR CAB-E - CAB TO ENGINE 36 60D Hood Down Relay Out
37 59D Hood Down Relay Control
38 60U Hood Up Relay Out
39 59U Hood Up Relay Control
40 35A-F Backup Alarm Relay Out
225415C1

1 21C-C Starter Relay Signal
2 61C AC Relay Out
3 21G EDC7 Crank Control Relay
4 21H Crank Control Relay LSD
5 18F-A LH Position/Tail Fused Power
6 Not Used
7 35A-C Backup Alarm Relay Out
8 44A-C Brake Light Relay Out
4002-123
CONNECTOR CAB-F - CAB FRONT CHASSIS CONNECTOR CAB-PW-CAB-POWER

1 1CB-A CAB CB Protected PWR
CONNECTOR CAB-RF - CAB TO ROOF

CONNECTION
291661A1

1 45L-C Left Turn Signal
2 51B-C Comfort Steering Solenoid Pwr
388710A1
3 45R-D Right Turn Signal
4 Not Used
A 43-A Dome Light Auto Mode
5 18G-G Position RH Fused Power
B 42R-C Rear Work Light Fused Power
6 18F-E Position LH Fused Power
C 42C-A Front Work Lights Fused Power
7 18B-A High Beam LH Fused Power
D 19U-D Dome Light Fused Power
8 36B Front Axle Temperature
E 46-C Beacon Switch Power
9 O-DY Front Axle Temperature Ground
F 0-DR Roof Splice Grounds
10 Not Used
G 0-DS Roof Splice Grounds
11 54B-A Height-RTT Signal
J 19K-C Rear Wiper Motor Fused Power
12 53B-B RTD Signal
K 68C Rear Wiper Park Control
13 64A Horn Power
L 68L-B Rear Wiper Switch Power
14 18D-A Low Beam LH Fused Power
M 0-EM Radio Ground
15 18E-A Low Beam RH Fused Power
N 12V-B 12V Fused Power to Radio
16 18C-A High Beam RH Fused Power
R 43S-A Door Open Signal
17 Not Used
S 19U-G Door Switch Fused Power
18 Not Used
19 53P-F Pilot Control Relay Out
20 57-A Pin Engage Sol Pwr
21 58-C Ride Control Sol Pwr
22 1-DR Brake Lamp Switch Power
23 44-A Brake Lamp Control Power
24 52P-A Park Brake Relay Out
25 Not Used
26 33P-A Low Brake Pressure Warning
Brake Declutch Switch Fused
27 19A-T
Power
28 25G-A Brake Declutch Switch Control
29 Not Used
30 Not Used
31 Not Used
4002-124
CONNECTOR CAB-T - CAB TO TRANMISSION CONNECTOR CAN - CAN BULK HEAD
380839A1

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

6 35X
Signal
CONNECTOR CAN2 - CAN BULK HEAD
7 25A-A Engine Speed Signal
8 25C-A Turbine Speed Signal
9 25B-A Intermediate Speed Signal
10 25D-A Output Speed Signal
11 0-DM Speed Sensor Ground
12 36R-E Trans Temp/Filter Return
13 36G-A TCO Temp Signal
14 Not Used
15 Not Used
16 25K-A Trans Solenoid Valve Y1
17 25L-A Trans Solenoid Valve Y2
18 25M-A Trans Solenoid Valve Y3
87315267
19 25N-A Trans Solenoid Valve Y4
20 25P-A Trans Solenoid Valve Y5
A CAN-H CAN High
21 25J-A Trans Solenoid Valve Y6
A CAN-HJ CAN High From Engine
22 25S-A Output Sw Power VPS1
B CAN-L CAN Low
23 31H-A Hyd Filter Restriction Switch Sig
B CAN-LM CAN Low From Engine
24 Not Used
25 Not Used
26 19S1 Sec. Steering Fused Power CONNECTOR CB1A-CIRCUIT BRKR
27 Not Used
28 0-DN Output Speed Sensor Ground CAV WIRE IDENT CIRCUIT
29 19A-M Output Speed Sen. Fused Pwr 1 1CB CAB CB Protected PWR
30 36H-A Hydraulic Oil Temp

31 32F-A Trans Filter Maint Switch
CONNECTOR CB2B-CAB+ CB

1 1NC CAB CB PRM PWR
4002-125
CONNECTOR CB3B-CAB+ CB CONNECTOR CNV - 24V TO 12V POWER
CONVERTER
1 1B9 PRM C PWR
CONNECTOR CBPW-CAB-POWER

1 1CB CAB CB Protected PWR
225351C1

CONNECTOR CL - CIGAR LIGHTER 1 19L-A Power Converter Fused Power
2 19L-B Power Converter Fused Power
3 0-EJ Power Converter Ground
4 Not Used
5 12V-C 12V Switched Power
6 0-ER Power Converter Ground
CONNECTOR D-OR - DIODE OR
3227856R1

1 19W Cigar Lighter Fused Power
2 0-DV Cigar Lighter Ground
CONNECTOR CLS - COOL JUMP - COOL SEND

245485C1

A 42C-D Front Work Lights Fused Power
B 41T-C Position Lights Switched Power
C 49 Back Light Power
194788A1 CONNECTOR DC1-DISCONNECT-BATTERY

A 31D_C Coolant Level Signal CAV WIRE IDENT CIRCUIT
B 0_BAF Coolant Level Sender Ground 1 0-NC Battery Disconnect
CONNECTOR DC2-DISCON-BLCK-GRND

1 0-NB Master Disconnect GND
4002-126
CONNECTOR DC3-FUEL-SOL-DISCONNECT CONNECTOR DM - DIODE OR

1 13C Fuel Shutoff Fused PWR
CONNECTOR DC4-FUEL-SOL-DISCONNECT

245485C1
1 13M Fuel Shutoff Fused PWR
A 19RR Sec. Steering Ignition Fused Pwr
CONNECTOR DIA - DIAGNOSTIC B Not Used

C 19R Sec. Steering Ignition Fused Pwr
CONNECTOR DNS-AC-SWITCH

1 DNS72
2 DNS68
4 DNS71
310057A1

CONNECTOR DNS-ACTUATOR
A 0-DH Ground
B 18K-A Diagnostics Fused Power CAV WIRE IDENT CIRCUIT
C CAN-HB Controller Area Network High 5 DNS48
D CAN-LB Controller Area Network Low 6 DNS49
E 20G-B EDC7 ISO-K Interface
CONNECTOR DNS-BLUE - ATC CONTROL

CONNECTOR DISC - DISCONNECT ENGINE PANEL

1 DNS8
3 DNS10
5 DNS11
6 DNS2
7 DNS4
9 DNS3
245482C1
10 DNS6
14 DNS9
A 13C Fuel Shutoff Fused Power
15 DNS31
B 13M Fuel Shutoff Fused Power
16 DNS13
17 DNS18
21 DNS7
23 DNS12
26 DNS19
4002-127
CONNECTOR DNS-COMPRESSOR-RELAY CONNECTOR DNS-HVAC2

85 DNS19
86 DNS20
30 DNS16
87 DNS14
CONNECTOR DNS-EXTERNAL-AIR-TEMP-SNS 225315C1

1 DNS36
1 DNS2
2 DNS35
2 DNS1
CONNECTOR DNS-INTERNAL-AIR-TEMP-SNS
CONNECTOR DNS-HVAC-CAN1
1 DNS4
2 DNS3
3 DNS17
4 DNS5
CONNECTOR DNS-NOT-USED
225294C1

A DNS9
B DNS8
CONNECTOR DNS-HVAC1
225326C1

1 DNS12
2 DNS11
3 DNS10
225294C1

A DNS14
B DNS15
C DNS13
4002-128
CONNECTOR DNS-YELLOW - ATC CONTROL CONNECTOR DNS-BLOWER
PANEL
CAV WIRE IDENT CIRCUIT 1 DNS41
1 DNS25 2 DNS42
2 DNS24
5 DNS47
CONNECTOR DNS-THERMOCOUPLE-SENSO
6 DNS43
8 DNS44
9 DNS21
1 DNS46
10 DNS23
2 DNS40
14 DNS28
15 DNS26
16 DNS30 CONNECTOR DNS-MIXED-AIR-SENSOR
17 DNS27
18 DNS29
1 DNS39
21 DNS22
2 DNS45
23 DNS45
24 DNS46
CONNECTOR DNS-VOLTAGE-CONVERTER
CONNECTOR DNS-PWM-BLOWER-PIN4
1 DNS34
2 DNS33
3 DNS32
4 DNS31
CONNECTOR DNS-ELECT-WATER-VALVE

1 DNS30
HIRSCHMANN 772717-001 2 DNS29
1 DNS38 4 DNS27
2 DNS47 6 DNS26
3 DNS37
CONNECTOR DNS-RECYCLING-MOTOR
CONNECTOR DNS-PWM-BLOWER-PIN2
1 DNS41 2 DNS22
2 DNS42 3 DNS23
5 DNS24
6 DNS25
4002-129
CONNECTOR DNS-SPEED-SELECTOR CONNECTOR DNS-RESISTOR

1 DNS74 1 DNS61
2 DNS61 2 DNS62
3 DNS62 3 DNS63
4 DNS63 4 DNS64
5 DNS73
CONNECTOR DNS-ELECT-WATER-VALVE-S
CONNECTOR DNS-CTRL-PANEL-LIGHT
1 DNS69 3 DNS56
2 DNS70 4 DNS57
5 DNS58
6 DNS59
CONNECTOR DNS-WATER-VALVE-POT
CONNECTOR DNS-DRIVER
1 DNS55
2 DNS54
CONNECTOR DNS-RECIRCULATING-SWITCH
CAV WIRE IDENT CIRCUIT 411311A1
1 DNS51 CAV WIRE IDENT CIRCUIT
2 DNS53 2 DNS50
3 DNS52
4 DNS49
CONNECTOR DNS-THERMOSTAT-1
5 DNS48
6 DNS55
7 DNS57
1 DNS67
8 DNS58
9 DNS59
CONNECTOR DNS-THERMOSTAT-2 11 DNS51
12 DNS53
13 DNS54
1 DNS68
14 DNS56
CONNECTOR DNS-ELECTRIC-FAN

1 DNS65
2 DNS66
4002-130
CONNECTOR DNS-HVAC1-S CONNECTOR DS - DOOR SWITCH
225294C1 245482C1
A DNS67 A 19U-F Door Switch Fused Power
B DNS76 B 43S-B Door Open Signal
C DNS69
CONNECTOR E-HD9-TRANS-HOOD
CONNECTOR DNS-HVAC2-S
245482C1

CAV WIRE IDENT CIRCUIT A 18G-L RH POSN/TAIL Fused PWR
1 DNS74 B 35A-9 Backup Alarm PWR
2 DNS75 C 0-LD Rear Light GND

4002-131
CONNECTOR ECA - ELECTRICAL CENTER A
87315248

C2 19J FNT WPR FSD PWR
C4 19H BKUP ALM RLY FSD PWR
C3 19K REAR WPR FSD PWR
C5 18M AC RELAY FUSED PWR
C6 19N SEAT CPRSR FSD PWR
L1 J8 FAN RVSR TURN SGNL
L1 J6 PLTEM DTNTS PRK BRK SOL SEC STR ACCESSORY FSD
C7 19M
PWR
L1 J7 PRK BRK SOL HRN
L1 J3 COMFORT STEER AIC PWR
TRANS ECM COMFORT
L1 J2 L1 J4 EMG STR AIC PWR
STEER
L1 J9 TURN SGNL ENG SHTDWN L1 J5 EMG STRG PLT EM DTNTS
L1 J1 TRANS ECM PWR
L2 J16 A/C SEAT COMP
L2 J15 BKUP A/C L2 J11 BLWR MOTOR PWR
L2 J12 BLWR MTR FRNT WIPR WASH

L2 J13 FRNT WIPR RER WIPR WSH
L2 J14 RER WIPR WSH BACKUP
L2 J18 SEAT COMP EMG STRTR
A1 19A_N TRANS FUSE PWR
A2 18L_A COMFORT STEER FSD PWR
A3 19E_A AIC WAKE UP IGN
A4 19RR SEC STR IGN FSD PWR
A5 19C_A PILOT CTRL RLY FSD PWR
A6 19D_A PARK BRK RLY FSD PWR
A7 19P PIN ENGAGE/FAN FSD PWR
A8 19B TURN SIGNAL FSD PWR
A9 13C_B FUEL SHUTOFF FUSED PWR
C1 18N BLOWER MOTOR FUSED PWR
4002-132
CONNECTOR ECB - ELECTRICAL CENTER B
87312843

B3 21K-B Ignition Switch Start Signal
A1 42FS Front Work Lights Power
A2 42RS Rear Work Lights Power B4 0-DE Neutral Start Relay Control Gnd
B5 21F EDC7 Digital Ground
A3 41H-B High Beam LH Power
A4 41H-C High Beam RH Power B6 0-DF Crank Request Relay Ctrl Gnd
B7 19P-E Fan Reverse Relay Fused Pwr
A5 41L-C Low Beam LH Power
A6 41L-B Low Beam RH Power B8 52 Fan Reverser LSD
B9 19D-C Park Brake relay Fused Pwr
A7 41T-B Position Lights LH Sw Power
B10 52C Park Brake Solenoid LSD
A8 41T-A Position Lights RH Sw Power
D1 13K-C Ignition Switch Power
A9 21H Crank Control Relay LSD
D2 13V Voltmeter Input ANALOG
A10 21C-B Neutral Start Relay Output
AA1 42C-C Front Work Lights Fused Power D3 25T Neutral Signal
D4 21C Neutral Start Relay Output
AA2 42R-C Rear Work Lights Fused Power
AA3 18B-A High Beam LH Fused Power D5 21C-A Neutral Start Relay Output
D6 21E Key Switch Crank
AA4 18C-A High Beam RH Fused Power
D7 19P-D Fan Reverse Relay Fused Pwr
AA5 18E-A Low Beam RH Fused Power
D8 52A-A Fan Reverse Relay Out
AA6 18D-A Low Beam LH Fused Power
D9 19D-B Park Brake Relay Fused Pwr
AA7 18F-C Pos Tail Lights LH Fused Power
D10 52P-B Park Brake Relay Out
AA8 18G Pos Tail Lights RH Fused Power
AA9 21D-A Starter Relay Signal
AA10 21G EDC7 Crank Control Relay
B1 18R-A Voltmeter Relay Fused Power
B2 0-DD Voltmeter Relay control Ground
4002-133
CONNECTOR ECC - ELECTRICAL CENTER C
87315249

A1 19U-B Beacon/Dome Lt Fused Pwr D4 19Y-B Hood Down Relay Fused Power
D5 44-A Brake Light Control Power
A2 42 Work Lights Sw Fused Pwr
A3 19Z Driving Lights Sw Fused Pwr D6 44A-A Brake Light Relay Out
D7 19U-E Horn relay Fused Power
A4 1-DV Brake Lts/Flasher Bat Pwr
D8 64-A Horn Power
A5 1DM Time Delay/Ign Sw Fused Pwr
D9 18L-B Comfort Steering Fused Power
A6 19U Horn Relay Fused Power
D10 51B-B Comfort Steering Solenoid Pwr
A7 19Y Hood Control Fused Power
A8 19W Cigar Lighter Fused Power L1-1 ECC-L1 Beacon/Dome Lights LI ECC
L1-1 J2-ECC Beacon/Dome Lt Work Lights
A9 18K-A Diagnostic Fused Power
B1 60U Hood Up Relay Out L1-2 J2-ECC Beacon/Dome Lt Work Lights
L1-2 J3-ECC Work Lights Driving Lights
B2 0-B25 Hood Up Control Ground
L1-3 J3-ECC Work Lights Driving Lights
B3 60D Hood Down Relay Out
L1-3 J4-ECC Driving Lights Brake Lights
B4 0-B16 Hood Down Control Ground
L1-4 J4-ECC Driving Lights Brake Lights
B5 1-DW Brake Light Relay Bat Power
L1-4 J5-ECC Brake Lights Delay Power
B6 0-EF Brake Light Relay Control Gnd
L1-5 J5-ECC Brake Lights Delay Power
B7 19U-A Horn Relay Fused Power
B8 64C Horn Relay Control L1-5 J6-ECC Delay Power Horn
L1-6 J6-ECC Delay Power horn
B9 18L-C Comfort Steering Fused Pwr
B10 51C Comfort Steering Control L1-6 J7-ECC Horn HOD Control
L1-7 J7-ECC Horn HOD Control
C2 0-B22 Hood Up Relay Ground
L1-7 J8-ECC HOD Control Cigar Lighter
C4 0-B12 Hood Down Relay Ground
L1-8 J8-ECC HOD Control Cigar Lighter
D1 59U Hood Up Relay Control
L1-8 J9-ECC Diagnostic Power
D2 19Y-A Hood Up Relay Fused Power
D3 59D Hood Down Relay Control L1-9 J9-ECC Diagnostic Power
4002-134
CONNECTOR ECD - ELECTRICAL CENTER D
87312843

B6 53C-A Pilot Control Solenoid LSD
A1 13H-C Trans ECM Time Delay Pwr
A2 13H-D Engine ECM Time Delay Pwr B7 58T Ride Control Relay Switch Pwr
B8 58L Ride Control Relay LSD
A3 13H-B AIC Time Delay Power
A4 12V-D Plug 1 12V Switched Power B9 18M AC Relay Fused Power
B10 0-DJ AC Relay Control Ground
A5 12V-E Plug 2 12V Switched Power
A6 12V-F Radio 12V Switched Power C2 63C2 Front Wiper Park Control
A7 12V-G 2 Way Radio 12V Sw Power C4 63C Front Wiper Park Control
Front Wiper Relay HS Ctrl
A9 35C Backup Alarm Relay Control D1 19J-D
Fused Pwr
A10 19H Backup Alarm Relay Fused Pwr
D2 63H-B Front Wiper HS Relay Out
AA1 19T-A TECM Delay Fused Power
Front Wiper Relay LS Ctrl Fused
AA2 18J-K EDC7 Time Delay Fused Power D3 19J-F
Pwr
AA3 19S-B AIC Delay Fused Power D4 63C2 Front Wiper Park Control
AA4 12V 12V Power to Outlet 1 D5 19C-C Pilot control Relay Fused Pwr
AA5 12V-A 12V Power to Outlet 2 D6 53P-C Pilot Control Relay Out
AA6 12V-B 12V Fused Power to Radio D7 58H-A Ride Ctrl Switched Pwr VPS2
AA9 35A-A Backup Alarm Relay Out D8 58-E Ride Control Solenoid Power
Backup Alarm Relay Ctrl Fused D9 61R-B AC Relay Control
AA10 19A-P
Pwr
D10 61C AC Relay Out
B1 19J-E Front Wiper Relay Fused Power
B2 63HC-B Front Wiper HS Relay Control
B3 63C3 Front Wiper Park Control
B4 63LC Front Wiper LS Relay Control
B5 19C-B Pilot Control Relay Fused Pwr
4002-135
CONNECTOR EM - HEIGHT CONTROL RTD - RTT CAV WIRE IDENT CIRCUIT
12 45R-AN Right Turn Signal
13 18R Voltmeter Relay Fused Power
14 18J-F EDC7 Time Delay Fused Power
15 21D Starter Relay Signal
16 28E Ether Relay Signal
17 0-BJ AIC Sensor Ground
18 18J-A EDC7 Time Delay Fused Power
19 0-BG AIC Power Ground
225351C1
20 0-BH AIC Power Ground Red
21 13C-A Fuel Shutoff Fused Power
1 55A-A RTT/Float Switched Power
22 52A-B Fan Reverse Relay Out
2 54A Height Control Switched Power
23 56-A Fan Control PWM
3 53A RTD Switched Power
24 68W-A Rear Washer Pump
4 53B-B RTD Control Signal
25 63W-A Front Washer Pump
5 54B-B HC-RTT Control Signal
26 14 Alternator D+
6 55B RTT Float Switch Control
27 21E-A Key Switch Crank
28 31F Air Filter Restriction Sw Signal
CONNECTOR ENG - ENGINE TO CAB 29 61R AC Relay Control
30 61A Trinary Pressure Switch Input
31 20G-A EDC7 ISO-K Interface
32 36A-A Rear Axle Temperature
33 36F Fuel Level ANALOG
34 36C Radiator Coolant Temp Signal
35 19Y-D Hood Switch Fused Power
36 60D-A Hood Down Relay Out
225414C1
37 59D-A Hood Down Relay Control
38 60U-A Hood Up Relay Out
1 21C-D Starter Relay signal
39 59U-A Hood Up Relay Control
2 61C-A AC Relay Out
40 35A-G Backup Alarm Relay Out
2 61C-B AC Relay Out
40 35A-GN Backup Alarm Relay Out
3 21GA EDC7 Crank Control Relay
4 21H-A Crank Control Relay LSD
5 18F-AN LH Position/Tail Fuse Power CONNECTOR ENG-D - DISCONECT HARNESS
5 18F-B LH Position/Tail Fuse Power
6 Not Used
7 35A-R Backup Alarm Relay Out
7 35A-J Reverse Light
8 44A-D Brake Light Relay Out
8 44A-DN Brake Light Relay Out
9 18G-H RH Position/Tail Fuse Power
9 18G-HN RH Position/Tail Fuse Power 245483C1
10 45L-A Left Turn Signal CAV WIRE IDENT CIRCUIT

10 45L-AN Left Turn Signal A 13C-A Fuel Shutoff Fused Power
11 21F-A EDC7 Digital Ground B 13M-A Fuel Shutoff Fused Power
12 45R-A Right Turn Signal B 13M-B Key Switch Power Disc Switch
4002-136
CONNECTOR ENG-H - ENGINE TO HOOD CONNECTOR ESS - ENGINE SPEED SENSOR
291718A1

225320C1
1 25A Engine Speed Signal
2 0-HF Engine Speed Sensor Ground
1 0-BAG-N Hood Ground (NA)
2 44A-DN Brake Light Relay Out
3 45L-AN Left Turn Signal
CONNECTOR ETHR-ETHER-SOLENOID
4 45R-AN Right Turn Signal
5 18G-HN RH Position/Tail Fused Pwr
6 18F-AN LH Position/Tail Fused Pwr
7 35A-GN Backup Alarm Relay Out
8 35A-R Backup Alarm Relay Out
CONNECTOR ENG-T - ENGINE TO

TRANSMISSION
245485C1

A 28P ETHER SOL PWR
B 0-BAN ETHER STRT GRND
C Not Used
225326C1

1 0-BZ Sec. Steering Splice Ground
2 0-BK Transmission Splice Grounds
Coolant Level Sender Eng
3 31D-C
Transmission
4 Not Used
4002-137
CONNECTOR FLSHR - FLASHER MODULE CONNECTOR FRONT - CAB FRONT CHASSIS
225389C1

373358A1
1 1-DU Flasher Module Power
2 45N-A Flasher Optional Side Control
1 45L Left Turn Signal
3 0-EH Flasher Module Ground
2 51B-D Comfort Steering Sol Power
4 0-EG Flasher Module Ground
3 45R Right Turn Signal
5 Not Used
4 Not Used
6 Not Used
5 18G-A RH Position/Tail Fused Power
7 45R-E Right Turn Signal
6 18F LH Position/Tail Fused Power
8 45L-D Left Turn Signal
7 18B LH High Beam Fused Power
9 45A-A Left Turn Switch Power
8 36B-A Front Axle Temperature
10 45B-A Right Turn Switch Power
9 0-AR Front Axle Temp Sensor GND
11 45H Hazard Switch Power
10 36D-A
12 45N-B Flasher Optional Side Control
11 54B Height-RTT Control Signal
12 53B RTD Control Signal
CONNECTOR FM - FILTER MAINTENANCE 13 64 Horn Power
SWITCH 14 18D LH Low Beam Fused Power
15 18E RH Low Beam Fused Power
16 18C RH High Beam Fused Power
17 Not Used
18 Not Used
19 53P-G Pilot Control Relay Out
20 57 Pin Engage Sol Pwr
21 58-B Ride Control Sol Pwr
Ride Control Solenoid to Front
21 58S-E
Cab
22 1-AA Brake Lamp Switch Power
371614A1
23 44 Brake Lamp Control Power
24 52P Park Brake Relay Out
1 32F Trans Filter Maint Sw
25 Not Used
2 36R-B Trans FM Switch Return
26 33P Low Brake Pressure Warning
27 19A-A Brake Declutch Sw Fused Pwr
28 25G Brake Declutch Switch Control
29 Not Used
30 Not Used
31 Not Used
4002-138
CONNECTOR FWM - FRONT WIPER MOTOR CONNECTOR FWW - FRONT WASHER
245715C1 3227856R1

A 63H-A Front Wiper High Speed Rly Out 1 63W-A Front Washer Pump
B 63L-A Front Wiper Low Speed Rly Out 2 0-B Front Washer Ground
C 19J-A Front Wiper Motor Fused Power
D 63C Front Wiper Park Control
CONNECTOR GND-CAB1-GROUD-A
CONNECTOR FWMG - FRONT WIPER MOTOR CAV WIRE IDENT CIRCUIT

GROUND 1 0-DR Roof Splice GNDS
1 0-DS Roof Splice GNDS
CONNECTOR GND-CAB2-GROUD-A

1 0-B6 CAB2 GND
1 0-B13 Back Light GND
1 0-B10 Hood GND
245480C1

1A 0-B8 Front Wiper Ground CONNECTOR GND-CAB3-GROUD-C

1 0-DG CAB Splice GNDS
1 0-DV Cigar Lighter GND
CONNECTOR GND-CAB4-GROUD-C

1 0-ED HVAC GNDS
1 0-EJ Power Converter GND
1 0-ER Power Converter GND
4002-139
CONNECTOR GND-CAB5-GROUD-C CAV WIRE IDENT CIRCUIT
K 0-DJ AC Relay Control Ground
CAV WIRE IDENT CIRCUIT L 0-DU Pilot Pressure Solenoid Gnd
1 0-EK AUX Power Outlet 1 GND M 0-DH Diagnostic Connector Ground
1 0-EL AUX Power Outlet 2 GND
CONNECTOR GND-CAB-SPL2 - SPLICE BACK

CONNECTOR LIGHT GROUND
GND-CAB6-STRT-FFH-WAT-SEPHTR

Splice Pack GND-CAB-SPL2
1 0-EQ
GND
CONNECTOR GND-CAB3D-GROUD-A

1 0-DP DIAG TECM GND
1 0-DQ DIAG TECM GND 87324393
1 0-DY Front AX TEMP SENS GND CAV WIRE IDENT CIRCUIT

1 0-DAV TECM Diagnostic GND A 0-DC Time Delay Module Ground
B 0-EA Time Delay Relay Control Gnd
C 0-EB Ignition Relay Control Ground
CONNECTOR GND-CAB-SPL - CAB GROUND
SPLICE D 0-EC ACC Relay Control Ground
E 0-DD Voltmeter Relay Control Gnd
Crank Request Relay Control
F 0-DF
Gnd
G 0-DE Neutral Start Relay Control Gnd
Splice Pack Gnd Cab SPL2
H 0-EQ
GND
J Not Used
K 0-EH Flasher Module Ground
L 0-EG Flasher Module Ground
M 0-EF Brake Lights Relay Control Gnd
87324393 CONNECTOR GND-ENG2-WIF-EDC

A 0-EE Diode Suppression Grounds CAV WIRE IDENT CIRCUIT
B 0-EM Radio Ground 1 0-BP WIF Sensor GND
C 0-EP Horn Switch Ground 1 0-BAC EDC7 GND
D Not Used 1 0-BAM Ether RLY SGNL GND
E Not Used
F 0-DG Cab Splice Grounds
G 0-DT Front Wiper/Washer Sw Gnd
H 0-DL Power Converter Relay Ctrl Gnd
I 0-DK Seat Compressor Motor Ground
4002-140
CONNECTOR GND-ENG3-SPLC-PK-WSHR-MTR CONNECTOR GND-PDST2-GROUND-A

1 0-BM Engine Splice GNDS 1 0-BA Pedestal GND STRAP
1 0-BAM Ether STRT GRND
1 0-BZ SEC Steering Splice GND
CONNECTOR GND-S1-GROUND-A
CONNECTOR GND-ENG6-DEDICATED CAV WIRE IDENT CIRCUIT

1 0-AP Front to Rear Chassis GND
1 0-BG AIC Power GND
CONNECTOR GND-S2-GROUND-A
1 0-BH AIC Power GND RED
1 0-BJ AIC Sensor GND
1 0-BAR WIF Body GRND
1 0-AP Front to Rear Chassis GND
CONNECTOR GND-ENG7-TRANNY-COOL-TEMP
CONNECTOR
GND-SSCHAS-SSM-GROUND-CABLE
1 0-BAF Cool Level SNDR GND
1 0-BAE EDC7 Sender GND
1 0-ND SSM Ground
1 0-BU Fuel Level Sender GND
1 0-BAS Rear AX TEMP SENS GND
1 0-BK TRANS Splice GNDS CONNECTOR
GND-SSMOD-SEC-STR-CHASSIS-GND
CONNECTOR GND-FC-GROUND-A CAV WIRE IDENT CIRCUIT

1 0-CE SEC Steering Chassis GND
1 0-AG Front Chassis GND
1 0-AK Park Brake /Warning GND
1 0-AB PROX SW GND
CONNECTOR GND-PDST-GROUND-A

1 0-BA Pedestal GND STRAP
CONNECTOR GND-PDST1-GROUND-A

1 0-DA AIC Chassis GND
4002-141
CONNECTOR HD-9-HOOD TO ENG CONNECTOR HD-HOOD SWITCH
245485C1

A 59D-A Hood Down RLY CTRL
B 19Y-D Hood Switch FSD PWR
225319C1
C 59U-A Hood UP RLY CTRL
1 0-LA Rear Light GND
2 SPL-L1 Brake Light PWR CONNECTOR HD-N - HOOD TO ENGINE
3 45L-9 Left Turn SGNL
4 45R-9 Right Turn SGNL
5 18G-K RH POSN/TAIL Fused PWR
6 18F-F LH POSN/TAIL Fused PWR
7 35A-9 Backup Alarm PWR
8 35A-M Reverse Light
CONNECTOR HD-E - HOOD HARNESS TO

TRANSMISSION HARNESS
225319C1

1 0-JA-N Hood Grounds (NA)
2 44A-EN Brake Light relay Out
3 45L-BN Left Turn Signal
4 45R-BN Right Turn Signal
5 18G-JN RH Position/Tail Fused Power
245484C1
6 18F-BN LH Position/Tail Fused Power
7 35A-HN Backup Alarm Relay Out
A 18G-E License Plate Light Fused Pwr
B 35A-H Backup Alarm Relay Out
C 0-JA Hood Ground (EURO)
4002-142
CONNECTOR HDM-HOOD-LIFT-MOTOR CONNECTOR HOT-RA-REAR-AX-OIL-TEMP
225316C1 225316C1

1 60U-A Hood UP RLY Out 1 36A-A Rear Axle TEMP
2 60D-A Hood Down RLYOut 2 0-BAS Rear Axle TEMP
CONNECTOR HN1-HORN-PWR CONNECTOR HOT - HYDRAULIC OIL

TEMPERATURE SENDER
1 64 Horn Power
CONNECTOR HN2-HORN-GRND

194788A1
1 0-AF Horn GND
A 36H Hydraulic Oil Temp Signal
CONNECTOR HOT-FA-FRNT-AX-OIL-TEMP B 0-HW Hydraulic Oil Temp Ground
CONNECTOR HVAC1 - HVAC1
225316C1

225295C1
1 36B-A Front Axle TEMP
2 0-AR Front AX TEMP SENS GND
A 61A-B Trinary Pressure Switch Input
B 18N-A Blower Motor Fused Power
C 49A Back Light Power
4002-143
CONNECTOR HVAC2 - HVAC2 CONNECTOR ISS - INT-SPEED-SENSOR
291718A1

87552622
1 25B INT Speed Signal
2 0-HG INT Speed Sensor Ground
2 0-ED HVAC Grounds
1 18N-B Blower Motor Fused Power
CONNECTOR K-WCO - WIPER CUTOUT
CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC
245731C1

30 63L-B Front Wiper LS Relay Out
85 63HC-A Wiper Cut Out Relay Control
87315267
86 19J-G Wiper Cut Out Relay Fused Pwr
87 Not Used
A CAN-HK CAN High
87A 63C3 Front Wiper Park Control
B CAN-LL CAN Low
CONNECTOR L1-ECC-ECC-BATT-PWR

Cs01 1-C ECC BAT PWR
4002-144
CONNECTOR LBEE - LIGHT BEACON EXTESION CONNECTOR LDM2-DOME LIGHT AUTO

1 43-B Dome LT AUTO MODE
CONNECTOR LDM3-DOME LIGHT GND

1 0-MB Dome Light GND
291730A1
CONNECTOR LLF - LH FRONT LIGHTS
A 46-E Beacon Light Power
B 0-MD Beacon Light Ground
CONNECTOR LBEG-LIGHT BEACON GRND

1 0-MD Beacon Light GND
225351C1

CONNECTOR LBEGRD-LIGHT BEACON GRND 1 0-AJ Lights Ground LH
2 18D Low Beam LH
CAV WIRE IDENT CIRCUIT 3 18B High Beam LH
1 0-MC Beacon Light GND 4 18F Position LH Fused Power
5 45L Left Turn Signal
6 Not Used
CONNECTOR LBEP-LIGHT BEACON PWR
CAV WIRE IDENT CIRCUIT CONNECTOR LLFW - LH FRONT WORK LAMP

1 46-E Beacon Light PWR
CONNECTOR LBEPWR-LIGHT BEACON PWR

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

A 42C-H LH Front Work Lamp Power
CAV WIRE IDENT CIRCUIT B 0-MU LH Front Work Lamp Ground
1 19U-C Dome LT FSD PWR
4002-145
CONNECTOR LLR-9 - LH REAR COMBINATION CONNECTOR LLRW- LH REAR WORK LAMP
LAMP
245483C1

225351C1
A 42R-H LH Rear Work Lamp Fused Pwr
B 0-ME LH Rear Work Lamp Ground
1 44A-L Brake Light Power
2 45L-9 Left Turn Signal
3 18F-F Left Tail Fused Power CONNECTOR LPL - LICENSE PLATE LAMP
4 35A-N Reverse Lamp
5 0-LB LH Rear Ground
6 Not Used
CONNECTOR LLR-N - LH REAR COMBINATION

LAMP
245482C1

A 18G-E License Plate Lamp Fused Pwr
A 18G-EN License Plate Lamp Fused Pwr
B 0-JC License Plate Lamp Ground
245715C1

A 44A-FN Brake Lamp Relay Out
B 18F-BN LH Tail Lamp Fused Pwr
C 45L-BN Left Turn Signal
D 0-BR-N LH Rear Light Ground (NA)
4002-146
CONNECTOR LRF - RH FRONT COMBINATION CONNECTOR LRR-9 - RH REAR COMBINATION
LAMP LAMP
225351C1 225351C1

1 0-AH RH Front Lights Ground 1 44A-K Brake Light Power
2 18E RH Low Beam Fused Pwr 2 45R-9 Right Turn Signal
3 18C RH High Beam Fused Pwr 3 18G-M Right Position/Tail Fused Pwr
4 18G-A RH Position/Tail Fused Pwr 4 35A-P Reverse Lamp
5 45R Right Turn Signal 5 0-BR Rear LH Ground
6 Not Used 6 Not Used
CONNECTOR LRFW - RH FRONT WORK LAMP CONNECTOR LRR-N - RH REAR COMBINATION

LAMP
245483C1

A 42C-G RH Front Work Lamp Fused Pwr 245715C1
B 0-MJ RH Front Work Lamp Ground CAV WIRE IDENT CIRCUIT

A 44A-GN Brake Lamp Relay Out
RH Position/Tail Lamp Fused
B 18G-CN
Pwr
C 45R-BN Right Turn Signal
D 0-BT-N RH Rear Light Ground (NA)
4002-147
CONNECTOR LRRW - RH REAR WORK LAMP CONNECTOR P-A1-B+ POWER

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

245483C1
1 1CB-A CAB CB Protected PWR
A 42R-G RH Rear Work Lamp Fused Pwr
B 0-MF RH Rear Work Lamp Ground CONNECTOR PAF - AIR FILTER RESTRICTION
SWITCH
CONNECTOR LSPK - LEFT SPEAKER
195552A1
1 65L Left Speaker Signal CAV WIRE IDENT CIRCUIT

2 0-PA Left Speaker Ground Air Filter Restriction Switch
1 31F
Signal
Air Filter Restriction Switch
2 0-BY
CONNECTOR OSS - OUTPUT SPEED SENSOR Grnd
CONNECTOR PBD - BRAKE DECLUTCH

PRESSURE SWITCH
291719A1

245482C1
1 0-HE Output Speed Ground
2 25D Output Speed Signal
A 19A-A Brake Declutch Sw Fused Pwr
3 19A Output Speed Fused Pwr
B 25G Brake Declutch Switch Control
4002-148
CONNECTOR PBL - BRAKE LAMP PRESSURE CONNECTOR PHF-HYD OIL FILT RES SW
SWITCH
1 31H HYD FLTR REST SW SGNL
CONNECTOR PO1 - POWER OUTLET
222136A1

1 1-AA Brake Lamp Switch Power
2 44 Brake Lamp Control Power
CONNECTOR PBW - BRAKE PRESSURE

WARNING SWITCH 12176446

A 12V 12V Pwr to Outlet 1
B Not Used
C 0-EK Aux Power Outlet 1 Gnd
CONNECTOR PO2 - POWER OUTLET
225316C1

1 33P Low Brake Press Warning
2 0-AL Brake Press Warn Sw Ground
CONNECTOR P-C5-B+ PWR-FRM-PRMC

1 1-B9 PRM C PWR 12176446

A 12V 12V Pwr to Outlet 2
CONNECTOR PFA-FRONT AXLE FILTER
B Not Used
C 0-EK Aux Power Outlet 2 Gnd
1 36D-B Rear Axle FLTR SNSR
4002-149
CONNECTOR PR - TRINARY PRESSURE SWITCH CONNECTOR PRB2 - REDUNDANT BRAKE
SWITCH
245483C1
182068A1
RDNT Brake Accumulator Press
A 33R-B
A 61-A Trinary Pressure Switch Input Low
B 61R AC Relay Control B 0-HL Ground
CONNECTOR PRA-REAR AXLE FILTER CONNECTOR PRBF - ROLLBACK PRESSURE

SWITCH
1 36D-C Front Axle FLTR SNSR
CONNECTOR PRB1 - REDUNDANT BRAKE

SWITCH
245483C1

A 58 Ride Control Solenoid Power
B 58-B Ride Control Solenoid Power
245483C1
CONNECTOR PRM-A1 - PRM SIGNAL
RDNT Brake Accumulator Press
A 33R-C
Low
B 0-HM Ground
256340A1

A 13K-B Ignition Switch Power
B 0-EB Ignition Relay Control Ground
4002-150
CONNECTOR PRM-B1 - PRM SIGNAL CONNECTOR PRM-C2 - PRM SIGNAL
409084A1

A Not Used 256340A1
C 13H Time Delay Power CAV WIRE IDENT CIRCUIT

A 28E Ether Relay Signal
A 28F Fuel Filter Heater Relay Control
CONNECTOR PRM-B2 - PRM SIGNAL
B 0-BAM Ether Relay Signal Ground
B 0-BN Filter Heater Control
CONNECTOR PRM-D1 - PRM SIGNAL
256340A1

A 13D Time Delay Relay Control Pwr
B 0-EA Time Delay Relay Control Gnd
256340A1

CONNECTOR PRM-C1 - PRM OUTPUT
A 12ACC-B ACC PRM Control Power
B 0-EC ACC Relay Control Ground
CONNECTOR PRM-E1 - PRM SIGNAL
409084A1

A 18R Voltmeter Relay Fused Pwr
C 28P Ether Solenoid Power
C 1-GA Filter Heater Power 409084A1

A Not Used
C 19L Power Converter FSD Power
4002-151
CONNECTOR PRM-E2 - PRM SIGNAL CONNECTOR PXH - HEIGHT CONTROL RTT
245485C1

256340A1
A 54B RTT Signal
B 0-AA Proximity Switch Ground
A 12ACC-C Pwr Converter PRM Control Pwr
C 53P-J Pilot Control Relay Out
B 0-DL Pwr Converter Relay Ctrl Gnd
CONNECTOR PXM - RTD

CONNECTOR PSS - SECONDARY STEERING
PRESSURE SWITCH
245485C1
CAV WIRE IDENT CIRCUIT A 53B-A RTD Control Signal
A 51P-A Secondary Steer High Pressure B 0-AM RTD Ground
B 0-CC Sec. Steer Press Switch Ground C 53P-I Pilot Control Relay Out
C 35X-A Secondary Steer Low Press Sig
CONNECTOR PXT - RTD

CONNECTOR PXF - RTD
245485C1
245485C1
A 53B-A RTD Control Signal
A 53B RTD Signal
B 0-AM RTD Ground
B 0-AC Proximity Switch Ground
C 53P-I Pilot Control Relay Out
C 53P-H Pilot Control Relay Out
4002-152
CONNECTOR QSM11-ENGINE CONTROLLER CONNECTOR RAD-J1 - RADIO POWER

7 18J-M QSM11 Time Delay PWR
8 18J-N QSM11 Time Delay PWR
17 18J-L QSM11 Time Delay PWR
18 18J-P QSM11 Time Delay PWR
28 18J-Q QSM11 Time Delay PWR
29 0-BAH QSM11 GND
30 0-BAI QSM11 GND
37 CAN-LM CAN Low from ENG
292497A1
38 13M-B KEY SW PWR DISC SW
39 0-BAJ QSM11 GND CAV WIRE IDENT CIRCUIT
40 0-BAK QSM11 GND 1 Not Used
41 0-BAL QSM11 GND 2 Not Used
46 CAN-HJ CAN High from ENG 3 Not Used
47 24B-A Throt Signal 4 RAD3 12V Fused Power to Radio
48 24S-A Throt Supply 5 Not Used
49 24R-A Throt GND 6 Not Used
50 0-BAP QSM11 GRND 7 RAD2 12V Fused Power to Radio

8 RAD1 Radio Ground
CONNECTOR RAD - RADIO POWER

CONNECTOR RAD-J2 - SPEAKER
292495A1
292501A1
1 Not Used
1 RAD11 Right Speaker
2 Not Used
2 RAD10 Right Speaker Ground
3 Not Used
3 RAD9 Not Used
4 12V-HB 12V Fused Power to Radio
4 RAD8 Not Used
5 Not Used
5 RAD7 Not Used
6 Not Used
6 RAD6 Not Used
7 12V-HA 12V Fused Power to Radio
7 RAD5 Left Speaker
8 0-EN Radio Ground
8 RAD4 Left Speaker Ground
4002-153
CONNECTOR RAD-J3 - RADIO JUMPER CONNECTOR RFLG-FUEL SEND GRND

1 0-BU Fuel Level Sender GRND
CONNECTOR ROOF - ROOF TO CAB

CONNECTION
411311A1

1 RAD10 Right Speaker Ground
2 RAD8 Not Used
3 RAD4 Left Speaker Ground
4 RAD6 Not Used
5 RAD1 Radio Ground
6 Not Used 388708A1
7 RAD3 12V Fused Power to Radio CAV WIRE IDENT CIRCUIT

8 RAD11 Right Speaker A 43-B Dome Light Auto Mode
9 RAD9 Not Used B 42R-F Rear Work Light Fused Power
10 RAD5 Left Speaker C 42C-F Front Work Lights Fused Power
11 RAD7 Not Used D 19U-C Done Light Fused Power
12 RAD2 12V Fused Power to Radio E 46-D Beacon Switch Power
13 Not Used F 0-MN Roof Grounds
14 Not Used G 0-MK Roof Grounds
J 19K-D Rear Wiper Motor Fused Power
K 68C-A Rear Wiper Park Control
CONNECTOR RECT - ENGINE COOLANT
TEMPERATURE L 68L-A Rear Wiper Switched Power
M 0-EN Radio Ground
N 12V-H 12V Fused Power to Radio
R 43S-B Door Open Signal
S 19U-F Door Switch Fused Power
CONNECTOR RSPK - RIGHT SPEAKER

194788A1

A 36C Radiator Coolant Temp Signal
B 0-BAE EDC7 Sender Ground
CONNECTOR RFL-FUEL SENDER

195552A1

1 36F Fuel Level Analog 1 65R Right Speaker Signal
2 0-PB Right Speaker Ground
4002-154
CONNECTOR RTHP - THROTTLE PEDAL CONNECTOR RWMG - REAR WIPER MOTOR
GROUND
225351C1
CAV WIRE IDENT CIRCUIT 245480C1
1 21F-C EDC7 DIGITAL Ground CAV WIRE IDENT CIRCUIT

2 Not Used A 0-MA Rear Wiper Motor Ground
3 24B Throttle Signal
3 24B-A Throttle Signal
CONNECTOR RWW - REAR WASHER
4 24R Throttle Position Sensor Ground
4 24R-A Throttle Position Sensor Ground
5 24S Throttle Supply
5 24S-A Throttle Supply
6 24L Low Idle Switch
CONNECTOR RWM - REAR WIPER MOTOR
3227856R1

1 68W-A Rear Washer Pump
2 0-BL Rear Washer Ground
245715C1

A Not Used
B 68L-A Rear Wiper Switch Power
C 19K-D Rear Wiper Motor Fused Power
D 68C-A Rear Wiper Park Control
4002-155
CONNECTOR S-KEY - IGNITION SWITCH CONNECTOR SBU - BACKUP ALARM DISABLE
SWITCH
225253C1
382391A1
1 1A Ign Sw Fused Power
1 35R-C Backup Alarm Switch
2 21K Ign Switch Start Signal
2 35A-B Backup Alarm Disable Switch
3 13K Ignition Switch Power
3 Not Used
4 12ACC Ign Switch Accessory Power
4 Not Used
5 Not Used
5 Not Used
6 Not Used
6 Not Used
7 0-B21 Back Light Ground
CONNECTOR SBE - BEACON SWITCH 8 49-L Back Light Power
9 Not Used
10 Not Used
CONNECTOR SC - SEAT COMPRESSOR MOTOR
382391A1

1 Not Used
2 19U-H Beacon Switch Fused Power
245482C1
3 46-C Beacon Switched Power
4 Not Used
A 19N Seat Compressor Fused Pwr
5 Not Used
B 0-DK Seat Compressor Motor Ground
6 Not Used
8 49-B Back Light Power
9 Not Used
10 Not Used
4002-156
CONNECTOR SCS - COMFOR STEER SWITCH CONNECTOR SDR - DRIVING LIGHTS SWITCH
382391A1 382391A1

1 51S Standard Steering Signal 1 Not Used
2 18L-D Comfort Steering Fused Power 2 19Z-A Driving lights Switch Fused Pwr
3 51CS Comfort Steering Switch 3 41T Position Lights Switch Power
5 Not Used Driving Lights Switch Fused
5 19Z-B
6 51B-A Comfort Steering Solenoid Pwr Power
7 0-B9 Back Light Ground 6 41J Driving Lights Power
8 49-U Back Light Power 7 0-B19 Back Light Ground
9 Not Used 8 49-P Back Light Power

10 Not Used
CONNECTOR SDC - DECLUTCH SWITCH

CONNECTOR SETHR - ETHER SWITCH
382391A1
1 25G-B Brake Declutch Switch Control CAV WIRE IDENT CIRCUIT
2 19A-R Declutch Switch Fused Power 1 Not Used
3 Not Used 2 28J Ether AIC OK Signal
4 Not Used 3 28H Ether Switch Signal
7 0-B18 Back Light Ground 6 Not Used
8 49-R Back Light Power 7 0-B30 Back Light Ground
9 Not Used 8 49U Back Light Power

10 Not Used
4002-157
CONNECTOR SFC - FAN CONTROL SWITCH CONNECTOR SFNR - FNR SWITCH
382391A1 382391A1

1 Not Used 1 26R-A FNR Reverse Signal
2 52J Fan Control Switch Jumper 2 26J FNR Switch Jumper
3 52-AU Fan Reverse Auto 3 26N-A FNR Neutral Signal
4 52J Fan Control Switch Jumper 4 26J FNR Switch Jumper
5 19P-C Fan Reverse Switch Fused Pwr 5 19A-V FNR Switch Fused Power
6 52M Fan Reverse Manual 6 26F-A FNR Forward Signal
7 0-B7 Back Light Ground 7 32J-A Trans Enable Indication
8 49-Q Back Light Power 8 19A-G FNR Switch Fused Power
CONNECTOR SFL - RETURN-TO-TRAVEL CONNECTOR SFWW - FRONT WIPER AND

SWITCH WASHER SWITCH
87345132
382391A1
1 Not Used
1 55A-B RTT/Float Switch Power 2 0-DT Front Wiper/Washer Sw Gnd
2 53P-B Pilot Control Relay Out
3 63LC Front Wiper LS Relay Control
3 55A-C RTT/Float Switch Power
4 Not Used
4 0-29 RTT/Float Ground
INT Wiper/Washer Sw Fused
5 19J-B
5 55B RTT Float Switch Control Pwr
6 54B-C HC-RTT Control Signal 6 Not Used
7 0-B2 Back Light Ground 7 63W Front Washer Pump
8 49-K Back Light Power 8 49-T Back Light Power
9 Not Used 9 63HC Front Wiper HS Relay Control

4002-158
CONNECTOR SHC - HEIGHT CONTROL SWITCH CONNECTOR SPB - PARKING BRAKE SWITCH
382391A1 382391A1
2 53P-D Pilot Control Relay Out 2 19A-L Park Brk Switch Fused Power
3 Not Used 3 33U Park Brake Switch

6 54A HC Control Switch Power 6 Not Used
7 0-B3 Back Light Ground 7 0-B29 RTT/Float Ground
8 49-M Back Light Power 8 49-V Back Light Power

CONNECTOR SHZ - HAZARD SWITCH CONNECTOR SPC - PILOT CONTROL SWITCH
382391A1 382391A1
2 1-KA Hazard Switch Power 2 19A-J Pilot Control Switch Fused Pwr
3 45H Hazard Switch Power 3 31L Pilot Control Switch High
7 0-B24 Back Light Ground 7 0-B1 Back Light Ground
8 49-D Back Light Power 8 49-N Back Light Power

4002-159
CONNECTOR SPE - PIN ENGAGE SWITCH CONNECTOR SPL-BCK-LGT - SPLICE BACK
LIGHT POWER
382391A1

1 57-B Pin Engage Solenoid Power
87324393
2 19P-A Pin Engage Sw Fused Power
3 Not Used
A 49 Back Light Power
4 Not Used
B Not Used
5 Not Used
C 49-C Back Light Power
6 Not Used
D 49-H Back Light Power
7 Not Used
E 49-L Back Light Power
8 Not Used
F 49A Back Light Power
G 49-P Back Light Power
10 49-F Back Light Power
H 49-R Back Light Power
J 49S Back Light Power
CONNECTOR SPK - SPEAKER K 49-E Back Light Power
L 49-B Back Light Power
M 49-A Back Light Power
292494A1

1 65R Right Speaker
2 0-PB Right Speaker Ground
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 65L Left Speaker
8 0-PA Left Speaker Ground
4002-160
CONNECTOR SPL-BCK-LGT2 - SPLICE BACK CAV WIRE IDENT CIRCUIT
LIGHT POWER
D Not Used
E 0-B17 Back Light Ground
F 0-B18 Back Light Ground
G 0-B19 Back Light Ground
H 0-B8 Front Wiper Motor Ground
J 0-B21 Back Light Ground
K 0-DAP Back Light Ground
L 0-B23 Back Light Ground
M Not Used
CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK

LIGHT GROUND
87324393

A 49-E Back Light Power
B Not Used
C 49-J Back Light Power
D 49-M Back Light Power
E 49-K Back Light Power
F 49-F Back Light Power
G 49-Q Back Light Power
H 49-T Back Light Power
J Not Used
K 49-G Back Light Power 87324393
L Not Used CAV WIRE IDENT CIRCUIT
M 49-S Back Light Power A Not Used

B 0-B2 Back Light Ground
C 0-B3 Back Light Ground
CONNECTOR SPL-BCK-LT-GD - SPLICE BACK
D 0-B4 Back Light Ground
LIGHT GROUND
E 0-B5 Back Light Ground
F 0-B6 CAB2 Ground
G 0-B26 Buzzer Switch Pad Ground
H Not Used
J 0-B20 Back Light Ground
K 0-29 RTT/Float Ground
L 0-B11 Back Light Ground
M 0-B7 Back Light Ground
87324393

A 0-B13 Back Light Ground
4002-161
CONNECTOR SPL-ENG-GND - GROUND SPLICE CONNECTOR SPL-PED-BL - SPL BACK LIGHT
6 PACK POWER 6 PACK
87324391 87324391

A 0-BM Engine Splice Grounds A 49-U Back Light Power
B 0-BY Air Filter Restriction Switch Gnd B 49-N Back Light Power
C Not Used C 49-D Back Light Power
D 0-BS Fan Control Ground D 49U Back Light Power
E 0-B Front Washer Ground E 49-V Back Light Power
F 0-BL Rear Washer Ground F 49-S Back Light Power
CONNECTOR SPL-HOOD-GRND HOOD GRND CONNECTOR SPL-PED-BL-GD - SPL BACK

6PCK LIGHT POWER 6 PACK

A 0-B12 Hood Down Relay GND
B 0-B16 Hood Down Control GND
C 0-B22 Hood Up Relay GND
D 0-B25 Hood Up Control GND
E 0-B10 Hood GND
87324391

A 0-B9 Back Light Ground
D 0-B30 Back Light Ground
E 0-B29 RTT/Float Ground
F 0-B11 Back Light Ground
4002-162
CONNECTOR SPL-PIN - SPL BACK LIGHT CAV WIRE IDENT CIRCUIT
POWER 6 PACK
K 35A-B Backup Alarm Disable Switch
L 35A-A Backup Alarm Relay Out
M 35A-C Backup Alarm Relay Out
CONNECTOR SPL-PK2 - SPLICE 3 - 4 WAY
87324391

A 19P-A Pin Engage Switch Fused Pwr
B 19P Pin Engage/Fan Fused Power
C 19P-C Ran Reverse Switch Fused Pwr
D Not Used 87324462
E 19P-D Fan Reverse Relay Fused Pwr CAV WIRE IDENT CIRCUIT
F 19P-E Fan Reverse Relay Fused Pwr A 41T-B Position Lights LH Switch Pwr
B 41T-E Position Lights Switch Pwr
C 41T Position Lights Switch Pwr
CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY
D 41T-A Position Lights RH Switch Pwr
E 19Z-A Driving Light Switch Fused Pwr
F 19Z-B Driving Light Switch Fused Pwr
G 19Z Driving Light Switch Fused Pwr
H 19Z-C High Beam Flash Fused Pwr
J 41H-C High Beam RH Power
K 41H-B High Beam LH Power
L 41H-A High Beam Power
M 41H-D High Beam Power
87324462

A 42C-A Front Work Lights Fused Pwr
B 42C-E Front Work Lights Fused Pwr
C 42C-D Front Work Lights Fused Pwr
D 42C-C Front Work Lights Fused Pwr
E 13K Ignition Switch Power
F 13K-B Ignition Switch Power
G 13K-A Ignition Switch Power
H 13K-C Ignition Switch Power
J 35A-D Backup Alarm Relay Out
4002-163
CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY CAV WIRE IDENT CIRCUIT
E 0-MF RH Rear Work Light Ground
F 0-MA Rear Wiper Motor Ground
G Not Used
H Not Used
J 0-MJ RH Front Work Light Ground
K Not Used
L 0-MN Roof Grounds
M 0-MK Roof Grounds
CONNECTOR SPL-SEC-STR - SEC STR 6PK

87324462

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

A 0-MC Beacon Light Ground
B 0-MB Dome Light Ground
C 0-MU LH Front Work Light Ground
D 0-ME LH Rear Work Light Ground
4002-164
CONNECTOR SPL-TRN-GRD - SPLICE CAV WIRE IDENT CIRCUIT
TRANSMISSION GROUND
Output Speed Sensor Fused
K 19A-M
Pwr
L 19A-S Trans Fused Pwr
M 19A-H Trans Shifter Fused Pwr
CONNECTOR SR-9-STR REL signal

1 21C-D STRTR RLY Signal
CONNECTOR SRC - RIDE CONTROL SWITCH

87324391

A 0-HC Transmission Splice Grounds
B Not Used
C 0-HW HOT Ground
D 0-HV Coolant Level Sender Ground
E 0-HL Redundant Brake Switch Grd
F 0-HM Redundant Brake Switch Grd
CONNECTOR SPL-TRNS-PWR - TRANSMISSION 382391A1
POWER CAV WIRE IDENT CIRCUIT

1 Not Used
2 19C-D Ride Ctrl Switch Fused Pwr
3 58C Ride Ctrl Switch Jumper
4 58T Ride Ctrl Relay Switch Pwr
5 58C Ride Ctrl Switch Jumper
6 58-F Ride Ctrl Solenoid Pwr
8 49-G Back Light Power
9 Not Used
10 Not Used
87324393

A 19A-N Trans Fused Power
B 19A-F Trans Enable Switch Fused Pwr
C 19A-Q Trans/Auto Switch Fused Pwr
D 19A-T Brake Declutch Sw Fused Pwr
E 19A-W Diagnostic Conn. Fused Pwr
F 19A-C FNR Switch Fused Pwr
Backup Alarm Rly Ctrl Fused
G 19A-P
Pwr
H 19A-R Declutch Switch Fused Pwr
J 19A-K TECM Fused Pwr
4002-165
CONNECTOR SRHSTLK - RH STALK SWITCH CONNECTOR SRWP - REAR WIPER SWITCH
382391A1

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

1 19S1 SEC STR FSD PWR
CONNECTOR SSS-SS MAG SWITCH

1 51-B SEC STR Motor CTRL
382391A1

1 Not Used
2 53P-E Pilot Control Relay Out
3 53A RTD Switched Power
4 Not Used
5 Not Used
6 Not Used
8 49-J Back Light Power
9 Not Used
10 Not Used
4002-166
CONNECTOR SS-TR - SS-MOD-TRANS CONNECTOR STA - TRANSMISSION AUTO
SWITCH
245489C1

A 19M-C Sec. Str Accessory Fused Pwr
B 19R-C Sec. Str Ignition Fused Pwr
C 35X-C Sec. Str Low Press Signal
382391A1
D 0-CD Sec. Str Splice Ground
E 19S1-X Sec. Str Fused Power
1 Not Used
F Not Used
2 19A-Q Trans Auto Sw Fused Power
3 25H Trans Auto Signal
CONNECTOR SSM - SECONDARY STEERING 4 Not Used
MODULE
5 Not Used
6 Not Used
8 49S Back Light Power
9 Not Used
10 Not Used
CONNECTOR STE - TRANSMISSION ENABLE

SWITCH
225389C1

1 19R-C
Pwr
2 51-A Secondary Steer Control
3 19S1-X Secondary Steer Fused Power
4 0-CE Secondary Steer Chassis Grnd
5 Not Used
6 Not Used
Secondary Steer ACC Fused 382391A1
7 19M-C
Pwr
8 35X-D Secondary Steer Low Press Sig
1 Not Used
9 51P-A Secondary Steer High Press
2 19A-D Trans Enable Sw Fused Power
10 Not Used
3 26E Trans Enable Signal
11 0-CA Secondary Steer Signal Grnd
4 Not Used
12 0-CB Secondary Steer Signal Grnd
5 Not Used
6 Not Used
7 0-DAP Back Light Ground
4002-167

8 49-H Back Light Power 5 31F-A Air Filter Rest Switch Signal
9 32J-C Trans Enable Indiction 6 Not Used
10 19A-E Trans Enable Sw Fused Pwr 7 CAN-HF CAN High
8 CAN-LF CAN Low
9 17P-A Switch Pad Pwr From AIC Pwr
CONNECTOR SWL - WORK LIGHTS SWITCH
10 0-B28 Switch Pad Ground
CONNECTOR TCOT - TORQUE CONVERTER

OUTPUT SENDER
382391A1

1 Not Used
2 42-A Work Lights Fused Power
3 42FS Front Work Lights Switch Power
291718A1
4 Not Used
5 42-B Work Lights Fused Power CAV WIRE IDENT CIRCUIT
6 42RS Rear Work Lights Switch Power 1 36G TCO Temperature Signal
7 0-B14 Back Light Ground 2 36R-D TCO Temperature Return
8 49-A Back Light Power

9 Not Used CONNECTOR TDM - TIME DELAY MODULE
10 Not Used
CONNECTOR SW-PD - SWITCH PAD
225351C1

1 13D Time Delay Relay Ctrl Power
2 1DN Time Delay Fused Power
3 0-DC Time Delay Module Ground
4 43S-D Time Delay Mod Door Sw Reset
87552623
5 13K-A Ignition Switch Power
6 Not Used
1 41H-D High Beam Power
2 41T-D Position Lights Switch Pwr
3 42C-E Front Work Light Fused Pwr
4 31H-A Hydraulic Filter Rest Sw Signal
4002-168
CONNECTOR TECM - TRANSMISSION CAV WIRE IDENT CIRCUIT
ELECTRONIC CONTROL MODULE
21 52P-C Park Brake Relay Out
22 25Y-A Trans Kick Down Signal
23 19T-A Time Delay Fused Power
25 CAN-HD CAN High
26 CAN-LK CAN Low
27 CAN-LJ CAN Low
29 25H Trans Auto Signal
30 26R-B FNR Reverse Signal
31 26E Trans Enable Signal
32 25M-A Trans Sol Valve Y3
39 36T-A Valve Body Temp Signal
41 25C-A Turb Speed Signal
42 25B-A Int Speed Signal
43 25F Forward Signal
44 26N-B FNR Neutral Signal
45 19A-K TECM Fused Power
46 36R-E Trans Temp/Filter Return
49 36G-A Torque Conv Out Temp Signal
51 25J-A Trans Sol Valve Y6
55 25N-A Trans Sol Valve Y4
56 25K-A Trans Sol Valve Y1
57 58L Ride Control Relay LSD
62 25D-A Output Speed Signal
63 25Z 1st and 4th Gear Signal
64 25R- Reverse Signal
65 25W 3rd and 4th Gear Signal
411398A1
66 25G-C Brake Declutch Switch Control
67 25T-C Neutral Signal
1 0-DP Diag TECM Ground
2 0-DQ Diag TECM Ground
3 0-DM Speed Sensors Ground
4 0-DN Out Speed Sensor Ground
5 32J-D Trans Enable Indicator Lamp
7 35C Backup Alarm Relay Control
8 58H-A Ride Control Sw Power VPS2
9 25P-A Trans Sol Valve Y5
10 25L-A Trans Sol Valve Y2
12 25S-B Output Sw Power VPS1
13 25S-C Output Sw Power VPS1
15 37D-A Diagnostic Signal
17 32F-A Trans Filter Maint Switch
18 37E Diagnostic Signal Switched
19 25A-A Engine Speed Signal
20 26F-B FNR Forward Signal
4002-169
CONNECTOR TR-SS - SEC-STR-MOD-OPT CONNECTOR TRANS - CAB TO TRANSMISSION
380838A1

1 33R-A Redundant Brake Switch Signal
Coolant Level Sender Eng
245488C1 2 31D-B
Trans
2 31D Coolant Level Signal
A 19M-A Sec. Steering ACC Fused Pwr
3 19M-A Sec. Steering ACC Fused Pwr
B 19R-A Sec. Steering Ignition Fused
Pwr 4 19R-A
Pwr
C 35X-B Sec. Steering Low Press Signal
5 36T Valve Body Temp Signal
D 0-HP Sec. Steering Splice Ground
6 35X-B Sec. Steering Low Press Signal
E 19S1-E Sec. Steering Fused Power
7 25A Engine Speed Signal
F Not Used
8 25C Turb Speed Signal
9 25B Intermediate Speed Signal
CONNECTOR TRAN-E - TRANS TO ENG 10 25D Output Speed Signal
11 0-HD Speed Sensor Ground
12 36R-A Trans Temp/Filter Return
13 36G Torque Conv Output Temp Sig
14 Not Used
15 Not Used
16 25K Trans Solenoid Valve Y1
16 25K-9 Trans Solenoid Valve Y2
17 25L-9 Trans Solenoid Valve Y1
17 25L Trans Solenoid Valve Y2
239451A1 18 25M Trans Solenoid Valve Y3
CAV WIRE IDENT CIRCUIT 19 25N Trans Solenoid Valve Y4
1 0-HP Sec. Steering Splice Ground 20 25P Trans Solenoid Valve Y5
2 0-HC Trans Splice Grounds 21 25J Trans Solenoid Valve Y6
Coolant Level Sender Eng 22 25S Output Sw Power VPS1
3 31D-B
Trans
23 31H Hyd Filter Restriction Sw Signal
4 Not Used
24 Not Used
25 Not Used
26 19S1-E Sec. Steering Fused Power
27 Not Used
28 0-HE Output Speed Sensor Ground
Output Speed Sensor Fused
29 19A
Pwr
30 36H Hydraulic Oil Temperature Sign
31 32F Trans Filter Maint Switch
4002-170
CONNECTOR TRC - TRANSMISSION CONTROL CONNECTOR TS1 - TRANSMISSION SHIFTER
245486C1
371566A1 CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT A 19A-H Trans Shifter Fused Power
1 25K Trans Solenoid Valve Y1 B 25F Forward Signal

1 25L-9 Trans Solenoid Valve Y1 C 25R Reverse Signal
2 25K-9 Trans Solenoid Valve Y2 D 25T-B Neutral Signal

2 25L Trans Solenoid Valve Y2
3 25M Trans Solenoid Valve Y3
CONNECTOR TS2 - TRANSMISSION SHIFTER
4 25N Trans Solenoid Valve Y4
5 25P Trans Solenoid Valve Y5
6 25J Trans Solenoid Valve Y6
7 25S Output Sw Power VPS1
8 36T Valve Body Temp Signal
9 36R-C Valve Body Temp Return
10 Not Used
11 Not Used
12 Not Used
245487C1
13 Not Used
14 Not Used
A Not Used
15 Not Used
16 Not Used B 25W 3rd and 4th Gear Signal
C 25Z 1st and 4th Gear Signal
D 25Y Transmission Kick Down Signal
4002-171
CONNECTOR TSS - TURBINE SPEED SENSOR CONNECTOR YFR - FAN REVERSING SOLENOID
225316C1

291718A1
1 52A-B Fan Reversing Relay Out
2 0-BB Fan Reversing Solenoid Ground
1 25C Turbine Speed Signal
2 0-HH Turbine Speed Ground
CONNECTOR YPB - PARKING BRAKE
SOLENOID
CONNECTOR YCS - COMFOR STEERING
SOLENOID
245482C1 291718A1

A 51B-D Comfort Steering Solenoid Pwr 1 52P Parking Brake Relay Out
B 0-AQ Comfort Steering Solenoid Gnd 2 0-AN Park Brake Solenoid Ground
CONNECTOR YFN - FAN PWM SOLENOID CONNECTOR YPP - PILOT PRESSURE

SOLENOID
245482C1
256340A1
CAV WIRE IDENT CIRCUIT A 5P-A Pilot Control Relay Out
A 56-A Fan Control PWM B 0-DU Pilot Pressure Solenoid Gnd
B 0-BQ Fan Speed PWM Solenoid Gnd
4002-172
CONNECTOR YRC - RIDE CONTROL OPT
291718A1

1 58 Ride Control Solenoid Power
1 58S-E Ride Control Sol To Front Cab
2 0-AD Ride Control Ground
CONNECTOR YSS - SECONDARY STEERING

SOLENOID
225316C1

1 51-C Sec. Steering Solenoid Control
2 0-CF Sec. Steering Solenoid Ground
Section
4003
BATTERIES

4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4003-3
SAFETY RULES
WARNING: Never try to charge the battery if WARNING: Battery acid causes severe
the electrolyte in the battery is frozen. burns. Batteries contain sulfuric acid. Avoid
47-83A contact with skin, eyes, or clothing. Antidote:
EXTERNAL-Flush with water.
WARNING: Never cause sparks to occur or
INTERNAL-Drink large quantities of water or
smoke near batteries that are charging or
milk. Follow with milk of magnesia, beaten
have been recently charged.
egg, or vegetable oil. Call physician
13-8A
immediately. Eyes: Flush with water for 15
WARNING: Disconnect the ground cable minutes and get prompt medical attention.
first when the battery cables are Batteries produce explosive gases. Keep
disconnected from the battery. sparks, flame, and cigarettes away. Ventilate
Connect the ground cable last when the when charging or using in enclosed area.
battery cables are connected to the battery. Always shield eyes when working near
47-55A batteries.
WARNING: Some batteries have a Keep out of reach of children.

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

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

(Load) Test. This tool is first used on Page 6.
4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery
If the battery is a maintenance free battery, check the If damage causes an electrolyte leak, replace the
level of the electrolyte every 1000 hours of operation battery.
or six months, whichever occurs first. For all other
Inspect the battery at regular intervals for dirt,
batteries, check the level of the electrolyte every 250
corrosion, and damage. Electrolyte and dirt on the
hours of operation.
top of the battery can cause the battery to discharge
NOTE: A maintenance free battery will have the words by making a passage for the current to flow.
Maintenance Free on the decal on the top of the battery. If
If the battery must be cleaned, remove the battery
the center part of the decal has been removed for access to
from the battery carrier and clean the battery, cable
the battery caps, it is possible that the words Maintenance
terminals, and the battery carrier.
Free have been removed from the decal.
Check the level of the electrolyte more often during
hot weather. The use of a large amount of water by
the battery can be cau se d by high b attery
temperature or a voltage regulator setting that is too
high. Keep the electrolyte level above the top of the
plates in the battery at all times to prevent damage to
the battery.
NOTE: On maintenance free batteries it is necessary to
remove the center part of the decal for access to the battery
caps. Do not discard the center part of the decal. Install the
center part of the decal after the battery caps have been
installed.
If the level of the electrolyte is low, add distilled water
or other clean water until the electrolyte is 5 mm
(¼ inch) below the level of the ring. Do not add more
water than is needed. Too much water can cause
bad performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.
4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the battery. 1� 2
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check B790863
A hydrometer is used to check the specific gravity 1. TEMPERATURE IN F 2. TEMPERATURE IN C

(weight) of the electrolyte. The specific gravity is an SPECIFIC GRAVITY CHART
indication of the level of charge for each cell. 4. Make a record of the corrected specific gravity
Hydrometers are made to show the correct specific reading for each cell.
gravity when the temperature of the electrolyte is 5. If the difference between the high reading and
26.7°C (80°F). the low reading is 0.050 or more, charge the
When you check the specific gravity, you must know battery and check the specific gravity again. If
the temperature of the electrolyte. If your hydrometer after charging, the difference is still 0.050 or
does not have a thermometer, get a thermometer to more, install a new battery.
che ck th e tempe rature of th e e lectro lyte. The 6. The corrected specific gravity reading shows the
thermometer must indicate a high temperature of at level of charge for the cell. The level of charge
least 52°C (120°F). must be at least 75% in each of the cells. ln
1. Remove enough electrolyte from a cell so that maintenance free batteries the level of charge is
the float is free in the tube. at least 75% if the corrected specific gravity
reading is 1.240 or higher. In all other batteries
NOTE: If the specific gravity cannot be checked without the level of charge is at least 75% if the corrected
first adding water to the cell, the battery must be charged specific gravity reading is 1.230 or higher.
for 15 minutes at 15 to 25 amperes to mix the water with
the electrolyte. Then check the specific gravity. 7. If the difference between the high reading and
the low reading is less than 0.050, and the level
2. Read the float. of charge is at least 75% in all of the cells, do the
3. Read the thermometer. If the reading is above Capacity (Load) Test.
26.7°C (80°F) add specific gravity points to the 8. If the difference between the high reading and
reading for specific gravity. If the reading is the low reading is less than 0.050, but the level
below 26.5°C (80°F) subtract specific gravity of charge is less than 75% in any of the cells,
points from the reading for specific gravity. See charge the battery and check the specific gravity
the following illustration and add or subtract again. If after charging:
specific gravity points as needed.
A. The level of charge is less than 75% in any of
the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.
4003-6
Capacity (Load) Test NOTE: Never apply a load for longer than 15 seconds.
After each 15 seconds, turn the load control knob to OFF for
This test can be done using a variable load tester at least one minute.
s u ch a s th e Su n Ele c tr ic VA T- 3 3 . O th e r t e s t
equipment can be used. Connect the test equipment 4. Apply a 15 ampere load to the battery for 15
according to the instructions of the manufacturer of seconds. Wait at least three minutes before
the equipment. applying the load again.
1. The level of charge of the battery must be at 5. Check and make a record of the temperature of
least 75%. Do the Specific Gravity Check in this the electrolyte.
section. 6. Find the correct load for this test in Specifications
2. Prepare the tester (Sun Electric VAT-33 shown) in Section 4001.
for the test. NOTE: The correct load is half of the cold cranking
A. Select the voltmeter range that will measure 1 amperes at -17°C (0°F).
to 18 volts. 7. Turn the load control knob until the ammeter
B. Make sure the load control knob is in the OFF indicates the specified load. Keep the load for 15
position. seconds and read the voltmeter. Turn the load
control knob to OFF.
C. Select the ammeter range that will measure 0
to 1000 amperes. 8. Compare the test reading and the temperature of
the electrolyte to the chart below.
D. Move the volt lead switch to the NT. position. Temperature of . . . . . . . . . . . . . . . Minimum Voltage
3. Connect the tester to the battery as shown. electrolyte
21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6
16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
2�
4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1
-7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.9
-12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
1 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
v o l t a g e s h o w n , t h e b a t t e r y i s in g o o d
condition.
B. If the test result is less than the voltage
shown, discard the battery.
B790499
1. LOAD CONTROL KNOB 2. AMMETER CLAMP (TIP OF

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

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

Reserve Capacity under Charge
Specifications
10 Hours at 5 Amperes
80 Minutes or Less
Above 80 to 125 Minutes 7.5 Hours at 10 Amperes
Above 125 to 170 Minutes
*lnitial rate for standard taper charger.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part
of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been
removed from the decal.
Continued on next page

4003-8
Charging Guide For Batteries Other Than Maintenance Free

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

Reserve Capacity under Charge
Specifications
80 Minutes or Less
7.5 Hours at 10 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
*lnitial rate for standard taper charger.
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
s p e cif ic g r a v ity is 1 . 2 5 0 o r mo r e a n d t h e
2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
e le ctro lyte. Th is will p er mit th e vo lu me o f
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
3. Install the caps on the battery.
the cell opening.
4. Connect a battery charger to the battery.
4003-9
7 8
3
6
1
4
5
W270-7R018
1. BATTERY 5. BOLT
2. ANGLE 6. NUT
3. CLAMP 7. WASHER
4. WASHER 8. BOLT
4003-10�
NOTES
Section
4005
INSTRUMENT CLUSTER

4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4005-3
INSTRUMENT CLUSTER
5�
4� 6�
1� 2� 3� 7� 8� 9� 10�
15� 11�
14� 12
13�
BS06H240
1. LOW BRAKE PRESSURE INDICATOR 9. LACK OF AUX STEER PRESSURE (OPTIONAL)
2. HIGH BEAM INDICATOR 10. PARKING BRAKE INDICATOR
3. TRANSMISSION OIL TEMPERATURE GAUGE 11. RIGHT TURN INDICATOR
4. CAUTION MASTER INDICATOR 12. FUEL LEVEL GAUGE
5. MULTI FUNCTION LCD DISPLAY 13. FUEL LEVEL AT MINIMUM
6. STOP MASTER INDICATOR 14. ENGINE COOLANT TEMPERATURE GAUGE
7. HYDRAULIC OIL TEMPERATURE GAUGE 15. LEFT TURN INDICATOR
8. WAIT TO START ENGINE PREHEAT
The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:
4005-4
Self-Test Power Circuit Test

1. Turn the ignition (key) switch to the ON position. A. Check fuse ECA-F3. If the fuse is bad, replace
the fuse and repeat Self-Test. If the fuse is
2. The instrument cluster will automatically check good, go to next step.
each monitored system.
B. Check wire 19EA for continuity.
3. All LED’s (Light Emitting Diodes) will illuminate R e p a ir / r ep l a c e t h e w ir e a s r eq u ir e d . I f
for 2 - 3 seconds. continuity is found go to next step.
4. Four gauges will energize for 2 - 3 seconds. C. Check power relay module A for proper
operation, see Section 4002. If the power
5. The warning alarm will sound for 2 - 3 seconds.
relay module checks good, go to next step.
6. If there is an open circuit between a sensor and D. Check the ignition switch for proper operation,
the instrument cluster, the LED will flash and the see Section 4002. If the ignition switch checks
warning alarm will sound for 5 seconds. good, go to next step.
7. If there were no faults detected during the check, E. Check fuse ECC-F5. If the fuse is bad, replace
all monitored systems will return to normal the fuse.
operation.
8. If only some of the LEDs illuminate, replace the
instrument cluster.
9. If the LEDs illuminate, but the warning alarm
does not sound, replace the instrument cluster.
10. If the warning alarm sounds but the LEDs do not
illuminate, if no power is present at buzzer,
replace the instrument cluster, if power is present
at the buzzer, replace the buzzer.
11. If the warning alarm does not sound and the
LEDs do not illuminate on the instrument cluster,
do the following steps to test the power circuit:
4005-5
LCD Multi-function Display 2. This example, shows that the Transmission

Control Lever is in Neutral. The display will show
Forward, Neutral, or Reverse, depending on
wh ere th e Dire ctiona l C ontro l L ever is
positioned.
NOTE: Forward and Reverse will blink if the transmission
clutches are disconnected.
3. This example shows the maximum gear allowed
when in Automatic mode. If display is blank the
Manual mode has been selected.
4. This example shows the current transmission
mode that has been selected.
A. If the Transmission is operating normally it will
display either
BD06H036
1. LCD MULTI-FUNCTION DISPLAY A - Automatic
The LCD Multi-Function Display is located at the M - Manual operation.
center of the modular dashboard. On start up the B. If the Transmission is not operating normally
cluster will flash the instructional lamps and the LCD the display will show
Multi-Display will flash, NEW HOLLAND, with the
machine model. C - Substitute Clutch.
L - Limp Home.
2�
1� S - Transmission Shutdown.
U - TCU Shutdown.
5. This example (not displayed) will show the
3� transmission clutches disengaged, if the Park
5� 4 Brake is OFF.
6. This example shows the Power Boost Status.
MAX - Maximum Power.
STD - Normal/Standard mode of Operation.
AUTO - Switches automatically between
Maximum and Standard Power.
ECO - Limited Power for fuel efficiency.
7. This example will show the Time in either 12
6� 7� hour or 24 hour.
BD06F185
LCD MULTI-FUNCTION DISPLAY
Information will be displayed in different zones on the
LCD, as directed by the operator or machine. In
most situations the operator or technician will be
given specific information to follow if conditions are
not correct.
1. In the example, above, the machine hours are
d i sp la y e d . M a c h i n e h o u r s w il l a lw a y s b e
displayed briefly, on start up. After, the machine
is started, the display will show engine rpm’s.
After, beginning travel, the machine will display
travel speed, if default settings were not changed
by the operator.
4005-6
Navigating Through The LCD Using The Arrow Keys
Multi-function Display Screens At any time, during operation or with the key switch
on, the operator may scroll through three information
screens and two trip screens by using the arrow
C� keys. These five screens are in a circular loop and
A� may be reached by pressing the up or down key. The
following sequence is using the down key only.
NOTE: Pressing the escape key will return the LCD back
to the normal driving screen.
D
B�
BD06H037
Located on the steering column, just to the left of the
Park Switch, is the key pad. Use this key pad to
move from one screen to another, choose various
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
the same basic manner.
A. Escape key: Use this key to exit and return to
the driving screen. Use this key anytime you BD06H037
would like to start over and begin again, plus From the driving screen push the down arrow, as
use to check active, acknowledge errors. shown.
B. Enter key: Use this key to confirm, yes, this is

the desired function.
C. Up arrow key: Use this key to scroll up to
selections.
D. Down arrow key: Use this key to scroll down
to selections.
NOTE: Arrows on the screen will indicate if selections are
up or down from the current selection.
NOTE: Display units can be changed by the operator.
BD06F183
Info 1 is the first information screen using the down

arrow from the driving screen. It displays engine
RPM’s, speed, fuel level, and the voltage level.
4005-7
BD06F169
Press the down button again and the Trip 1 screen
BD06F027
will display. The LCD provides two trip computers.
Info 2 will be displayed next. The Info 2 screen will These will display since last reset the total time in
displa y coolant temp eratur e, tu rbo cha rger a ir hours , t he t ot al f uel, and the av erage f uel
temp era ture , en gin e oil temp era ture in eithe r consumption per hour.
Fahrenheit or Celsius, as well as oil pressure PSI.
BD06F170
By continuing to scroll down, the fifth screen will
BD06F184
Push the down button again and the Info 3 screen. display the Trip 2 screen. Trip 1 and Trip 2 screens
This screen displays the temperature in Fahrenheit can be reset independently. The previous screen can
or Celsius of the transmission oil, hydraulic oil, sump be accessed by using the up arrow key.
oil, and radiator coolant temperature.
4005-8
Reset The Trip Information
BD06F172
BD06F170 The trip screen will indicate a reset message. At this
Highlight the trip screen you wish to set. screen, press confirm to clear the numbers and reset
the trip information. The current date and time will
display automatically. The hours, fuel consumption,
and fuel used per hour will reset and revert to zero.
BD06H037
Press the confirm button to reset the trip selection to
zero.
4005-9
Entering The Service Screens

After the machine has been started or the key switch has been turned to on the operator or service technican may
use this service menu to adjust machine configurations to working conditions, test components, view faults that
may have occurred, or select preferences.
NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery disconnect you may
loose all of your selections and need to reprogram the LCD Multi-function display.
BD06H038 / BD06H037
Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to
scroll through the menu’s.
Items and selections in this menu are: Month
1. Power Mode Menu Year
Max - Maximum power possible 6. Cluster H/W
Std. - Normal/Standard operation Part Number
Auto - Will cycle between Max and Normal Serial Number
Eco - Limited power for economy ID
2. Preferences Menu Version
Language - English, Italian, French, Spanish, 7. Cluster S/W
Portuguese, German Part Number
Units - Metric, English or Imperial Loader Version
Clock - 24 or 12 hour ID
3. Options Menu Version
Fan Auto - manual or automatic 8. Config Menu
Idle Auto - manual or automatic Change Model *
Show RPM Select Tires (Select tire sizes)
Show MPH/KPH Clutch Calibration (calibrate gear box)*
4. Display Menu Gear Limits (choose maximum gear)
Day Display Park Brake (Park brake test)
Day LED Cold Start (choose cold start system)
Night Display FAN Test (sound level)
Night LED Special
5. Clock Menu - Reset Error
Hour - Factory Set
Minute
Day
4005-10
* The tests in the configuration menu should be Software Screen
performed only by a qualified operator or technician,
as some tests require the engine to be running at
high RPM’s.
Select Screen
Th e select screen will allow you to make time
s e t t i n g s a s w e ll a s g i v e a c c e s s t o m a c h i n e
information. Navigate this screen also by highlighting
your selection and pressing confirm. This will allow
you to change clock settings or view the hardware
and software screens. No operator changes can be
made to the hardware or software screens.
BD06H028
The cluster software selection will display the CNH
part number, serial number, ID number and software
version of the Instrument cluster. This display is a
convenient source of information when ordering parts
or accessories. Press escape to exit from this field
and return to the selection menu or use the up or
down arrow key to toggle to the software information
screen.
Selecting Power Modes
The power mode allows the operator to choose the
BD06F177 most effective machine power for the current job
Hardware Screen conditions. Most commonly auto is chosen, as the
power will automatically increase or de crease
Scroll to the hardware selection and press confirm to between maximum power and standard power while
display machine information. the machine is working. This allows for maximum
power if necessary, but will switch to standard mode
for economy. Maximum power can be chosen for
more severe work conditions. Economy can be
chosen for limited power and fuel efficiency.
Press and hold the confirmation button for two
seconds to arrive at the service screen.
BD106F193
The cluster hardware selection will display the CNH
part number, serial number, ID number and version
of the Instrument cluster. This display is a convenient
so ur ce o f in fo rma tion w he n or de rin g p a rts or
accessories. Press escape to exit from this field and
return to the selection menu or use the up or down
arrow key to toggle to the software information BD06H038
screen. At the screen shown above, highlight the power
mode and press the confirmation button to move to
the Power Mode Selection Menu.
4005-11
Preferences
BD06F178
At the Power Mode Menu press the confirmation BD06F179
b u t t o n a g a in t o a c t iv a t e t h e s e le ct io n s . T h e Language Screen, Measurement Units,
highlighted section will flash to indicate a new
selection can be made.
and Clock
The LCD screen can be set with language, units, and
Press the up or down button to select the Power
clock preferences. Use the arrow keys to scroll to the
Mode, and then press the confirmation button again.
preferences menu. Press confirm.
This changes the mode and locks it into memory.
Ch oo se the pr efere nce s de sire d, lang ua ge in
The selected mode will display in zone 3 (bottom) of
(English, Italian, Spanish, Portuguese, German,
the Multi-Function Display when power mode is
French, measurement units in English, Metric, or
correctly selected.
Imperial and clock units in either 12 or 24 hour).
NOTE: Selecting options and navigating through the Highlight the preference you wish to change and
screen menus are the same for all functions. The display press the confirm key. The preference will flash and
will tell the operator if errors have occurred. allow you to scroll through the choices. When the
correct preference is chosen, use the confirm key to
lock in the preference for the display. The escape
key will allow you to leave this application.
BD06F176
S h o u ld a n e r r o r me s sa g e d is p la y , p r e s s t h e
confirmation button to acknowledge and begin again.
4005-12
Clutch Calibration
After warming the oil temperature:
1. Park the machine on a firm level surface.
2. Place the Transmission Control Lever in
NEUTRAL.
3. Set the Park Brake.
4. With the engine running, at idle, enter the
Service Screen Menu and scroll to Config.
BD06F196
If, conditions are not correct, an error message will
appear and guide the operator or technican.
There are six, if conditions not met, screens:
Not in neutral
Park Brake OFF
Machine moving
Oil temp too low
Oil temp too high
BD06F202
Engine RPM low
Use the confirm and arrow button to scroll to the
screen shown above. At this screen push the confirm Engine RPM high
button again. If conditions are correct the operator or technican will
see six calibration screens pass. They will display in
this order:
Adjust K1
Adjust K2
Adjust K3
Adjust K4
Adjust KV
Adjust KR
Once the process is completed this screen will direct
the operator or technican to shut the engine OFF and
then re-start.
BD06F195
If the process is not completed the operator or
This screen will prompt the operator or technican to technican will be prompted to escape.
confirm or escape.
4005-13
Auto Idle
Idling can be changed from automatic to a fixed rate.
The fixed idle rate is defined as Standard Idle at 900
RPM. Highlight the auto idle selection by using the
arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.
Display Menu
The disp lay men u can be use d to cha nge the
background and brightness of the screen. Use the
arrow keys to make your selection from the display
menu and press the confirm key to lock the selection
BD06F174
into memory. The screen display can be changed to
Options Menu suit working conditions for day and night separately.
Use the arrow keys to choose the options menu. RPM
Press the confirm key, and the options sub-menu will
Engine speed in RPM will show on the display if the
appear. The options menu will allow the operator to
engine speed is running up to 550 RPM’s, and will
choose options for the fan, idle.
disappear if the engine speed is lower than 300
Fan Auto RPM.
The fan can be set to run at automatic or the fan will MPH/KPH
run at maximum speed. Automatic is the more
common or preferred setting. It will switch between Vehicle speed will show on the display if it is up to 1.0
high speed, low speed, or reverse as conditions MPH / 1.5 KPH and will disappear if the vehicle
require depending on actual temperature of the speed is less than 0.6 MPH / 1.0 KPH.
coolant, turbocharger air, transmission oil, and
hydraulic oil.
The operator can choose fan speed or reversing
capabilities. Highlight the fan auto selection by using
the arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.
4005-14
RETRIEVING FAULT CODES

General Fault Code Identification Fault Code Grouping
1. Press and hold the escape key and up arrow key 1. 1000 to 1999 vehicle errors.
for more than 2 seconds to access the fault
2. 2000 to 2999 not used.
codes.
3. 3000 to 3999 engine errors.
4. 4000 to 4999 transmission errors.
5. 5000 to 5999 eltro-hydraulic system errors.
C
A� 6. 6000 to 6999 reserved.
7. 7000 to 7999 reserved.
8. 8000 to 8999 optional equipment IE: GPS.
D�
B� 9. 9000 to 9999 internal AIC errors.
BD06H037
A. ESCAPE KEY
B. ENTER KEY
C. UP KEY
D. DOWN KEY
2. Yellow Faults, buzzer will beep once every 2

seconds:
A. Operator can acknowledge it by pressing the
enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
D. Yellow lamp will stay ON.
E. Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer will be continuous,
alternating sounds:
A. Operator can acknowledge it by pressing the
enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.
4005-15
VEHICLE FAULT CODES
CODE DEFINITION POSSIBLE STEPS FOR REPAIR
1310 Hydraulic filter blocked Change filter

1311 Engine air filter blocked Change filter
1312 Hydraulic oil temperature above normal 1. Stop machine operations
2. Run engine at 1500 rpm
1313 Hydraulic oil temperature to high 3. Check fan operation
1314 4. Check cooling core for clogs
Transmission oil temperature above normal
1315 Transmission oil temperature to high
1. Stop machine operations
1316 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
1317 Steering pressure too low 3. Check steering system for operation
4. Check steering system for leaks
1318 Engine coolant temperature above normal 1. Stop machine operations
1319 3. Check fan operation
Engine coolant temperature high - critical
4. Check radiator core for clogs
1320 Engine oil pressure too low 1. Stop machine operations
2. Check engine oil level
1321 Engine oil pressure below normal 3. Check pressure sender unit
1. Check engine oil for proper type
1322 Engine oil pressure above normal 2. Check pressure sender unit
1323 Battery voltage low
Check charging system
1324 Battery voltage high
1325 Oil temperature too high 2. Run engine at 1500 rpm
3. Check sending unit
1326 Coolant level low Fill radiator level
1327 Moved during accelerated idle No information available at time of print.
1328 Moving when shifting to low idle No information available at time of print.
Electrical charging system voltage low - 1. Stop machine operations
1331 2. Check charging system
critical level
1332 Water detected in fuel Drain fuel filter
1333 Engine overspeed Check engine speeds
1334 Intake manifold temperature high - critical Check for defective or clogged after cooler
1335 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
4005-16
1336 Transmission oil filter blocked Replace filter
NOTE: The following fault codes are for optional climate controlled heating and air conditioning system.
DESCRIPTION AND POSSIBLE

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

1. Check sensor for short circuit to ground or
open circuit.
1910 Short circuit evaporator temperature sensor
2. Check harness between control module and
relay.
1. Verify if the system controls are functioning
Water valve motor output failure, does not properly when requesting heat or AC.
1919
work correctly 2. The motor is working in a degraded mode,
replace valve.
1. Turn system on with fan speed on low, verify
position of flap.
Recirculation actuator DC motor output failure, 2. Place the fan speed on high, check position of
1920
does not work correctly flap.
3. Check harness between controller and flap
motor.
1. Check for proper connection of relay.
2. Replace relay with known good relay and retest
system.
1921 AC relay output failure, does not work. 3. Verify system activation when AC button is
pressed.
4. Check charge level of AC system.
4005-17
ENGINE FAULT CODES

CODE DEFINITION
STEPS FOR REPAIR
3002 Short circuit in wiring or in accelerator pedal.

Foot throttle sensor signal above range max.
Check wiring or replace accelerator pedal.
Short circuit in wiring or in accelerator pedal.
3003 Foot throttle sensor signal below range min.
Check wiring or replace accelerator pedal.
3004 Foot throttle sensor - no signal Check wiring or replace accelerator pedal
Sensor defective or short circuit to external
Coolant temperature sensor signal above
3007 source.
range max.
Check wiring or replace sensor.
Coolant temperature sensor signal below Sensor defective or short circuit to ground.
3008
range min. Check wiring or replace sensor.
Sensor defective or short circuit to ground.
3016 Fuel temperature signal below range min.
Boost pressure sensor signal above range
3019 source.
max.
Difference of ambient and boost pressure is out
3022 Boost pressure sensor signal not plausible of range.
Atmospheric pressure sensor signal not
3023
plausible
Ambient pressure sensor inside ECU is defect.
Atmospheric pressure sensor signal above
3024 Replace ECU (not necessary if never running in
range max.
high altitude and if turbocharger is without VGT)
Atmospheric pressure sensor signal below
3025
range min.
Inaccurate oil pressure sensor or defect (e.g. too
low oil level, leakage...) in the oil system.
3028 Oil pressure sensor pressure too low
Check oil pressure sensor for accuracy and
check oil system.
3029 Oil pressure sensor short-circuit to battery source.
3030 Oil pressure sensor short-circuit to ground
Oil temperature sensor signal above range
3034 source.
max.
Oil temperature sensor signal below range Sensor defective or short circuit to ground.
3035
min. Check wiring or replace sensor.
3037 Boost pressure sensor signal low
4005-18

CODE DEFINITION
STEPS FOR REPAIR
Vehicle speed sensing hardware conversion

3043 No information available at time of print.
error
3046 Vehicle speed sensing signal not plausible No information available at time of print.
3051 Alternator voltage governor defect.

Battery voltage to ECM too high
Replace alternator governor device or alternator.
Battery defect, alternator defect, wiring problems
(too high resistance) or ECU defect. Occurrence
3052 Battery voltage to ECM too low possible during cold start.
Replace battery or alternator. Check ECU and
wiring.
Check the wiring and the injection signals,
3062 Cylinder 1 signal low
replace ECU
3066 Check the wiring and the injection signals,

Cylinder 5 signal low
replace ECU.

replace ECU.
replace ECU.

replace ECU.
replace ECU.
3161 Fan actuator signal low No information available at time of print.
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3280 Sensor supply voltage 1 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Insufficient battery voltage, defect in wiring
harness, electrical failure connected sensors or
3281 in the EDC.
Sensor supply voltage 1 low
replace EDC
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3283 Sensor supply voltage 2 high
replace EDC
4005-19

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

harness, electrical failure connected sensors or
in the EDC.
3284 Sensor supply voltage 2 low
replace EDC
Turbo compound monitoring signal not
3290 No information available at time of print.
plausible
Progressive power derate with increasing time
from alert. If engine protection shutdown feature
Engine oil pressure sensor circuit - data
3801 is enabled, engine will shut down 30 seconds
incorrect
after red lamp starts flashing.
Engine speed/positions sensor circuit - lost Engine will die and will not start.
3802
one of two signals from sensors Check wiring or replace sensors.
3803 Engine control module - critical internal failure Possible none on performance or severe derate.
Progressive power derate with increasing time
after alert. If Engine Protection Shutdown feature
Engine coolant level sensor circuit - data
3804 is enabled, engine will shut down 30 seconds
incorrect
after red lamp starts flashing.
Engine control module - critical internal
3805 Possible none on performance or severe derate.
hardware failure
3806 Cylinder power imbalance between cylinders Engine will possibly have rough idle or misfire.
Accelerator pedal position sensor circuit - low
3807 Calibration dependent power and speed derate.
frequency
3808 Accelerator pedal position sensor circuit - high

Calibration dependent power and speed derate.
frequency
Possible white smoke, loss of power, or hard
starting.
3809 Water in fuel sensor circuit - shorted high Check battery voltage, check wiring for correct
replace EDC.
Possible white smoke, loss of power, or hard
starting.
3810 Water in fuel sensor circuit - shorted low Check battery voltage, check wiring for correct
replace EDC.
3811 Engine hot after shutdown No action taken by the ECM.
3812 Low oil level in the sentinel makeup oil tank None on performance. Sentinel deactivated.
No engine protection for OEM temperature.
3813 Temperature sensor signal input - shorted low
replace EDC.
4005-20

CODE DEFINITION
STEPS FOR REPAIR
External speed input (multiple un Engine will die and will not start.
3814
synchronization) - data incorrect Check wiring or replace sensors.
Accelerator pedal idle validation circuit -
3815 Engine will idle only.
shorted low
No engine protection for OEM temperature.
3816 Temperature sensor signal input - shorted Check battery voltage, check wiring for correct
high voltage supply of the sensor and the EDC,
replace EDC.
Electronic service tool or other datalink will
Data transmission error on J1587/J1922 data
3817 possibly not operate.
link
Check wiring.
Accelerator pedal idle validation circuit - out of
3818 Engine will idle only.
calibration
3819 SAE J1939 multiplexing accelerator pedal

Engine will idle only.
sensor system error
3820 SAE J1939 multiplexing remote throttle - data

The engine will not respond to the remote throttle.
error
3821 SAE J1939 multiplexing PGN time-out error
possibly not operate.
3822 Data transmission error on J1587/J1922 data Electronic service tool or other datalink will
link possibly not operate.
3823 Supply voltage low at engine brake circuit 1 Engine brake 1 can not be activated.
3824 Engine shutdown commanded by J1939 No action taken by the ECM.
3825 SAE J1939 data link - wrong transmission rate
Injector solenoid valve cylinder #1 circuit -
3826
open circuit
3827
open circuit
3828
open circuit
Amperage to injector is shut off.
3829
open circuit
3830
open circuit
3831
open circuit
The ECM turns off the FSO supply voltage. The
3832 Fuel shutoff valve circuit - shorted low
engine will shut down.
None on performance. Fuel shutoff valve will stay
3833 Fuel shutoff valve circuit - shorted high
open.
3834 Supply voltage low at engine brake circuit 2 Engine brake 2 can not be activated.
4005-21

CODE DEFINITION
STEPS FOR REPAIR
Yellow lamp is lit until high battery voltage

Electrical charging system voltage high -
3835 condition is corrected.
warning level
Check charging circuit.
3836 Auxiliary input/output #2 circuit - shorted high No action taken by the ECM.
3837 Power lost without ignition off Possible no noticeable performance effects OR
possibility of engine dying OR hard starting. Fault
3838 Engine control module data lost information, trip information, and maintenance
monitor data will possibly be inaccurate.
3839 Auxiliary input/output #3 circuit - shorted high No action taken by the ECM.
3840 Remote accelerator pedal position sensor None on performance if remote throttle is not
circuit - shorted low used. Check wiring or replace sensor.
3841 At least one multiplexed device will not operate

SAE J1939 multiplexing configuration error
properly.
3842 None on performance. J1939 devices will

SAE J1939 data link - cannot transmit
External speed input (multiple un

3843
synchronization) - data incorrect
3844 Accelerator pedal position sensor supply

voltage circuit - shorted low
Yellow lamp is lit until low battery voltage
condition is corrected. The ECM will possibly
increase idle speed and deactivate idle
3845 Electrical charging system voltage low -
decrement switch if idle speedup is enabled. The
warning level
engine will run continuously if “ICON” is active
(automotive only).
Check charging circuit.
Remote accelerator pedal position sensor None on performance if remote throttle is not
3846
circuit - shorted high used. Check wiring or replace sensor.
3847 Accelerator pedal position sensor supply

voltage circuit - shorted high
3848 Voltage low at waste gate actuator #1 Engine will run derated.
3849 Intake manifold pressure senor - general error Engine is derated to no air setting.
3850 Add OEM/vehicle diagnostic codes have been

None on engine performance.
logged. Check ECM’s for DTC’s
3851 Error detected at OEM harness Pin34 and 32 Multiple unit synchronization is disabled.
3852 Voltage high at waste gate actuator #1 Engine will run derated.
3853 Voltage low at waste gate actuator #2 Engine will run derated.
Engine oil burn valve solenoid circuit - shorted
3854 None on performance. Sentinel deactivated.
low
3855 Voltage high at waste gate actuator #2 Engine will run derated.
4005-22
TRANSMISSION FAULT CODES
1. Check the cables from the TCU to the FNR

switch.
4113 Logical error at FNR switch 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch.
switch.
4114 Logical error at direction select signal 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.
1. Check the cables from the TCU to the
4116 Logic error at park brake status instrument cluster connector 2 pin 6.
2. Check park brake switch.
switch.
4117 Logic error at direction select signal 2 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.
4119 Short circuit to ground at ride control 1. Check the cables from the TCU to the ride
control relay.
4120 Short circuit to battery voltage at ride control 2. Check the connectors from the TCU to the ride
control relay.
4121 Open circuit at ride control 3. Check the ride control relay.
Short circuit to battery voltage or open circuit 1. Check the connectors.
4133
at temperature sensor 2. Check the temperature sensor.
4134 Short circuit to ground at temperature sensor
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4135
at converter output temperature sensor 2. Check the connectors.
3. Check the temperature sensor.
Short circuit to ground at converter output
4136
temperature sensor
1. Check the cables from TCU to the sensor.
Short circuit to battery voltage or open circuit 2. Check the connectors.
4137
at parking brake sensor input 3. Check the parking brake sensor.
4145 Short circuit to battery voltage or open circuit 1. Check the parking brake fuse.
at engine speed sensor 2. Check the parking brake relay.
4146 3. Check the parking brake solenoid.
Short circuit to ground at engine speed sensor
2. Check the connectors.
3. Check the speed sensor.
4147 Logical error at engine speed sensor input
NOTE: This fault code is reset after power up of the
TCU. It is also reset if the signal is above zero
speed threshold.
4005-23
Short circuit to battery voltage or open circuit

4148 1. Check the cables from TCU to the sensor.
at turbine speed sensor input
Short circuit to ground at turbine speed sensor 3. Check the speed sensor.
4149
input
4150 Logical error at turbine speed sensor input 3. Check the speed sensor.
TCU.
Short circuit to battery voltage or open circuit
4151 1. Check the cables from TCU to the sensor.
at intermediate speed sensor input
Short circuit to ground at intermediate speed 3. Check the speed sensor.
4152
input
Logical error at intermediate speed sensor 3. Check the speed sensor.
4153
input
TCU.
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4154
at output speed sensor 2. Check the connectors.
4155 Short circuit to ground at output speed sensor 3. Check the speed sensor.

4156 Logical error at output speed sensor 3. Check the speed sensor.
TCU.
1. Check the sensor signal of the output speed
sensor.
2. Check the connector connected to the output
Output speed zero, does not match other speed.
4158
speeds. 3. Check the cable from the TCU to the sensor.
TCU.
1. Check the cluster controller.
4160 Invalid gear range restriction (CAN) 2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
4180 Vehicle controller time-out (CAN)
1. Check the cluster controller.
4185 Invalid test mode signal (CAN) 2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
4186 Invalid park brake status (CAN)
4005-24
4209 Short circuit to battery voltage at clutch K1

4210 Short circuit to ground at clutch K1
4211 Open circuit at clutch K1
1. Check the cable from the TCU to the
4216 Short circuit to ground at clutch K3 transmission control valve.
4217 Open circuit at clutch K3 2. Check the connectors from the TCU to the
transmission control valve.
4225 Short circuit to battery voltage at clutch K4 3. Check the regulator resistance.
4. Check internal wire harness of the transmission
control valve.
4228 Short circuit to battery voltage at clutch KV
4229 Short circuit to ground at clutch KV
4230 Open circuit at clutch KV
4231 Short circuit to battery voltage at clutch KR
4232 Short circuit to ground at clutch KR
4233 Open circuit at clutch KR
4241 Short circuit to ground at backup alarm relay 1. Check the cable from the TCU to the backup.
alarm relay.
Short circuit to battery voltage at backup alarm 2. Check the connectors from the backup alarm
4242
relay relay to TCU.
3. Check the resistance of backup alarm relay
4243 Open circuit at backup alarm relay circuit.
1. Check pressure at clutch K1.
2. Check main pressure in the system.
4273 Slippage at clutch K1 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
5. Replace clutch.
5. Replace clutch.
4005-25

5. Replace clutch.
1. Check pressure at clutch KV.
4277 Slippage at clutch KV 3. Check signal at internal speed sensor.
5. Replace clutch.
1. Check pressure at clutch KR.
4278 Slippage at clutch KR 3. Check signal at internal speed sensor.
5. Replace clutch.
1. A critical stop function warning has occurred.
2. Red stop indicator comes on and continuous
buzzer sounds.
3. Stop machine and perform required service on
4279 Oil temperature at valve body is above limit the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
Engine speed is measured above 5,000 rpm
4281 Check engine speed sensor
for 0.2 seconds
1. Check oil filter.
2. Check wiring from TCU to filter maintenance
4282 TCU sensed a voltage at oil filter maintenance switch.
switch out of the allowed range (dirty filter) 3. Check filter maintenance switch (measure
resistance).
4284 Overspeed output No information available at time of print.
4288 Engine torque or engine power overload No information available at time of print.
4289 Transmission output torque overload No information available at time of print.
4290 Transmission input torque overload No information available at time of print.
1. A critical stop function warning has occurred.
2. Red stop indicator comes on and continuous
buzzer sounds.
Oil temperature at converter output is above 3. Stop machine and perform required service on
4291
limit the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
1. Check the cables from the TCU to the joystick.
2. Check the connectors from the TCU to the
4292 Joystick status indicator short-circuit to ground joystick.
3. Check the resistance of the joystick.
4005-26

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

Configuration error
vehicle.
4339 Application error (ZF internal) Replace the TCU.
4341 Clutch calibration fault
Do the transmission clutch calibration procedure.
4342 Clutch adjustment data lost
4005-27
INSTRUMENT CLUSTER FAULT CODES

CODE DEFINITION
STEPS FOR REPAIR
9128 CAN timed out during operation

If error is permanent or repeats often, check CAN
9129 CAN timed out during operation wiring harness and connections on the CAN bus
circuits.
9130 CAN timed out during operation
4005-28
NOTES
SECTION INDEX
STEERING
Removal and Installation of Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001

Steering Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002
Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005
Center Pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006
Auxiliary Steering Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5007
Section
5001
REMOVAL AND INSTALLATION OF

STEERING COMPONENTS

5001-2
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5001-3
STEERING CONTROL VALVE

Removal STEP 7
STEP 1
Remove the cab skirts from the cab or canopy.
STEP 2
Remove all dirt and grease from steering control
valve.
STEP 3
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.
BD06J100
STEP 4 Remove the mounting nut and washers from the
Tag hoses connected to steering control valve. steering shaft.
STEP 5 STEP 8
BD06G262 BD06J101
Disconnect hoses from steering control valve, cap or Remove the steering wheel from the shaft.
plug the fittings and hoses, turn off the vacuum
pump.
STEP 9
STEP 6
BD06J102
Remove the six mounting screws from the instrument

BD06J099
cluster cover.
Remove the center cap from the steering wheel.
5001-4
STEP 10 STEP 13
BD06J103 BD06J106
D is c o n n e c t th e w i re s t o t h e sw i tc h e s o n t h e Disconnect the ignition switch.

instrument cluster cover.
STEP 14
STEP 11
BD06J107
BD06J104. Remove the six mounting screws for the left and right
Rem ove t he two m ounting s crews f rom the hand trim.
instrument cluster.
STEP 15
STEP 12
BD06J108
BD06J105. If equipped, remove the mounting bolts for the right
Disconnect the wires to the instrument cluster. side brake pedal.
5001-5
STEP 16 STEP 19
BD06J109 BD06J112
Remove the spacer block from the slot in the floor Pull floor mat away from the column and remove the
mat. lower trim from the column.
STEP 17 STEP 20
BD06J110 BD06J113
Remove the snap ring from the pin, remove the right Remove the four mounting bolts for the steering
pedal. control valve.
IMPORTANT: Have an assistant support and remove the
STEP 18 valve while removing the mounting bolts.
BD06J111
Remove the two mounting screws from the lower

console trim.
5001-6
Installation STEP 24
STEP 21
BD06J111
Install the lower trim onto the column, install and

BD06G264
tighten the two mounting screws mounting the lower
Put the rubber bushing on the spacer with the trim, place the floor mat into position.
tapered end towards the steering valve.
STEP 25
STEP 22
Have an assistant push the valve into place while
turning the steering shaft, this will engage the
splines.
STEP 23
BD06J110
If equipped, install the right pedal pivot onto the left

pedal, install the snap ring onto the pin.
STEP 26
BD06J113
Install and tighten the four mounting bolts for the

steering control valve.
BD06J109
Place the spacer block into the slot in the floor mat.
5001-7
STEP 27 STEP 30
BD06J108 BD06J105.
Install and tighten the mounting bolts for the right Connect the wires to the instrument cluster.
side brake pedal.
STEP 31
STEP 28
BD06J104.
BD06J107 Install and tighten the two mounting screws for the
Install and tighten the mounting screws for the left instrument cluster.
and right hand trim.
STEP 32
STEP 29
BD06J103
BD06J106 Connect the wires to the switches on the instrument
Connect the ignition switch. cluster cover.
5001-8
STEP 33 STEP 36
BD06J102 BD06G262
Install and tighten the six mounting screws for the Start the vacuum pump, remove the caps and plugs
instrument cover. the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
STEP 34 removal, remove and discard the tags.
STEP 37
Turn off and remove the vacuum pump from the
reservoir, install and tighten the reservoir fill cap.
STEP 38
Start and run the machine at low idle, turn the wheel
to full left and then to full right, stop the machine and
check for leaks.
STEP 39
BD06J100
Install the skirts onto the cab or canopy.
Install the steering wheel, install and tighten the
mounting nut and washers. STEP 40
Check fluid level in hydraulic reservoir. Add oil as
STEP 35 required. See Section 1002 for specifications.
BD06J099
Install the center cap on the steering wheel.

5001-9
NOTES
5001-10
AUXILIARY STEERING PRIORITY VALVE

1. Park loader on level ground and lower bucket to 1. Connect and hand tighten fitting (5) to the elbow
ground. Put transmission in NEUTRAL, apply in the steering priority valve.
parking brake, and shut down engine, 2. Install cap screws, washers and nuts (6).
2. Put master disconnect switch in OFF position. 3. Tighten pressure tube fitting (5).
3. Remove all dirt and grease from auxiliary 4. Tighten the nuts (6).
steering priority valve and adjacent area. See
5. Connect and tighten pressure hose (7).
illustration on page 11.
6. Connect and tighten steering pressure hose (9).
4. Remove hydraulic reservoir fill cap.
7. Connect and tighten steering load sensing hose
5. Connect a vacuum pump to hydraulic reservoir. (1).
6. Start vacuum pump. 8. Connect and tighten load sensing hose (2).
7. Tag and disconnect suction hose from the 9. Connect electrical connector to the pressure
suction port (4) from auxiliary steering pump and switch (3).
motor. Install a cap on the fitting and a plug in the
hose. 10. Connect electrical connector to the steering
solenoid (8).
8. Tag and disconnect tank return tube (10) from
the priority valve. Install a cap on the elbow and 11. Start vacuum pump.
a plug in the tube. 12. Connect and tighten tank return tube (10).
9. Stop the vacuum pump. 13. Connect and tighten hose to auxiliary steering
10. Tag and disconnect the wiring from the steering pump port (4).
solenoid (8). 14. Stop vacuum pump. Disconnect vacuum pump
11. Tag and disconnect the wiring from the pressure from hydraulic reservoir.
switch (3). 15. Install fill cap on hydraulic reservoir.
12. Tag and disconnect load sensing hose (2) from 16. Put battery disconnect switch in ON position.
auxiliary steering priority valve. Install a cap on Start engine and run at low idle for 30 seconds.
the elbow and a plug in the hose. Stop engine and check for leaks.
13. Tag and disconnect load sensing hose (1) from 17. Check to make sure priority valve operates
the priority valve. Install a cap on the elbow and correctly. See Section 5002.
a plug in the hose.
18. Check fluid level in hydraulic reservoir. Add oil as
14. Tag and disconnect steering pressure hose (9) required. See Section 1002 for specifications.
from priority valve. Install a cap on the fitting and
a plug in the hose.
15. Tag and disconnect pressure hose (7) from
priority valve. Install a cap on the fitting and a
plug in the hose.
16. Loosen fitting (5) connected to elbow installed in
steering priority valve.
17. Support auxiliary steering priority valve. Remove
four nuts (6), cap screws, and washers.
18. Remove auxiliary steering priority valve.
5001-11
17�
7�
11�
9�
6�
2� 9� 2�
15� 10�
18�
1�
3� 10�
12� 13�
4�
8�
11�
4�
1�
16�
5�
7� 14
W270-4R015
1. STEERING LOAD SENSING HOSE TO PRIORITY VALVE 10. TANK RETURN TUBE
2. STEERING LOAD SENSING HOSE TO STEERING VALVE 11. REAR CHASSIS
3. PRESSURE SWITCH 12. HYDRAULIC TANK
4. SUCTION PORT 13. FILTER MANIFOLD
5. PUMP OUT PRESSURE TUBE FITTING 14. PRIORITY VALVE
6. CAP SCREWS AND NUTS 15. MANIFOLD AUXILIARY STEERING
7. PRESSURE HOSE 16. PUMP MOTOR
8. STEERING SOLENOID 17. STEERING ORBITROL
9. STEERING PRESSURE HOSE 18. TANK BOTTOM
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION
5001-12
PRIORITY VALVE
NOTE: When disconnecting hydraulic fittings, plug 1. Install all new O-rings.
hoses and cap fittings to prevent entry of foreign 2. Install four bolts with washers (7) through
matter into hydraulic system. mounting holes in the priority valve.
1. Park loader on level ground and lower bucket to 3. Mount the priority valve on the pumps and hand
ground. Put transmission in NEUTRAL, apply tighten the four mounting bolts (7).
parking brake, and shut down engine.
4. Install four bolts with washers (8) and hand
2. Put master disconnect switch in OFF position. tighten.
3. Remove all dirt and grease from the priority valve 5. Tourque mounting bolts (7 and 8) to 73.5 to 90.5
(9) and adjacent area. See illustration on page 9. Nm (750 to 900 pound-inches).
4. Remove hydraulic reservoir fill cap. 6. Connect loader valve hose (6).
5. Connect a vacuum pump to hydraulic reservoir. 7. Install pilot pressure tubes (3 and 4).
6. Start vacuum pump. 8. Connect steering pump pressure hose (5).
7. If equiped, tag and disconnect load sensing tube 9. Connect the load sense hose (2).
from e lbo ws installe d in au xilia ry steering
10. Connect tank return hose (1).
solenoid valve and the priority valve (9).
11. If equiped, connect fitting to elbow installed in the
8. If equiped, loosen fitting, auxiliary steering
priority valve (9). Tighten tee, auxiliary steering
supply tube, and tee. Disconnect fitting from
supply tube, and fitting.
elbow installed in the priority valve.
12. If equiped, connect load sensing tube to elbows
9. Disconnect tank return hose (1).
installed in auxiliary steering solenoid valve and
10. Disconnect the load sense hose (2). steering priority valve (9).
11. Disconnect steering pump pressure hose (5). 13. Stop vacuum pump.
12. Remove pilot pressure tubes (3 and 4). 14. Disconnect vacuum pump from hydraulic
reservoir.
13. Disconnect loader valve hose (6).
15. Install fill cap on hydraulic reservoir.
14. Support steering priority valve (9). Remove four
b o lts an d w as h e r s (8 ) a n d fo u r b o lt s a n d 16. Put battery disconnect switch in ON position.
washers (7). Start engine and run at low idle for 30 seconds.
Stop engine and check for leaks.
15. Remove steering priority valve (9).
17. Check to make sure the priority valve operates
correctly. See Section 5002.
18. Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
5001-13
BC06A243
1. RETURNO TO TANK 6. TO LOADER VALVE

2. STEERING LOAD SENSE 7. BOLT
3. PILOT PRESSURE TUBE 8. MOUNTING BOLTS
4. PILOT PRESSURE TUBE 9. PRIORITY VALVE
5. TO STEERING CONTROL VALVE
PRIORITY VALVE ILLUSTRATION
5001-14
AUXILIARY STEERING PUMP AND MOTOR

Removal 7. Stop and disconnect vacuum pump. Install fill
cap in hydraulic reservoir.
1. Park loader on level ground and lower bucket to
ground. Put transmission in NEUTRAL, apply 8. Connect ground cable (3) to ground stud of
parking brake, and shut down engine, auxiliary steering pump and motor (7) following
tag installed during removal.
2. Put master disconnect switch in OFF position.
9. Connect positive cable (2) to B+ stud of auxiliary
3. Tag and disconnect two wiring harness wires (1) steering pump a nd mo tor (7 ) following tag
from auxiliary steering pump and motor (7) installed during removal.
solenoid. See illustration on page 15.
10. Connect wiring harness wires (1) to auxiliary
4. Tag and disconnect positive cable (2) from B+ steering pump and motor (7) following tags
stud of auxiliary steering pump and motor (7). installed during removal.
5. Tag and disconnect ground cable (3) from 11. Remove and discard tags installed during
ground stud of auxiliary steering pump and motor removal.
(7).
12. Put master disconnect switch in ON position.
6. Remove hydraulic reservoir fill cap.
13. Start and run engine at low idle and raise bucket
7. Connect a vacuum pump to hydraulic reservoir. 500 mm (20 inches) above ground. Check that
8. Start vacuum pump. auxiliary steering light on information center is
OFF.
9. Disconnect suction hose (4) from elbow installed
in auxiliary steering pump and motor (7). Install a IMPORTANT: In following Step, do not run auxiliary
plug in suction hose and cap on elbow. steering pump and motor continuously for more than
20 seconds at a time without a two minute cool down.
10. Stop vacuum pump.
14. With engine at low idle and machine steering
11. Loosen fittings on pressure tube (5). straight ahead, turn key switch to OFF position to
12. Support auxiliary steering pump and motor (7). stop engine and then immediately back to ON
Remove nuts (6), bolts, and washers securing position (not START position). Auxiliary steering
auxiliary steering pump and motor (7). pump and motor should start operating
immediately. Check that auxiliary steering light
13. Remove pressure tube (5) and auxiliary steering o n in fo rma tion ce n ter is O N a n d au xiliar y
pump and motor (7). steering pump and motor is operating.
15. Turn steering wheel all the way to left and right to
make sure that auxiliary steering pump and
Installation motor operates correctly.
1. Connect and hand tighten pressure tube (5) to 16. Restart engine. Check that auxiliary steering light
auxiliary steering pump and motor (7). See on information center stays ON and auxiliary
illustration on page 15. steering pump and motor is operating. After
2. Position auxiliary steering pump and motor (7) on about three seconds motor should stop operating
its mounting plate while connecting and hand and auxiliary steering light should go out.
tightening pressure tube (5) to auxiliary steering 17. Let engine run and allow batteries to recharge for
priority valve (8). a minimum of 10 minutes.
3. While supporting auxiliary steering pump and
mo t o r ( 7 ) h a v e a n a s si st a n t in s ta ll b o lt s,
washers, and nuts (6) to secure auxiliary steering
pump and motor (7).
4. Tighten pressure tube (5) fittings securely.
5. Start vacuum pump.
6. Remove plug from suction hose (4) and cap from
elbow. Connect suction hose to elbow installed in
auxiliary steering pump and motor (7).
5001-15
2� 5�
7� 11�
12� 1
9� 3�
4� 10�
11�
4�
7�
5� 8�
6�
W270-4R016
1. WIRING HARNESS 5. PRESSURE TUBE 9. TANK BOTTOM

2. POSITIVE CABLE 6. NUT (4) 10. HYDRAULIC TANK
3. GROUND CABLE 7. AUXILIARY STEERING PUMP AND MOTOR 11. REAR CHASSIS
4. SUCTION HOSE 8. AUXILIARY STEERING PRIORITY VALVE 12. MANIFOLD AUXILIARY STEERING
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
5001-16
STEERING CYLINDER
NOTE: When disconnecting hydraulic fittings, plug 1. Put steering cylinders (17) in position in machine.
hoses and cap fittings to prevent entry of foreign See illustration on page 17.
matter into hydraulic system.
2. Install the pivot pin (4) to secure rear of steering
1. Loosen the fill cap for the hydraulic reservoir to cylinders (17) to machine frame. Install spacer
release pressure in the reservoir, then tighten the (3), washer (2), and bolt (1) to secure pivot pin
fill cap. (4).
2. Disconnect grease hoses (16 and 20) from 3. Install washer (5) and nut (6), tighten nut (6).
steering cylinders (17). See illustration on page
4. Install pin (13) in front of steering cylinders (17).
17.
5. Install and tighten bolt and washer (21).
3. Disconnect hydraulic hoses (7, 8, 18, and 19)
from steering cylinders (17). 6. Install washer (14) on bolt (15), put bolt (15)
through pin (13).
4. Remove locknut (9), washer (10), sealing ring
(11), and polymer spacer (12). 7. Install polymer washer (12), sealing ring (11),
washer (10), and nut (9). Tighten nut (9).
5. Remove bolt (15) and hardened washer (14).
8. Connect hose assemblies (7, 8, 18, and 19) to
6. Remove bolt and washer (21), remove pin (13).
steering cylinders (17).
7. Remove nut (6), wahser (5), bolt (1), washer (2),
9. Connect grease hoses (16 and 20) to steering
and spacer (3) securing pivot pin (4) at rear of
cylinders (17).
steering cylinders (17).
10. Tighten hydraulic reservoir fill cap.
8. Use a suitable driver and drive pivot pin (4) out of
steering cylinders (17). 11. Start engine.
9. Remove steering cylinders (17). 12. Turn steering wheel all the way to right and then
to the left several times.
13. Stop engine. Check the hydraulic oil level. See
Section 1002 for specifications.
5001-17
BC06A242
1. BOLT 8. HOSE LEFT CYLINDER CLOSED END 15. BOLT

2. WASHER 9. NUT 16. GREASE HOSE
3. SPACER 10. WASHER 17. STEERING CYLINDERS
4. PIN 11. SEALING RING 18. HOSE RIGHT CYLINDER CLOSED END
5. WASHER 12. POLYMER SPACER 19. HOSE RIGHT CYLINDER ROD END
6. NUT 13. PIN 20. GREASE HOSE
7. HOSE LEFT CYLINDER ROD END 14. HARDENED WASHER 21. BOLT AND WASHER
STEERING CYLINDER ILLUSTRATION
5001-18
NOTES
Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS,

AND TROUBLESHOOTING

5002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNDERSTANDING THE RESULTS OF THE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5002-3
SPECIAL TOOLS
B785789 B009638
OEM1239 380001731 FLOWMETER 380001739 PRESSURE TEST FITTING KIT
B797157
380001740 FLOWMETER FITTING KIT
TROUBLESHOOTING THE STEERING SYSTEM

NOTE: The steering hydraulic schematic is included in the 3. Do the main hydraulic pump test. See Section
hydraulic schematic. Refer to the rear pocket of this 8002. If the main pump is bad, repair or replace
manual. the main hydraulic pump.
1. Make sure the oil level in the hydraulic reservoir 4. Test the steering cylinders for leakage, refer to
is correct. Visually inspect the steering system instructions on page 9. If a steering cylinder is
for leakage and damage. leaking, repair or replace the steering cylinder.
2. Do the steering limit valve pressure test. Refer to
p ag e 7 . If the pr es su re is ab ov e o r b e lo w
specifications, adjust the steering limit valve.
5002-4
AUXILIARY STEERING SYSTEM PUMP TEST

Equipment Required
1. 380001731 Flowmeter
2. 380001740 Flowmeter fitting kit
Test Procedure
1
BB830300
1. AMMETER CLAMP
6. Connect the ammeter clamp (1) to the cable as
in illustration above.
7. Make sure that the parking brake is applied and
the bucket is on the floor.
W270-1R006
8. Make sure that the oil is at operating
1. ARTICULATION LOCK temperature.
1. Install articulation lock. 9. Make sure that the load valve for the flowmeter is
open (zero pressure).
NOTE: When performing this pressure check, always be
sure the articulation lock is in place, especially when 10. Start and run the engine.
working in the articulation joint areas. 11. Stop the engine and turn the key back to the On
2. Loosen and remove the outlet hose of the position.
Auxiliary Steering Pump from the Steering 12. Turn the steering wheel, this will activate the
Priority Valve. auxiliary steering pump.
3. Install a plug into the hose. 13. Turn the load valve on the flowmeter towards
4. Connect the inlet of the flowmeter to the outlet CLOSED until the pressure is 104 bar (1500 psi).
fitting on the Steering Priority Valve. 14. Read the flowmeter and ammeter gauges and
5. Install the outlet hose of the flowmeter in the record the readings.
hydraulic reservoir and hold in place with wire. 15. The flowmeter reading must not be less than
2 4.6 L /min, (6 .5 U .S. g pm ). Th e am mete r
reading must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.
5002-5
AUXILIARY STEERING SYSTEM MOTOR TEST

Test Equipment 5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
1. A 24 volt battery that is fully charged.
6. Turn the load control (8) until the voltmeter (7)
NOTE: A 24 volt battery system (two 12 volt batteries in a indicates 24 volts. Look at the ammeter (6) in the
series) is used for this test. A 12 volt battery system will tester. Make a record of the ammeter indication.
cause damage to the auxiliary steering motor.
2. A remote starter switch.
6� 7
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
System Tester.
Test Procedure 8�
1. Remove the connector that is between the
te rmin a ls o n th e m ag ne tic sw itch a nd th e
auxiliary steering motor.
2. Remove the auxiliary steering motor from the
B795328
auxiliary steering pump.
6. AMMETER
3. Remove the drive coupling from the auxiliary 7. VOLTMETER
steering motor (3). 8. LOAD CONTROL
4. Connect the auxiliary steering motor (3), remote 7. Hold the tachometer against the armature shaft.
starter switch (1) and tester (2) to the 24 volt Look at the tachometer. Make a record of the
battery system (5) as illustrated. indication.
8. Release the button on the remote starter
switch (1).
1� 2�
4�
3�
5
B790852
1. REMOTE STARTER SWITCH

2. TESTER
3. AUXILIARY STEERING MOTOR
4. AMMETER CLAMP
5. 24 VOLT BATTERY SYSTEM
5002-6
UNDERSTANDING THE RESULTS OF THE TEST

1. If the ammeter indication in step 6 was 30 4. If the armature did not turn, and the ammeter
amperes or less and the tachometer indication in indication was zero amperes, possible causes
st ep 7 wa s 69 5 0 r /min (rp m) or mor e, t he include the following:
auxiliary steering motor is good.
A. An open field coil.
2. If the armature speed was less than 6950 r/min
B. An open armature coil. After the motor is
(rpm) and the ammeter indication was higher
disassembled, look at the commutator on the
than 30 amperes, possible causes include the
armature. If the commutator is badly burned,
following:
the armature coil is probably open.
A. Damaged bearings.
C. Broken brush springs or worn brush springs.
B. Loose pole shoes.
5. If the armature speed was less than 6950 r/min
C. A short circuit in the armature coil. The (rpm) and the ammeter indication was less than
arm at ure c oil mus t be check ed on an 3 0 a mp e r es , po s s ibl e ca u s es in c lu d e th e
armatu re tester afte r the moto r is following:
disassembled.
A. Bad connections between the brushes and the
D. A ground connection in the field coil. field coil.
3. If the armature did not turn and the ammeter B. Dirty commutator.
indication was higher than 30 amperes, possible
6. If the armature speed was 6950 r/min (rpm) or
causes include the following:
more and the ammeter indication was more than
A. The motor terminal is in contact with the field 30 amperes, there is probably a short circuit in
frame. the field coil. A short circuit in the field coil is
difficult to find. It is recommended that a new
B. .A damaged bearing that will not let the
field frame assembly be installed.
armature turn.
5002-7
STEERING PRIORITY VALVE

NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002
Testing and Adjusting the Loader/Steering Pump differential Pressure.
Pressure Setting Test 2. Make sure that the temperature of the hydraulic
oil is at least 54° C (129° F).
3. To measure the temperature of the oil using the
instrument panel:
A. Press the program switch (left side of the
program/reset switch).
B. Press the up count switch to function 008.
C. Return the program switch to the OFF (center)
position.
4. Apply the parking brake.
5. Start and run the engine at full throttle.
6. Lower the lift arms and hold the control lever in
W270-1R006
the FLOAT position.
1. ARTICULATION LOCK
7. Hold the bucket control lever in the rollback
position.
1. Install articulation lock.
8. Continue holding until the specified temperature
IMPORTANT: When performing the following pressure of the oil is reached.
check and adjustment, the articulation lock must be
9. Stop the engine.
installed. Use caution when working in or near the
articulation area. 10. Remove the cap on the hydraulic reservoir to
release any pressure in the hydraulic system.
2� 1
BD03A086
1. STEERING PRIORITY VALVE

2. PUMP PRESSURE TEST PORT
11. Remove the dust cap from the test port (2).
12. Connect a 345 bar (5000 psi) pressure gauge to
the test port (2).
NOTE: Make sure when you connect the pressure gauge
that you do so in a manner that you can read the pressure
gauge while sitting in the operators seat.
5002-8
13. Start the engine and operate the machine at full Pressure Setting Adjustment
throttle.
14. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
15. Continue holding the steering wheel, and read
the pressure gauge.
16. The pressure gauge must indicate 239 to 243
bar (3465 to 3523 psi). If the pressure is not
correct, adjust the steering relief valve.
2� 1
BD03A086

2. “T” PORT
17. The adjusting screw is located inside the “T” port

on the steering priority valve.
18. Turn the adjusting screw clockwise to increase
the pressure setting. Turn the adjusting screw
counterclockwise to decrease the pressure
setting.
19. Repeat pressure test procedure.
20. If necessary, adjust the limit valve again until
within the specified range.
21. Stop the engine before removing the pressure
gauge.
5002-9
STEERING CYLINDER LEAK TEST

NOTE: Make sure all persons are clear of the area of the 9. Connect the tube to the rod end of the left-hand
center pivot. Make sure the center pivot is free of any steering cylinder.
obstructions.
10. Turn the machine all the way to the left.
1. Park the machine on a level surface.
11. Stop the engine.
2. Turn the machine all the way to the right.
12. Find the tube that is connected to the rod end of
3. Stop the engine and apply the parking brake. the right-hand steering cylinder. Disconnect the
tube from the right-hand steering cylinder.
4. Find the tube that is connected to the rod end of
the left-hand steering cylinder. Disconnect the 13. Install a plug in the tube.
tube from the left-hand cylinder.
14. Start and run the engine at full throttle.
5. Install a plug in the tube.
15. Turn the steering wheel to the left. Hold the
6. Start and run the engine at full throttle. steering wheel for a full left turn. Have another
person check for leakage at the opening of the
7. Turn the steering wheel to the right. Hold the
rod end of the right-hand steering cylinder.
steering wheel for a full right turn. Have another
person check for leakage from the opening of the 16. If there is constant leakage from the rod end, the
rod end of the left-hand steering cylinder. piston packing in the right-hand steering cylinder
is damaged. Repairs must be made. See Section
8. If there is constant leakage from the rod end, the
5005.
piston packing in the left-hand steering cylinder
is damaged. Repairs must be made. See Section 17. Connect the tube to the rod end of the right-hand
5005. steering cylinder.
5002-10
NOTES
Section
5005
STEERING CYLINDERS

5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5005-3
SPECIFICATIONS
Torque for piston cap screw ..................................................................1600 to 1830 Nm (1180 to 1350 pound-feet)
Torque for gland ............................................................................................339 to 475 Nm (250 to 350 pound-feet)
STEERING CYLINDER
Disassembly Inspection
1. Loosen and remove the lock screw (1) from the 1. Discard the O-ring (4), backup ring (3), wide seal
gland (2) and tube (18), see illustration on page (6), narrow seal (7), wiper (5), and bushing (8)
4. that were removed from the gland (2).
2. Fasten the cylinder in a vise with soft jaws. Be 2. Discard the seal (12), loader ring (11), cast iron
careful not to damage the tube (18). ring (10), and wear ring (13) that were removed
from the piston (14).
3. Loosen and remove the gland (2) from the tube
(18). 3. Clean all parts in cleaning solvent.
4. Pull the piston (14) straight out of the tube (18). 4. Check to be sure that the piston rod (9) is
straight. If the piston rod (9) is bent, a new piston
5. Fasten the rod eye on the piston rod (9) in the
rod (9) must be used.
vise and put a support below the piston rod (9)
near the piston (14). Use a shop cloth between 5. Inspect the inside of the tube (18) for deep
the support and the piston rod (9) to prevent grooves and other damage. If there is an y
damage to the piston rod (9). damage to the tube (18), a new tube (18) must
be used.
6. Loosen and remove the cap screw with washer
(15) that hold the piston (14). 6. Remove small scratches on the piston rod (9) or
inside the tube (18) with emery cloth of medium
7. Remove the piston (14) from the piston rod (9).
grit. Use the emery cloth with a rotary motion.
8. Remove the seal (12), loader ring (11), cast iron
7. Inspect the self-aligning bushings (17). Replace
ring (10), and wear ring (13) from the piston (14).
as required.
9. Remove the gland (2) from the piston rod (9).
10. Remove the O-ring (4), backup ring (3), wide
seal (6), narrow seal (7), wiper (5), and bushing
(8) from the gland (2).
5005-4
BC06A176
1. LOCK SCREW 7. NARROW SEAL 13. WEAR RING

2. GLAND 8. BUSHING 14. PISTON
3. BACKUP RING 9. PISTON ROD 15. CAP SCREW WITH WASHER
4. O-RING 10. CAST IRON RING 16. SNAP RING
5. WIPER 11. LOADER RING 17. SELF-ALIGNING BUSHING
6. WIDE SEAL 12. PISTON SEAL 18. TUBE
FIGURE 1 STEERING CYLINDER
5005-5
Assembly 18. Install the cap screw with washer (15) in the
piston (14).
1. If a new gland (2) is being installed, stamp the
part number of the cylinder on the new gland (2), 19. Install the piston (14) on the piston rod (9) and
see illustration on page 4. start the cap screw (15) into the piston rod (9).
2. Install the wide seal (6) in the gland (2) with the 20. Tighten the cap screw (15) to 1600 to 1830 Nm
lips toward the small end of the gland (2). (1180 to 1350 pound-feet).
3. Install the narrow seal (7) with the groove toward 21. Fasten the tube (18) in the vise. Be careful not to
the inside of the gland (2). damage the tube (18).
4. Install the bushing (8) in the gland (2). 22. Apply petroleum jelly to the O-ring (4) and
backup ring (3) on the gland (2) and to the
5. Install the wiper (7) into the gland (2) with the lip sealing surface in the tube (18).
out.
23. Lubricate the piston (14) and the inside of the
6. Install the O-ring (4) on the gland (2). The O-ring tube (18) with clean hydraulic oil.
(4) must be toward the small end of the gland (2).
24. Push the piston (14) straight into the tube (18).
7. Install the backup ring (3) on the gland (2). The Be careful not to damage the wear ring (13), seal
backup ring (3) must be toward the large end of (12), and cast iron ring (10) on the piston (14).
the gland (2). If the backup ring (3) is not flat on
both sides, the side that is not flat must be 25. When the piston (14) is in the smooth part of the
toward the O-ring (4). tube (18), start the gland (2) into the tube (18).
8. Fasten the rod eye on the piston rod (9) in a vise. 26. If the original gland and tube are being used:
9. Lubricate the piston rod (9) and the bore in the A. Tighten the gland to 340 to 475 Nm (251 to
gland (2) with clean hydraulic oil. 350 pound-feet) until the holes for the lock
screw (1) are aligned.
10. Push the gland (2) onto the piston rod (9). If
necessary, use a soft hammer to drive the gland B. Install and tighten the lock screw (1).
(2) onto the piston rod (9). C. If, after tightening the gland (2), the lock screw
11. Put a support below and near the end of the holes are not aligned, a new hole for the lock
piston rod (9). Put a cloth between the support screw (1) must be drilled. See the next step.
and the piston rod (9) to prevent damage to the 27. If a new gland (2) or tube (18) is being used:
piston rod (9).
A. Tighten the gland (2) to 339 to 475 Nm (250 to
12. Install a new wear ring (13) on the piston (14). 350 pound-feet).
13. Install a new loader ring (11) on the piston (14). B. Use a No. 26 drill and drill a hole half in the
14. Install a new seal (12) over the loader ring (11). gland (2) and half in the tube (18). Drill to a
depth of 11 mm (7/16 inch). Do not drill within
15. Install a new cast iron ring (10) on the piston 12 mm (1/2 inch) of a hole for the gland
(14). wrench.
16. Clean the threads on the end of the piston rod (9) C. Install and tighten the lock screw (1).
and the threads of the cap screw (15) using
Loctite cleaning solvent. Allow to dry.
17. Apply Loctite 243 to piston rod threads 6.4 mm
(1/4 inch) from open end of piston rod so that
there is 12.7 mm (1/2 inch) of Loctite 243 on
piston rod threads. DO NOT apply Loctite to first
6.4 mm (1/4/inch) of piston rod threads.
5005-6
NOTES
Section
5006
CENTER PIVOT

5006-2
TABLE OF CONTENTS
SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5006-3
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin.......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for 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 ........................................................................................................ Molydisulfide grease
Steering cylinder rod eyes...................................................................................................... Molydisulfide grease
SPECIAL TOOLS
380001730....................................................................................................................... Hand pump (hydraulic ram)
380001734....................................................................................................................................... 10 ton ram (long)
380001735........................................................................................................... Puller set, includes 24827 leg ends
380001736................................................................................Bearing cup and seal puller, includes 24850 adapter
380001729..............................................................................................................................Vacuum pump (12 volt)
CAS2212 .................................................................................. *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from 380001735)
BC06A175
CAS2212 DRIVER SET
5006-4
CENTER PIVOT
Disassembly 19. Disconnect the supply hose.
1. Remove all dirt and grease from the area of the 20. Install a cap on the hose and a plug in the fitting.
ce nte r pivo t. P ar k th e mac hin e o n a le ve l 21. Stop the vacuum pump.
surface.
22. Loosen and remove the self-locking nut and bolt
2. Lower the bucket until the bucket is flat on the that hold the pivot pin for the steering cylinder
floor. rod eye.
3. Stop the engine and apply the parking brake. 23. Remove the pivot pin from the rear frame and the
4. Remove the covers from both sides of the steering cylinder rod eye.
machine. 24. Remove the washer from the rear frame. Move
5. Disconnect the front wiring harness from the cab the steering cylinder out of the way.
floor. 25. Repeat steps 22, 23 and 24 for the other steering
6. Remove any tie straps that fasten the front wiring cylinder.
harness to the chassis near the center pivot. 26. Loosen and remove the Ferry head screws and
7. Loosen and remove the nut and washer that retainers that fasten the drive shaft to the front
fasten the chassis ground wire and cab ground yoke. Move the drive shaft out of the way.
wire to the studs. 27. Place two stands below and in contact with the
8. Loosen and remove the bolt, lock washer, and front frame.
nut that fasten the clamp on the front wiring 28. Install blocks between the rear axle and the rear
harness to the bracket on the rear frame. Move frame on both sides of the machine to prevent
the front wiring harness out of the way. the rear frame from tipping.
9. Loosen and remove the fill cap for the hydraulic 29. Put a jack in contact with both sides of the rear
reservoir. frame near the center pivot area. Use another
10. Connect a vacuum pump to the hydraulic jack at the rear of the machine to prevent the
reservoir. Start the vacuum pump. rear frame from tipping.
11. Disconnect the brake hose from the backside of 30. Loosen and remove the bolt (1), washer (2), and
front brake line bracket. spacer (3) that fasten the upper pivot pin (4) to
the front chassis (5), see illustration on page 5.
12. Install a plug in the tube and a cap on the fitting.
31. Use a prybar to remove the upper pivot pin (4).
13. Disconnect the hoses for the steering cylinder.
32. Loosen and remove the bolts (1) and washers
14. Install caps on the fittings and plugs in the hoses. (2) that fasten the lower pin plate (15) to the
15. Loosen and remove the bolts, lock washers, and lower pivot pin (10).
self-locking nuts that fasten the mounting bracket 33. Loosen and remove the bolts (1) and washers
for the hoses to the bracket on the front frame. (2) that fasten the lower pin plate (15) to the
16. Loosen and remove the bolts, flat washers, and bottom of the rear chassis (5).
self-locking nuts that fasten the bracket for the 34. Use the ram and hand pump to remove the lower
hoses to the rear frame. pivot pin (10).
17. Disconnect the return hose. 35. Install the puller on the bottom spacer (14), see
18. Install the cap on the hose and a plug in the Special Tools in this section.
fitting.
5006-5
1�
2�
3�
1�
4�
2�
7�
8�
9�
5�
10�
6� 6
16� 11�
8
14�
15�
12� 2� 2�
1� 1�
8� 13�
2�
1�
W270-5R006
1. BOLT 5. FRONT CHASSIS 9. UPPER PIVOT BEARING 13. BEARING RETAINER

2. WASHER 6. SEAL 10. LOWER PIVOT PIN 14. BOTTOM SPACER
3. SPACER 7. BEARING RETAINER 11. LOWER BEARING SPACER 15. LOWER PIN PLATE
4. UPPER PIVOT PIN 8. SHIM 12. LOWER PIVOT BEARING 16. REAR CHASSIS
FIGURE 1. CENTER PIVOT ASSEMBLY
5006-6
36. Remove the bottom spacer (14). Assembly
37. Release the parking brake. 1. Pack the bearing cones with grease. Be careful
38. Use prybars to turn the left rear wheel backwards not to mix the bearing cones.
and the right rear wheel forward to move the 2. Lubricate the bore in the top pivot with grease.
front of the rear frame to the left for access to the
bearings. Install blocks under the wheels to 3. Install a bearing cup (20) in the top pivot (22),
prevent the rear frame from moving. refer to Figure 2.
39. Apply the parking brake. 4. Install the bearing driver (17) and plate (21).
40. Hold the bearing retainer (13) in place and

17� 18� 19�
loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (13) and shims
(8) to the bottom of the rear pivot.
41. Remove the bearing retainer (13) and shims (8).
42. Remove the lower bearing spacer (11) from the
top of the lower pivot.
43. Loosen and remove the bolts (1) and washers 20�
(2) that fasten the bearing retainer (7) and shims
21� 22�
(8) to the top of the top pivot.
BC06A118
44. Remove the bearing retainer (7) and shims (8).
17. BEARING DRIVER 20. BEARING CUP
45. Use the puller to remove the seal (6) from the top 18. NUT 21. PLATE
of the bottom pivot. 19. SREW 22. TOP PIVOT
46. Use the puller to remove the seal (6) from the FIGURE 2.
bottom of the top pivot. 5. Tighten a nut (18) on the screw (19) until the
bearing cup (20) is seated in the bore of the top
47. Use an acceptable driver, the hydraulic ram, and
pivot (22). Remove the bearing driver (17) and
the h an d pu mp to r emo ve the up pe r p ivo t
plate (21) from the top pivot (22).
bearing (9) from the top pivot. See Special Tools
in this section. 6. Install a bearing cone (25), spacer (24), the other
bearing cone (23), and the remaining bearing
NOTE: The spacers are matched to the bearing sets. Do
cup (26) in the top pivot (22), refer to Figure 3.
not mix the spacers. Do not use the old spacers if new
bearing sets are being installed. 7. Install the bearing driver (17) and plate (21).
48. Use an acceptable driver, the hydraulic ram, and 8. Tighten a nut (18) on the screw (19) until the
the hand pump to remove the lower pivot bearing bearing cup (26) is seated against the spacer
(12) from the bottom pivot. See Special Tools in (24). Remove the bearing driver (17) and plate
this section. (21) from the top pivot (22).
NOTE: The spacers are matched to the bearing sets. Do
17� 18� 19�
not mix the spacers. Do not use the old spacers if new
23�
bearing sets are being installed. 26�
49. Use an acceptable driver to press the seal (6) out 24�
of each bearing retainer (7 and 13).
25�
21� 22
BC06A119
23. BEARING CONE 25. BEARING CONE

24. SPCAER 26. BEARING CUP
FIGURE 3.
5006-7
9. Put the bearing retainer (7) in place on the upper 18. Use an acceptable driver to install the seal (6) in
pivot bearing assembly (9), refer to Figure 4. the bottom of the top pivot, refer to Figure 6.
10. Install the bearing driver (17) and plate (21). 19. The bottom of the seal (6) must be even with the
bottom of the top pivot.
11. Tighten a nut (18) on the screw (19) until the
bearing retainer (7) is tight against the upper
pivot bearing assembly (9).
17� 18� 19� 27�

7�
9�
BC06A125
21� 22� FIGURE 6.
BC06A120
20. Apply grease to the upper pivot pin (4).
FIGURE 4. 21. Install the upper pivot pin (4) in the top pivot.
12. Measure the gap (27) between the bearing
22. Lubricate the top pivot until grease is forced out
retainer (7) and the top pivot (22). Make a record
of the seal (6).
of the measurement. Subtract 0.0762 to 0.1016
mm (0.003 to 0.004 inch) from the measurement. 23. Rotate the upper pivot pin (4) to check the
Select shims (8) (figure 1) equal to that value. bearing assembly. The upper pivot pin (4) must
rotate smoothly, but not easily. Leave the upper
13. Remove the bearing driver (17), plate (21), and
pivot pin (4) in place to keep dirt out of the upper
bearing retainer (7) from the top pivot.
pivot bearing (9).
14. Install the shims (8) and the bearing retainer (7),
24. Lubricate the bore for the bottom pivot with
refer to figure 1.
grease. Install a bearing cup in the bottom pivot.
15. Install the washers (2) and bolts (1). Tighten the
25. Install the bearing driver (17) and plate (21), refer
bolts (1) to 488 to 515 Nm (360 to 380
to Figure 7.
pound-feet).
16. Install the seal (6) in the bearing retainer (7). The 19�
top of the seal (6) must be even with the top of 21�
the bearing retainer (7), refer to Figure 5. 18�
28�
29
17�
BC06A123
FIGURE 7.
bearing cup (28) is seated in the bore in the
BC06A121 bottom pivot (29).
FIGURE 5.
27. Remove the bearing driver (17) and plate (21)
17. Fill the other seal (6) for the top pivot with
from the bottom pivot (29).
grease.
5006-8
28. Install a bearing cone (25), spacer (24), the other 37. Install the shims (8), the bearing retainer (13),
bearing cone (23), and the remaining bearing washers (2) and bolts (1), refer to figure 1.
cup (26) in the bottom pivot (29), refer to Figure
38. Tighten the bolts (1) to 488 to 515 Nm (360 to
8.
380 pound-feet).
29. Install the bearing driver (17) and plate (21).
39. Fill the seal (6) for the bearing retainer (13) with
grease.
21� 18� 19�
25� 40. Install the seal (6) in the bearing retainer (13).
The bottom of the seal (6) must be even with the
24� bearing retainer (13), refer to Figure 10.
29�
23� 26�
17�
BC06A124
FIGURE 8.
bottom bearing cup (26) is seated against the
spacer (24).
BC06A126
31. Remove the bearing driver (17) and plate (21) FIGURE 10.
from the bottom pivot (29).
41. Install the other seal (6) in the bottom pivot, refer
32. Put the bearing retainer (13) in place on the to Figure 11. The top of the seal (6) must be
lower pivot bearing (12). even with the top of the bottom pivot.
33. Install the bearing driver and plate, refer to
Figure 9.
21� 18� 19�
29
12� 30�
13� BC06A121
17� FIGURE 11.

42. Install the lower bearing spacer (11) and the
BC06A125
FIGURE 9. bottom spacer (14).
34. Tighten a nut (18) on the screw (19) until the 43. Apply grease to the lower pivot pin (10).
bearing retainer (13) is tight against the lower
44. Install the lower pivot pin (10) in the bottom pivot.
pivot bearing assembly (12).
45. Hold the bottom spacer (14) in place and
35. Measure the gap (30) between the bearing
lubricate the bottom pivot until grease is forced
retainer (13) and the bottom pivot (29). Make a
out of the seal (6).
record of the measurement. Subtract 0.0762 to
0.10 16 mm (0 .003 to 0.004 inch ) fr om the 46. Rotate the lower pivot pin (10) to check the
measurement. Select shims (8) (figure 1) equal bearing assembly. The lower pivot pin (10) must
to that value. rotate smoothly, but not easily.
36. Remove the bearing driver (17), plate (21) and 47. Remove the lower pivot pin (10) and the upper
bearing retainer (13) from the bottom pivot. pivot pin (4).
48. Remove the bottom spacer (14).
5006-9
CONNECTING THE FRONT FRAME TO THE REAR FRAME

1. Release the parking brake. 24. Tighten the Ferry head screws to 61 to 81 Nm
(45 to 60 pound-feet).
2. Move the rear frame into alignment with the front
frame. 25. Put the steering cylinder rod eye in position in the
frame. Install the washer between the steering
3. Move the steering cylinders as required to move
cylinder rod eye and the rear frame.
the rear frame into alignment with the front
frame. 26. Align the hole in the pivot pin with the holes in the
steering cylinder rod eye, and install the pivot
pin.
5. Apply grease to the upper pivot pin (4), see
27. Install the bolt and self-locking nut that hold the
pivot pin.
6. Install the upper pivot pin (4), spacer (3), washer
28. Repeat steps 25, 26 and 27 for the other steering
(2) and bolt (1). Be careful not to damage the
cylinder.
seal (6).
29. Start the vacuum pump.
7. Tighten the bolt (1) to 386 to 433 Nm (285 to 320
pound-feet). 30. Connect the return hose.
8. Apply grease to the lower pivot pin (10). 31. Connect the supply hose.
9. Install the lower pivot pin (10) in the frames. Be 32. Put the bracket for the hoses in position on the
careful not to damage the seal (6). rear frame. Install the bolts, flat washers, and
self-locking nuts that fasten the bracket to the
10. Use the ram and hand pump to install the bottom
rear frame.
spacer (14). See Special Tools in this section.
33. Put the bracket for the hoses in position on the
11. Install the lower pin plate (15), three inner bolts
front frame.
(1), and washers (2) that fasten the lower pin
plate (15) to the lower pivot pin (10). 34. Install the bolts, flat washers, and self-locking
nuts that fasten the bracket to the front frame.
12. Tighten the bolts (1) to 68 Nm (50 pound-feet).
35. Connect the hoses for the steering cylinders.
13. Measure the gap between the lower pin plate
(15) and the bottom pivot. Make a record of the 36. Connect the brake hose for the front brakes at
measurement. Subtract 0.0762 to 0.1016 mm the front bracket.
(0.003 to 0.004 inch) from the measurement.
37. Stop the vacuum pump.
Select shims equal to that value.
38. Connect the front wiring harness to the rear
14. Loosen the bolts (1) that fasten the lower pin
wiring harness.
plate (15) to the lower pivot pin (10).
39. Put the clamp on the wiring harness in position
15. Start the six outer bolts (1) into the lower pin
on the bracket. Install the bolt, lock washer, and
plate (15) and the bottom pivot.
nut that fasten the clamp on the wiring harness to
16. Install the shims (8). the bracket.
17. Tighten the six outer bolts (1) to 488 to 515 Nm 40. Put the ground wire in position on the stud. Install
(360 to 380 pound-feet). the washer and nut that fasten the ground wire to
the stud.
18. Tighten the three inner bolts (1) to 488 to 515 Nm
(360 to 380 pound-feet). 41. Install a tie strap to fasten the wiring harness to
the tube.
19. Remove the jacks from the rear frame.
42. Disconnect the vacuum pump from the hydraulic
20. Remove the blocks from the rear axle.
reservoir.
21. Remove the stands from the front frame.
43. Check the fluid level in the hydraulic reservoir.
22. Put the drive shaft in position on the front yoke. Add oil as required.
23. Install new Ferry head screws that fasten the 44. Install the fill cap in the hydraulic reservoir.
drive shaft to the front yoke.
5006-10
45. Bleed air from the front axle bleed screws. Refer 46. Lubricate the pivot pins for the steering cylinder
to Section 7002 for complete brake bleeding rod eyes.
instructions.
47. Install the covers on both sides of the machine.
Section
5007
AUXILIARY STEERING MOTOR AND PUMP

5007-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5007-3
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Motor .......................................................................................................................................................... 24 volts
Auxiliary steering pump
Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)
5007-4
AUXILIARY STEERING MOTOR AND PUMP

Disassembly Assembly
NOTE: Refer to Section 5001 for removal and installation 1. Lubricate all parts with clean hydraulic oil before
of the auxiliary steering motor and pump. assembly.
NOTE: The pump is the only component that is 2. Lubricate and install a new seal (4) and retaining
disassembled. The switch (8) and motor (1) are replaced as ring (3) on the plate (17). Refer to the illustration
units and are not serviced. Refer to the illustration on page on page 5.
5.
3. Lubricate and install a new backup ring (5) and a
1. Make an alignment mark on the pump assembly new seal (6) on the plate (17).
and motor (1).
4. Lubricate and install new O-rings (7) on the body
2. Loosen and remove the two screws (15) and lock (18).
washers (14) that hold the pump assembly to the
5. Lubricate and install the pins (22), drive gear
motor (1).
(20), driven gear (19) and wear plates (23) on the
3. Remove and discard the mounting gasket (13), body (18).
retaining ring (3) and seal (4) from the pump
6. Lubricate and install a new backup ring (5) and a
assembly.
new seal (6) on the end plate (21).
4. Loosen and remove the four bolts (2) that hold
7. Align the marks, made during disassembly, on
the pump assembly together.
the end plate (21), body (18) and plate (17) and
5. Remove the end plate (21) from the body (18). install the four bolts (2). Tighten the four bolts (2).
6. Remove and discard the seal (6) and backup 8. Install a new gasket (13) on the pump assembly.
ring (5) from the end plate (21).
9. Align the marks, made during disassembly, on
7. Remove the wear plate (23), drive gear (20) and the pump assembly and the motor (1).
driven gear (19) from the body (18).
10. Install the lock washer (14) and screw (15).
8. Remove the body (18) from the plate (17). Torque the screw (15) to 35 to 39 Nm (312 to
348 pound-inches).
9. Remove and discard the O-rings (7) from the
body (18).
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup
ring (5) from the plate (17).
NOTE: The only serviceable items on the pump assembly
are the seals (6), backup rings (5), O-rings (7), seal (4),
retaining ring (3) and gasket (13). If any of the other items
are damaged, replace the pump assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.
5007-5
10� 8�
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
1. MOTOR 7. O-RING 13. GASKET 19. DRIVEN GEAR

2. BOLT 8. SWITCH 14. LOCK WASHER 20. DRIVE GEAR
3. RETAINING RING 9. CABLE 15. SCREW 21. END PLATE
4. SEAL 10. SCREW 16. WIRE 22. PINS
5. BACKUP RING 11. LOCK WASHER 17. PLATE 23. WEAR PLATE
6. SEAL 12. WASHER 18. BODY
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
5007-6
NOTES
SECTION INDEX
POWER TRAIN
Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001

Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Front and Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Drive Shafts, Center Bearing, and Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006
Transmission Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007
Section
6001
REMOVAL AND INSTALLATION OF

POWER TRAIN COMPONENTS

6001-2
TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REAR AXLE AND TRUNNIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6001-3
SPECIAL TORQUES
Self-locking nuts for front axle mounting bolts . . . . . . . . . . . . . . . . . . 1877 to 1985 Nm (1380 to 1460 pound-feet)
Drive shaft mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 to 108 Nm (70 to 80 pound-feet)
Nuts for trunnion mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563 to 590 Nm (415 to 435 pound-feet)
Rear trunnion spacer to axle bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 to 210 Nm (140 to 155 pound-feet)
Cap screws for cover plate to rear trunnion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 to 95 Nm (60 to 70 pound-feet)
Nuts for transmission mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .929 to 1044 Nm (685 to 770 pound-feet)
Cap screws for transmission to bracket. . . . . . . . . . . . . . . . . . . . . . . . . . .1125 to 1274 Nm (830 to 940 pound-feet)
Nuts for bolt in rear engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386 to 434 Nm (285 to 320 pound-feet)
Cap screws for hydraulic pump to transmission . . . . . . . . . . . . . . . . . . . . . . . .102 to 113 Nm (75 to 83 pound-feet)
Transmission to flywheel housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 to 60 Nm (40 to 44 pound-feet)
Flywheel to flex plate nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 to 53 Nm (420 to 468 pound-inches)
Cab and canopy mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .786 to 841 Nm (580 to 620 pound-feet)
Wheel mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary 298 Nm (220 pound feet)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final 640 to 720 Nm (475 to 530 pound-feet)
6001-4
TRANSMISSION
Removal 7. Disconnect the hose from the reservoir tube (9)
from the hydraulic filter, refer to illustration on
NOTE: The transmission must be removed with the page 5.
engine. Do the procedure for engine removal in
Section 2000 but DO NOT disconnect the engine 8. Disconnect the suction hoses (10) from the
from the transmission remove both from the machine reservoir to the hydraulic pumps.
as a single unit. 9. Disconnect the hydraulic pump case drain hoses
1. Remove the filler cap for the hydraulic reservoir. (11) at the reservoir.
2. Drain the hydraulic reservoir. Approximately 118 10. Disconnect the hose for the brake pump (12) at
liters (31 U.S. gallons) will be drained. the reservoir.
3. Remove the cap screw (1), lock washers (2) and 11. Disconnect the hose loader valve pressure (13).
flat washers (3) that hold the cover (4) to the
relay mounting plate (5).
4. Remove the nuts (6) and lock washers (7) that
hold the relay mounting plate (5) to the reservoir.
5. Remove the relay mounting plate (5).
6. Remove the spacers (8) from the studs for the
relay mounting plate (5).
B910705J
1. CAP SCREW 5. RELAY MTG PLATE

2. LOCK WASHER 6. NUT
3. FLAT WASHER 7. LOCK WASHER
4. COVER 8. SPACER
RELAY MOUNTING PLATE

6001-5
11� 12�
10�
14�
9�
13
W270-2R003
9. RETURN FROM HYDRAULIC FILTER 12. BRAKE PUMP SUCTION HOSE

10. SUCTION HOSES TO HYDRAULIC PUMPS 13. HOSE LOADER VALVE PRESSURE
11. HYDRAULIC PUMP CASE DRAIN HOSES 14. HYDRAULIC RESERVOIR
HYDRAULIC RESERVOIR
6001-6
NOTE: If equipped with air conditioning, do step 12. NOTE: The equipment pump has a weight of
If not equipped with air conditioning, go to step 13. approximately 130 pounds (59 kg). Use suitable
equipment to support the equipment pump while the
transmission is out of the machine.
16. Remove the washers and cap screws that fasten
the equipment pump to the transmission.
17. Remove the cap screws (22) from the center
drive shaft (23) at the transmission, refer to
18. Remove the cap screws (22) from the rear drive
shaft (24) at the transmission.
19. Remove the cap screws from the rear drive shaft
(24) at the rear axle. Remove the rear drive shaft
BC06A071 (24).
15. DOUBLE CLAMP 17. COMPRESSOR 19. WASHER

HOSE
16. DRYER HOSE 18. NUT 20. RESERVOIR
12. If equipped with air conditioning, remove the nut

(18), lock washer (19) and clamp (15) that holds
the hoses (16 and 17) the hydraulic reservoir.
13. Fasten acceptable lifting equipment to the
hydraulic reservoir.
14. Remove the nuts, hardened washers, and bolts
that mount the hydraulic reservoir to the frame.
15. Carefully raise the reservoir and remove the
reservoir.
6001-7
BC06A077
21. DRIVE SHAFT FLANGE 23. CENTER DRIVE SHAFT

22. CAP SCREW 24. REAR DRIVE SHAFT
DRIVE SHAFTS
6001-8
20. Loosen the clamp and remove the sight gauge 23. Tag and remove the filter bypass hose (25).
upper hose (30) from the fitting at the top of the
24. Tag and remove the filter inlet hose (26).
transmission, refer to illustration on page 9.
25. Tag and remove the filter return hose (27).
21. Loosen the clamp and remove the sight gauge
lower hose (29) from the fill tube (31). 26. Tag and disconnect the parking brake hose (not
shown).
22. Remove the filler tube (31) from the
transmission. 27. Tag and disconnect the oil cooler hoses (not
shown).
6001-9
25�
30�
31�
29�
27�
32�
26
28�
W270-2R004
25. FILTER BYPASS HOSE 28. FILTERS 31. FILLER TUBE

26. FILTER INLET HOSE 29. SIGHT GAUGE LOWER HOSE 32. SIGHT GAUGE BRACKET
27. FILTER RETURN HOSE 30. SIGHT GAUGE UPPER HOSE
TRANSMISSION LINES
6001-10
28. Tag and disconnect hydraulic oil temperature 36. Remove the harness retaining clamp (41).
sender (33), refer to illustration on page 11-12.
37. Tag and disconnect the intermediate speed
29. Tag and disconnect the transmission filter sensor (42).
clogged switch (34).
38. Tag and disconnect the turbine speed sensor
30. Tag and disconnect the hydraulic filter clogged (43).
switch (35).
39. Tag and disconnect the engine speed sensor
31. Remove the harness retaining clamp (36). (44).
32. Tag and disconnect the transmission controller 40. Tag and disconnect the PRB2 redundant brake
(37). switch (45).
33. Tag and disconnect the torque converter output 41. Tag and disconnect the PRB1 redundant brake
sender (38). switch (46).
34. If equipped, tag and disconnect the secondary 42. Tag and disconnect the output speed sensor
steering harness (39). (47).
35. Tag and disconnect the transmission ground 43. Move the wiring harness out and away from the
(40). transmission.
6001-11
39�
41�
40�
37�
38�
45�
36�
46� 35�
34�
33
47�
W270-2R005
33. HYDRAULIC OIL TEMPERATURE SENDER 38. TORQUE CONVERTER OUTPUT SENDER 43. TURBINE SPEED SENSOR
34. TRANSMISSION FILTER CLOGGED SWITCH 39. SECONDARY STEERING (OPT) 44. ENGINE SPEED SENSOR
35. HYDRAULIC FILTER CLOGGED SWITCH 40. TRANSMISSION GROUND 45. PRB2 BRAKE SWITCH
36. CLAMP 41. CLAMP 46. PRB1 BRAKE SWITCH
37. TRANSMISSION CONTROLLER 42. INTERMEDIATE SPEED SENSOR 47. OUTPUT SPEED SENSOR
TRANSMISSION WIRING HARNESS

6001-12
43�
42�
44
W270-2R006

6001-13
44. Remove the self-locking nuts (53), hardened
washers (54), bolts (48), and washers (49).
45. Loosen the nuts on the front ROPS cab or
canopy mounting bolts and raise the rear of the
ROPS cab or canopy approximately 152 mm (6
inches).
46. Install a block on each side.
47. Raise the engine and transmission, move the
engine and transmission to th e rear of the
machine. Do this as required until the
transmission is free of the ROPS cab or canopy.
48. Remove the engine and transmission from the
machine. Put the engine and transmission on an
acceptable support.
49. Remove the starter from the engine.
transmission.
51. Using the engine turning tool, turn the flywheel
for access to the flex plate nuts.
52. Remove the twelve hardened washers and nuts
from the flex plate.
BC06A075
53. Remove the cap screws that hold the
transmission to the flywheel housing.
48. BOLT 53. NUT
49. WASHER 54. WASHER 54. Remove the transmission.
50. MOUNTING BRACKETS 55. SPACER
51. BOLT 56. RESILIENT MOUNT
52. WASHER
TRANSMISSION MOUNTING BRACKETS

6001-14
Installation
NOTE: The transmission must be installed with the
engine. See Section 2001 for engine installation.
transmission.
2. Replace the cap screws that hold the
transmission to the flywheel housing. Tighten the
cap screws to 54 to 60 Nm (40-44 pound-feet).
3. Using the engine turning tool, turn the flywheel to
access, install and tighten the twelve hardened
washers and nuts for the flex plate.
4. Replace the engine starter.
5. Replace the engine and transmission in the
machine.
6. Lower the ROPS cab or canopy and tighten the
front mounting bolt nuts to 786 to 841 Nm (580 to
620 pound-feet).
7. Install the self-locking nuts on the bolts. Tighten
the n uts to 78 6 to 84 1 Nm (5 80 to 6 20
pound-feet).
BC06A075
48. BOLT 53. NUT

49. WASHER 54. WASHER
50. MOUNTING BRACKETS 55. SPACER
51. BOLT 56. RESILIENT MOUNT
52. WASHER
TRANSMISSION MOUNTING BRACKETS
8. Install the self-locking nuts (53), hardened

washers (54), insulators (56), washers (49), and
bolts (48) that hold the transmission mounting
br acke ts (5 0) to the mach in e. Tig hte n th e
self-locking bolts to 685 to 929 to 1044 Nm (770
pound-feet), refer to Figure.
6001-15
9. Place the wiring harness into position over the 17. Connect the transmission ground (40).
transmission, refer to illustration on page 16-17.
18. If equipped, connect the secondary steering
10. Connect the output speed sensor (47). harness (39).
11. Connect the PRB1 redundant brake switch (46). 19. Connect the torque converter output sender (38).
12. Connect the PRB2 redundant brake switch (45). 20. Connect the transmission controller (37).
13. Connect the engine speed sensor (44). 21. Install the harness retaining clamp (36).
14. Connect the turbine speed sensor (43). 22. Connect the hydraulic filter clogged switch (35).
15. Connect the intermediate speed sensor (42). 23. Connect the transmission filter clogged switch
(34).
16. Install the harness retaining clamp (41).
24. Connect hydraulic oil temperature sender (33).
6001-16
39�
41�
40�
37�
38�
45�
36�
46� 35�
34�
33
47�
W270-2R005
33. HYDRAULIC OIL TEMPERATURE SENDER 38. TORQUE CONVERTER OUTPUT SENDER 43. TURBINE SPEED SENSOR
34. TRANSMISSION FILTER CLOGGED SWITCH 39. SECONDARY STEERING (OPT) 44. ENGINE SPEED SENSOR
35. HYDRAULIC FILTER CLOGGED SWITCH 40. TRANSMISSION GROUND 45. PRB2 BRAKE SWITCH
36. CLAMP 41. CLAMP 46. PRB1 BRAKE SWITCH
37. TRANSMISSION CONTROLLER 42. INTERMEDIATE SPEED SENSOR 47. OUTPUT SPEED SENSOR

6001-17
43�
42�
44
W270-2R006

6001-18
25. Install the sight gauge upper hose (30) to the 28. Install the filter bypass hose (25).
fitting at the top of the transmission and tighten
29. Install the filter inlet hose (26).
the clamp., refer to illustration on page 19.
30. Install the filter return hose (27).
26. Install the filler tube (31) on the transmission.
31. Install the parking brake hose (not shown).
27. Install the sight gauge lower hose (29) to the fill
tube (31) and tighten the clamp. 32. Install the oil cooler hoses (not shown).
6001-19
25�
30�
31�
29�
27�
32�
26
28�
W270-2R004
25. FILTER BYPASS HOSE 28. FILTERS 31. FILLER TUBE

26. FILTER INLET HOSE 29. SIGHT GAUGE LOWER HOSE 32. SIGHT GAUGE BRACKET
27. FILTER RETURN HOSE 30. SIGHT GAUGE UPPER HOSE
TRANSMISSION LINES
6001-20
33. Install the washers and cap screws that fasten 35. Put the rear drive shaft (24) into position on the
the equipment pump to the transmission. Tighten machine.
the cap screws to 102 to 113 Nm (75 to 83
36. Replace the cap screws to the rear drive shaft
pound-feet) of torque.
(24) at the rear axle. Tighten the cap screws to
34. Install the cap screws (22) to fasten the center 95 to 108 Nm (70 to 80 pound-feet).
drive shaft (23) to the transmission. Tighten the
37. Install the cap screws (22) to the rear drive shaft
cap screws to 95 to 108 Nm (70 to 80
(24) to the transmission. Tighten the cap screws
pound-feet). refer to illustration on page 21.
to 95 to 108 Nm (70 to 80 pound-feet).
6001-21
BC06A077
21. DRIVE SHAFT FLANGE 23. CENTER DRIVE SHAFT

22. CAP SCREW 24. REAR DRIVE SHAFT
DRIVE SHAFTS
6001-22
38. Carefully place the reservoir into position onto 41. Connect the hose to the reservoir tube (9) from
the machine. the hydraulic filter, refer to illustration on page
23.
39. Install the nuts, hardened washers, and bolts that
mount the hydraulic reservoir to the frame, 42. Connect the suction hoses (10) to the reservoir
tighten the bolts. and the hydraulic pumps.
NOTE: If equipped with air conditioning, do step 40. 43. Connect the hydraulic pump case drain hoses
If not equipped with air conditioning, go to step 41. (11) to the reservoir.
44. Connect the hose for the brake pump (12) to the
reservoir.
45. Connect the hose loader valve pressure (13).
BC06A071
15. DOUBLE CLAMP 17. COMPRESSOR 19. WASHER

HOSE
16. DRYER HOSE 18. NUT 20. RESERVOIR
40. If equipped with air conditioning, install the clamp

(15), lock washer (19), and nut (18) that holds
the hoses (16 and 17) the hydraulic reservoir,
tighten the nut.
6001-23
11� 12�
10�
14�
9�
13
W270-2R003
9. RETURN FROM HYDRAULIC FILTER 12. BRAKE PUMP SUCTION HOSE

10. SUCTION HOSES TO HYDRAULIC PUMPS 13. HOSE LOADER VALVE PRESSURE
11. HYDRAULIC PUMP CASE DRAIN HOSES 14. HYDRAULIC RESERVOIR
HYDRAULIC RESERVOIR
6001-24
46. Install the spacers (8) on the studs for the relay
mounting plate (5).
47. Install the mounting plate (5).
48. Install the nuts (6) and lock washers (7) that hold
the mounting plate (5) for the relay.
49. Install the cap screw (1) that holds the cover (4)
for relay mounting plate (5).
50. Fill the hydraulic reservoir. Approximately 118
liters (31 U.S. gallons) will be required.
51. Replace the filler cap for the hydraulic reservoir.
52. Fill the transmission with proper lubricant, refer
to section 1002.
53. Refer to section 2000 and complete the engine
installation procedures.
B910705J 54. Start and run the machine until all systems are at
operating temperature, check for leaks and
1. CAP SCREW 5. RELAY MTG PLATE repair as needed.
2. LOCK WASHER 6. NUT
3. FLAT WASHER 7. LOCK WASHER
4. COVER 8. SPACER
RELAY MOUNTING PLATE

6001-25
FRONT AXLE
Removal 6. Using a crisis-cross pattern, tighten the eight
axle mounting nuts (4) to a torque of 1877 to
1. Remove the four bolts (2) that fasten the front 1985 Nm (1380 to 1460 pound-feet).
drive shaft (3) universal joint to the front axle (1),
refer to illustration on page 26. 7. Engage the front drive shaft (3) universal joint
with the front axle (1) and install the four bolts
2. Use a prybar and disengage the front drive shaft (2). Tighten the bolts (2) to a torque of 95 to 108
(3) universal joint from the front axle (1). Nm (70 to 80 pound-feet).
3. Tag and disconnect the brake and cooler lines 8. Install the wheels, washers, and wheel nuts.
from the front axle. Install caps and plugs.
9. Torque the wheel bolts in the sequence shown to
4. Raise the front wheels off the floor and use a preliminary torque of 298 Nm (220 pound-feet).
acceptable supports to hold the machine. Final torque the wheel bolts to 640 to 720 Nm
5. Remove the wheels from the front axle. (475 to 530 pound-feet) in the same sequence.
6. Use acceptable lifting equipment (transmission

jack) to hold and lower the front axle.
7. Fasten the jack to the front axle to keep the front
axle from moving when the mounting bolts are
removed. The weight of the axle is approximately
3039 kg (6700 pounds).
8. Remove the self-locking nuts (4), washers (5),
and bolts (6) on each side of the front axle (1).
9. Carefully lower and remove the front axle (1)
from the machine.
Installation
1. Position front axle into position using a suitable
jack.
2. Install one bolt (6) and washer (5) on each side
of the front axle (1). The bolts (6) should be
BC06A079
placed through the top of the frame and then WHEEL BOLT TIGHTENING SEQUENCE
through the axle mounting holes.
10. Lower the machine to the ground.
3. From the bottom of the front axle (1), secure the
front axle to the frame with washer (5) and a 11. Connect the brake and cooler line to the front
self-locking nut (4). axle.
4. Place the remaining six bolts (6) and washers (5) 12. Fill the axle with proper lubricant, see section
through the top of the frame and then through the 1002.
front axle (1) mounting holes. From the bottom of 13. Bleed the brakes, see section 7002.
the front axle (1), secure the front axle to the
frame with six washers (5) and six self-locking
nuts (4).
5. Slowly tighten the bolt (6) on each side of the
front axle (1) and raise the front axle against the
frame. Tighten the bolts (6) until snug.
6001-26
BC06A074
1. FRONT AXLE 4. SELF LOCKING NUT

2. BOLT 5. WASHER
3. FRONT DRIVE SHAFT 6. BOLT
FRONT AXLE MOUNTING
6001-27
REAR AXLE AND TRUNNIONS

Removal 4. Tighten the cap screws (8) to a torque of 190 to
210 Nm (140 to 155 pound-feet).
1. Remove the grease hoses from the rear axle
trunnions (2 and 3), refer to illustration on page 5. Install the other thrust washer (5). Fasten the
28. rear cover (7) to the rear trunnion (3) using six
washers (9) and cap screws (8).
2. Tag and disconnect the brake and oil cooler lines
from the rear axle (1). Install caps and plugs. 6. Tighten the cap screws (8) to a torque of 81 to 95
Nm (60 to 70 pound-feet).
3. Remove the cap screws that fasten the rear drive
shaft (12) to the rear axle (1). 7. Install the front trunnion (2) to the rear axle (1).
Ensure trunnion is properly positioned, see
4. Use a prybar and disengage the rear drive shaft illustration on page 28.
(12) from the rear axle (1).Raise the rear wheels
off the floor and use acceptable supports to hold 8. Using acceptable lifting equipment, slowly move
the machine in place. the rear axle (1) and trunnions (2 and 3) into
position under the rear chassis.
5. Remove the rear wheels.
9. Install the bolts (10), hardened washers (9), and
6. Put acceptable lifting equipment (transmission self-locking nuts (11) to fasten the trunnions (2
jack) under the rear axle (1) and trunnions (2 and and 3) to the rear chassis.
3). The weight of the axle is approximately 3039
kg (6700 pounds). 10. Tighten the self-locking nuts (11) to a torque of
660 to 741 Nm (485 to 545 pound-feet).
7. Remove the self-locking nuts (11) from the bolts
(10). 11. Fasten the rear drive shaft (12) to the rear axle
(1). Use four cap screws and tighten to a torque
8. Remove the rear axle (1) and trunnions (2 and 3) of 95 to 108 Nm (70 to 80 pound-feet).
from the machine. Place the rear axle (1) and
trunnions (2 and 3) onto blocks or suitable work 12. Install the rear wheels, hardened washers and
bench. bolts.
9. Remove the front trunnion (2) from the rear axle 13. Torque the wheel bolts in the sequence shown to
(1). a preliminary torque of 298 Nm (220 pound-feet).
Final torque the wheel bolts to 640 to 720 Nm
10. Remove the cap screws (8) and washers (9) (475 to 530 pound-feet) in the same sequence.
from the rear cover (7) on the rear trunnion (3).
11. Remove the rear cover (7) from the rear trunnion
(3).
12. Remove the thrust washer (5).
13. Remove the cap screws (8) and washers (9) that
fasten the spacer (6) to the rear axle (1).
14. Remove the spacer (6) and thrust washer (5).
15. Remove the rear trunnion (3) from the rear axle
(1).
NOTE: Replace the seals and busings in the
trunnions as required.
Installation
1. Put the rear axle (1) on blocks.
2. Install the rear trunnion (3) to the rear axle (1).
Ensure bushing is properly positioned.
BC06A079
3. Install a thrust washer (5) and the spacer (6). WHEEL BOLT TIGHTENING SEQUENCE
Use eight cap screws (8) and hardened washers
(9) to fasten the spacer (6) to the rear axle (1).
6001-28
14. Lower the machine to the ground. 17. Fill the axle with proper lubricant, see section
1002.
15. Connect the brake and cooler lines to the rear
axle. 18. Pump grease into front and rear trunnions until
grease is extruded through seals.
16. Connect the grease hoses to the trunnions (2
and 3). 19. Bleed the brakes, see section 7002.
BC06A076
1. REAR AXLE 4. OIL SEAL 7. COVER 10. BOLT

2. FRONT TRUNNION 5. THRUST WASHER 8. CAP SCREW 11. SELF-LOCKING NUT
3. REAR TRUNNION 6. SPACER 9. WASHER 12. REAR DRIVE SHAFT
REAR AXLE MOUNTING
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING

6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 20
6002-3
SPECIAL TOOLS
380001743 Transmission supplemental fitting kit. 380001740 Flowmeter kit
Includes: 380000509 special 90 degree adapter and
380001750 Flowmeter adapter
380001749 plug and cap set.
380001745 Flow test kit
380001739 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (230 to 265 psi)
Converter in pressure .................................................................................................8.5 to 10.5 bar (125 to 154 psi)
Pressure reduction for solenoids ......................................................................................9 to 11 bar (130 to 160 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) ...................................................................................115 L/min (30 U.S. gpm)
Transmission oil operating temperature .........................................................................80 to 120 °C (176 to 248 °F)
Clutch KV........................................................................................................................16 to 18 bar (230 to 265 psi)
Clutch KR .......................................................................................................................16 to 18 bar (230 to 265 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (230 to 265 psi)
6002-4
GS99C601
1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR
2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR
5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE
6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH
7. TRANSMISSION 14. FILTER RESTRICTION SWITCH (REMOTE MOUNTED)
FIGURE 1. COMPONENT LOCATIONS SYSTEMS

6002-5
GS98K624
1. ENGINE CONNECTION (DIRECT MOUNTING) 9. CLUTCH K2 (2ND GEAR)
2. CONVERTER 10. CLUTCH K3 (3RD&4TH GEAR)
3. BREATHER 11. OUTPUT FRONT AXLE
4. DRIVE 12. OUTPUT REAR AXLE
5. ELECTRO-HYDRAULIC SHIFT VALVE 13. LAYSHAFT
6. 1ST POWER TAKE-OFF (PUMP DRIVE) 14. CLUTCH K4 (FORWARD, HIGH SPEED)
7. CONVERTER CHARGE AND CONTROL PRESSURE PUMP 15. CLUTCH KR (REVERSE, LOW SPEED
8. CLUTCH K1 (FIRST GEAR) 16. CLUTCH KV (FORWARD, LOW SPEED)
FIGURE 2. COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6
GS99C623
1. LIFTING LUGS 5. OIL DRAIN PLUG
2. BREATHER 6. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK
3. ELECTRO-HYDRAULIC SHIFT CONTROL 7. OUTPUT REAR AXLE
4. ENGINE CONNECTION DIRECT MOUNTING 8. OIL FILLER PIPE WITH OIL DIPSTICK
FIGURE 3. COMPONENT LOCATIONS FRONT VIEW

6002-7
GS99C622
1. ENGINE CONNECTION DIRECT MOUNTING 9. CONNECTION TO CLUTCH K2
2. LIFTING LUGS 10. CONNECTION TO CLUTCH K3
3. BREATHER 11. CONNECTION TO LUBRICATION K3/K4
4. ELECTRO-HYDRAULIC SHIFT CONTROL 12. OUTPUT FRONT AXLE
5. CONNECTION TO CLUTCH K1 13. OUTPUT REAR AXLE
6. CONNECTION TO CLUTCH KV 14. TRANSMISSION SUSPENSION HOLES
7. CONNECTION TO CLUTCH KR 15. CONNECTION CLUTCH K4
8. CONNECTION TO LUBRICATION K2/KR 16. MOUNTING HOLE
FIGURE 4. COMPONENT LOCATIONS SIDE VIEW

6002-8
GS98K621
1. 2ND POWER TAKE-OFF 7. OIL FILLER PIPE WITH OIL DIPSTICK
2. PRESSURE LINE CLUTCH K1 8. MODEL IDENTIFICATION PLATE
3. PRESSURE LINE CLUTCH K3 9. OUTPUT FRONT AXLE
4. PRESSURE LINE CLUTCH KV 10. LUBRICATING LINE CLUTCH KR/K2
5. PRESSURE LINE CLUTCH K4 11. LUBRICATING LINE CLUTCH K4/K3
6. PRESSURE LINE CLUTCH KR 12. PRESSURE LINE CLUTCH K2
FIGURE 5. COMPONENT LOCATIONS REAR VIEW

6002-9
TRANSMISSION OPERATION
General B. Protect the engine and transmission turbine
from ove rspee d co ndition s d uring
The transmissions is equipped with a Transmission
downloading.
ECM (Electronic Control Module). This module
controls modulation and shifting that were normally C. Receives speed information from the engine
asso ciated with hydr aulically modu la te d speed sensor, the turbine speed sensor, the
tra ns mis sion s, p ro vidin g smo oth er sh ifts an d intermediate clutch speed sensor and the
enhanced clutch life. transmission output speed sensor. These
speed sensors are checked to determine if
The Transmission ECM relies on signal from several
normal sensor operation is present. The data
solenoids that are incorporated into the design.
is also used to control modulation during
These solenoids measure the speed of several
shifting and to determine the appropriate shift
components, as well as other sensors that measure
patterns.
temperature. These solenoids and sensors are
further defined in the following paragraphs. D. Detects system failures and determines the
appropriate alternative actions.
In addition, the transmission incorporates a two-piece
t r a n s m is s i o n c a s e f o r e a s e o f t r a n s mi s s i o n E. Provides various diagnostic messages to the
maintenance, helical cut gears that help reduce noise. Information Center.
Transmission ECM F. Provides other information to the information

center, which in turn displays engine speed,
Mo du la tio n an d sh ifting a re con tro lle d b y th e
wheel speed, gear shift selection, and actual
T ransmi ssi on Electron ic C ontrol Mod ule
gear selection.
(Transmission ECM). This module replaces the oil
and springs that are found in hydraulically modulated G. Provides a method to calibrate the
transmissions. transmission clutch control.
The T ransmission ECM controls the clutch H. Establishes clutch modulation pressure during
e n g a g e m e n t , p r o v i d i n g s m o o t h e r s h if t s a n d transmission shifts.
enhanced clutch life, whether the transmission is set
to the automatic or manual shift mode. Transmission Sensor Data Collection
The Transmission ECM also informs the Information The Transmission EC M c ollects and uses
Center, by the use of diagnostic codes, of any information from four sensors to accurately shift the
transmission error and the hours of operation that the transmission and determine if any clutches are
error occurred. slipping. These sensors are:
Engine (Speed) Sensor - monitors engine speed to
Electrical Shift Solenoids determine the load on the engine for shift points and
Electrical Shift Solenoids control the modulation of sends the engine rpm to the Transmission ECM,
the clutches, eliminating the need for a modulation which sends the information to the tachometer in the
valve, and providing a smooth shift while maintaining Information Center.
constant control over clutch engagement as follows:
Turbine (Speed) Sensor - assists the engine speed
A. A temperature sensor relays the oil se nso r in d eter min in g the loa d g oing in to th e
temperature to the Transmission ECM. transmission and helps determine shift points.
B. The Transmission ECM times the rate the Intermediate (Shaft Speed) Sensor - determines
solenoid energizes and de-energizes. differential gear speed in the transmission to check
for clutch slippage.
C. As the transmission changes gears, there is
reduced hesitation from one gear to the next. Output (Speed) Sensor - monitors transmission
output shaft speed to help determine the load on the
Transmission ECM Tasks transmission and to assist in determining shift points.
The Transmission ECM performs a variety of tasks in Sends output shaft speed to Transmission ECM
the overall system. The Transmission ECM: which sends the information to the speedometer in
the Information Center.
A. Determines which clutches to engage in the
transmission.
6002-10
Th e t r a n s m is s io n E C M a l s o r e v ie w s v o lt a g e If the Transmission ECM generates a code, the
infor mation from the shifter a nd tran smis sio n w r e n ch o v e r t h e s e r vi ce m a n u a l i co n w ill b e
solenoids to determine if there are any short circuits displayed on the Information Center.
or open circuits 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
three modes:
individual transmission in the machine. Clutch Filling
A. Clutch Modulation Substitute Mode Parameter Calibration is performed on each machine
B. Limp-Home Mode at the plant and should be repeated at the first 250
hours of use and every 1000 hours thereafter.
C. Transmission/Transmission ECM Shutdown
Mode Before doing the following transmission clutch
calibration procedures make sure of the following:
Clutch Modulation Substitute Mode
1. The machine is running and the transmission oil
In this mode, the transmission clutch modulation is is warm.
time dependant rather than load dependant. The
transmission will go into the Clutch Modulation 2. Engine low idle speed is correct.
Substitute Mode if any of the four speed sensors fail. 3. The transmission is in neutral.
If the o utp ut spe ed sen so r is w orking a nd th e
4. The park brake is applied.
transmission is in gear, the shift points in Automatic
mode will be speed dependant but the modulation 5. If steps 1 through 4 have been accomplished,
will be a predetermined amount of time. calibrate the transmission clutches as follows:
If the output speed sensor is not working and the A. Put the transmission in the manual shift mode
transmission is in gear, the shift points will be load and the gear selector in 3rd gear neutral.
d e p e n d a n t b u t t h e m o d u la t io n w i ll s ti ll b e a
B. Press the program/reset switch to program.
predetermined amount of time.
C. Press the up/down count switch to up count
If the transmission is shifted from neutral into a
until the display reads 011.
direction in the Clutch Modulation Substitute Mode in
automatic, the transmission will shift into 4th gear D. Put the program/reset switch in the OFF
and shift down until it gets the correct output speed (center) position.
from the turbine.
E. Press the up/down count switch to up count
Limp-Home Mode twice, so the display reads 02.
In this mode, the transmission will go into second F. 2 00 00 will begin to flash in the display center.
gear, forward or reverse, no matter what gear is G. After one second, the Clutch Calibration Main
selected. If second gear is not obtainable, the Code status will be displayed in the 3rd and
Transmission ECM selects a series of prioritized 4th spaces (2 XX 00, the XX represents the
gears unt il an operable gear is found. The
3rd and 4th spaces).
transmission will go into the Limp Home Mode if
there is a fault on one clutch, a fault on one clutch H. The Modulation Cycle Number will be
valve, or a fault on more than one speed sensor. displayed in the 1st and 2nd spaces (2 00 XX,
the XX represents the 1st and 2nd spaces).
Transmission/Transmission ECM I. During Clutch Calibration, the Clutch
Shutdown Mode Calibration Main Code will change from 01 to
In this mode, the Transmission ECM has detected a 07 as the process is completed. Code 07
seve re failu re tha t disa ble s con tro l o f th e in dicates that the calibra tion proce ss is
transmission. The transmission will go into Shutdown complete and the information center will return
Mode if there is a fault on more than one clutch, a to normal working status.
fault on the solenoid power supply, or invalid voltage.
In this mode, the Transmission ECM will shut off all
solenoid valves an d the power supply an d the
transmission shifts into and stays in neutral.
6002-11
J. If any of the Clutch Calibration parameters are
incorrect, the display center will stop flashing CLUTCH CALIBRATION SUB CODES
and display a code in the 1st, 2nd, 3rd, and Sub Code Meaning
4th spaces.
00 Calibration in process.
If this occurs, the code in the 3rd and 4th
spaces will be a Clutch Calibration Main Code 01 Fault present.
09 through 14 and indicate what process the
calibration was in when it was aborted. 02 Shift lever not in neutral.
The 1st and 2nd spaces will produce the 03 Park brake not applied.
Clutch Calibration Sub Code, which is the
04 Output speed not 0 kph/mph.
code that informs the operator of the reason
the process was aborted. 05 Low transmission oil temperature.
K. After completing the Clutch Calibration 06 High transmission oil temperature.
procedure, turn the machine OFF for 15
seconds. This sets the calibration in the 07 Low engine RPM.
controller. 08 High engine RPM.
CLUTCH CALIBRATION MAIN CODES

Main Code Meaning Gear Selections
Clutch Calibration Mode was not The transmission provides 4 forward and 3 reverse
00 initiated because one of the ge ar sele ctio ns. Th e transmission ratios were
requirements was not met. designed to give optimized speed and torque for
each gear selection. The torque converter is a single
01 Adjusting 1st gear. stage torque converter (one locking unit in the torque
converter).
02 Adjusting 2nd gear.
03 Adjusting 3rd gear. Automatic/Manual Modes
04 Adjusting 4th gear. The automatic/manual switch is located on the right
control panel. The transmission is in automatic mode
05 Adjusting Forward gear. when the top of the automatic/manual switch is
de pr esse d. Th e Tra nsmission Display Cen ter
06 Adjusting Reverse gear.
indicates when the machine is in the automatic
07 Clutch Calibration Completed. mode.
Operator aborted calibration
08
procedure.
09 Aborted while adjusting 1st gear.
10 Aborted while adjusting 2nd gear.
11 Aborted while adjusting 3rd gear.
12 Aborted while adjusting 4th gear.
13 Aborted while adjusting Forward gear.
14 Aborted while adjusting Reverse gear.
6002-12
Upshifting in Automatic Mode Cold Start Protection System
Upshifting is determined by machine speed and the The transmission has a cold start protection system.
torque on the transmission. When the transmission sump temperature is minus
10° C (14° F), the Transmission ECM will keep the
The transmission will shift from first or second gear
transmission in neutral.
up to the highest gear selected as the accelerator is
depressed, machine speed increases, and required When the transmission sump temperature warms up
torque is reduced. to minus 10° C (14°F) (within approximately one
minute), the machine will operate in all gears.
If the machine speed is increasing, but the operator
is not depressing the accelerator (such as when Downshift Button
going down a hill), the transmission will not upshift.
The downshift button is located on front of the
As the operator depresses the accelerator and the joystick control lever in machines with a single lever
torque on the trans mi ss ion is l owered, the configuration, and on top of the control tower in
transmission will upshift. machines with a three lever configuration.
Downshifting in Automatic Mode With the number of different ways the downshift
Downshifting is determined directly by machine button functions, the operator can tailor the use of
speed and transmission torque. The transmission will the machine to the application at hand.
downshift to first or second gear as machine speed
decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
and the machine speed decreases, as the torque
re q u ir e me n t in cr e a se s , th e tr a ns mis si on w ill
downshift into third, then second, and down to first
gear, if necessary.
Upshifting in Manual Mode

In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the
operator selects another gear or direction. The
transmission can be upshifted without reducing
engine speed or machine speed.
If the gear selected is two or more gears higher than
the present gear, the transmission will shift up
through the gears at 2.5 second intervals until the
selected gear has been reached.
Downshifting in Manual 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
transmission will downshift into 2nd gear for 1.2
seconds and then will shift into 1st gear.
6002-13
Automatic Mode Brake Pedal Transmission Declutch
In the Automatic Mode, the downshift button only A transmission declutch feature concentrates more
shifts down. The downshift button allows the operator engine power on the loader when digging in heavy or
to downshift through the entire range of gears. This is tough conditions, providing smoother stops and
useful in long haul applications or roading. starts. Total disconnection of the transmission from
the engine is prevented. This feature will function in
Each time the button is pushed the transmission will
1st, 2nd, or 3rd gear only. It will not function in 4th
instantly downshift one gear from 4th to 3rd, then
gear.
from 3rd to 2nd, and then from 2nd to 1st.
The transmission will automatically downshift and When the transmission declutch switch is in the on
then upshift, as needed, to the last gear that was p o s i ti o n a n d th e b r a k e p e d a l is p u sh e d , th e
selected with the downshift button. Transmission ECM reduces the pressure to the
transmission forward or reverse clutch.
EXAMPLE: If the downshift button was used to shift from
4th to 3rd gear, the transmission will automatically shift The Transmission ECM will not completely
from 3rd down and then back up to 3rd again. It will not disconnect the clutch from the engine, but gradually
shift into 4th until the transmission has been returned to the reduces the forward or reverse clutch pressure down
full range automatic mode. to a lower level.
Th e tra n smiss ion w ill re tu rn to t he fu ll r an g e When the brake pedal is released, the Transmission
automatic mode when: ECM gradually increases the forward or reverse
clutch back up to system clutch pressure.
A. Another gear is selected.
If the direction is changed while the transmission is
B. The shifter is moved into neutral and then into declutched, the selected forward or reverse clutch
forward or reverse. will be filled and maintain a low pressure until the
C. The autoshift switch is recycled. brake pedal is released. Then the selected forward or
reverse clutch pressure will gradually increase up to
Manual Mode system clutch pressure.
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
button again, the transmission upshifts into 2nd gear.
If the machine is in 2nd gear and the downshift
button is pushed, the transmission instantly shifts
into 1st gear. When the operator shuttles the shifter,
the transmission upshifts back into 2nd gear.
6002-14
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 9 bar M10x1 H
52 Behind the Converter - Opening Pressure 3.5 bar M14x1.5
53 Clutch Forward 16+2 bar KV M10x1 B
55 Clutch Reverse 16+2 bar KR M10x1 E
56 Clutch 16+2 bar K1 M10x1 D
57 Clutch 16+2 bar K2 M10x1 A
58 Clutch 16+2 bar K3 M10x1 C
60 Clutch 16+2 bar K4 M10x1 F
63 Behind the Converter Temperature 100° C, Short Time 120° C M14x1/5
65 System Pressure 16+2 bar M10x1 K
Connections
15 Connection to the Heat Exchanger M42x2
16 Connection from the Heat Exchanger M42x2
29 Connection from filter M42x2
30 Connection to filter 1-11/16 UN 2A
31 Connection to Brake Valve M16x1.5
32 Connection Return Line from Brake Valve M26x1.5
49 Plug Connection on the Hydraulic Control Unit
68 Pilot Pressure M16x1.5 J
69 System Pressure M16x1.5 G
Inductive Transmitter and Speed Sensor
5 Inductive Transmitter n Central Gear Chain M18x1.5
9 Inductive Transmitter n Engine M18x1.5
13 Speed Sensor n Output and Speedometer
14 Inductive Transmitter n Turbine M18x1.5
NOTE: See Figure 6 for Measuring Point, Transmitter, Sensor and Connection locations.
6002-15�
BC00E065
FIGURE 6. MEASURING POINTS AND CONNECTIONS
6002-16
ENGAGED
* PRESSURE REGULATOR UNDER VOLTAGE CLUTCHES
DRIVING DIRECTION SPEED Y1 Y2 Y3 Y4 Y5 Y6

FORWARD 1 * * KV K1
2 * * KV K2
3 * * KV K3
4 * * K3 K4
REVERSE 1 * * KR K1
2 * * KR K2
3 * * KR K3
NEUTRAL
CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.
P.I.N. Number: Date:
TEST POINTS
Shift P V R 1 2 3 4 5 6 LP
Speed 65 53 55 56 57 58 60 51 52
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
P= MAIN PRESSURE 1= FIRST GEAR CLUTCH 4= FOURTH GEAR CLUTCH LP= LUBE PRESSURE
V= FORWARD CLUTCH 2= SECOND GEAR CLUTCH 5= CONVERTER IN
R= REVERSE CLUTCH 3= THIRD GEAR CLUTCH 6= CONVERTER OUT

6002-17
PRESSURE TEST RESULTS

All or Most Pressures Low and/or Not Enough Power
Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
3. Oil operating temperature high. A. Check engine and fuel system for problem.
4. Screen for suction tube plugged. B. Check that torque converter installation is
correct.
5. Suction tube or gaskets leak.
3. Engine RPM above Stall Test specified RPM.
6. Main pressure valve, springs, or valve bore.
A. Check converter pressures and flow.
7. Reduction valve, springs, or valve bore.
B. Check that torque converter installation is
8. Charge pump seals or gaskets leak. correct.
9. Charge pump worn.
Machine Stops or Hesitates While
10. Oil supply flange not sealing correctly.
Shifting - Intermittent
Some Pressures Low Possible causes include:
Possible causes include: 1. Check orifice and O-ring. (See Section 6007 for
replacing.)
1. Circuit isolation does not correct low pressure.
2. Check for foreign material plugging orifices or
A. Control valve or gasket.
sticking valves.
B. Channel plate or gasket.
3. Check for reduced pressure at test pressure
2. Circuit isolation corrects low pressure. points.
A. Clutch shaft or seals.
B. Clutch drum or piston.
6002-18
CONVERTER OUT PRESSURE CHECK

Test Equipment Required 2. Apply the parking brakes.
0 to 28 bar (400 psi) gauge with hose long enough to 3. Install the pressure gauge.
take readings in the cab and 380000509 Special 4. Heat the oil to an operating temperature of 80 to
Adapter. 100° C (176 to 212° F).
5. While in the cab, put the transmission in
Test Procedure NEUTRAL. Run the engine at full throttle. Record
1. Block the machine tires. the reading in the chart on page 6002.16.
Pressure must be 3.5 to 6.5 bar (51 to 96 psi).
LUBRICATION PRESSURE CHECK

Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 6002-16. Pressure
must be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
Test Equipment Required 3. Heat the oil to an operating temperature of 80 to
100° C (176 to 212° F).
380001740 Flowmeter Kit; 380001750 Flowmeter
Adapter. 4. Remove the filter and install the 380001750
adapter.
Flowmeter Test Procedure 5. Install the flowmeter between the adapter and
the filter.
1. Block the machine tires.
2. Apply the parking brakes. Put the transmission in NEUTRAL and record the
flow measurement. The correct flow is 80 L/min
(21 U.S. gpm) at 2000 rpm.
CONSUMPTION TEST PROCEDURE

1. Block the machine tires. 6. Repeat the procedure with the transmission in
FORWARD in third gear. The flow must be 9.1
2. Apply the parking brakes.
L/min (2 U.S. gpm).
3. Heat the oil to an operating temperature of 80 to
7. Repeat the procedure with the transmission in
100° C (176 to 212 °F).
REVERSE in third gear. The flow must be 9.1
4. Install the flowmeter to converter outlet line (line L/min (2 U.S. gpm).
to cooler) in series.
Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 L/min
(2 U.S. gpm).
6002-19
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56 degrees C (100 degrees F)
above the ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Understanding Results to determine possible cause of any test results not within specifications.
6002-20
ERROR CODES
In case of possible errors in the system, a wrench appears on the display, combined with indication of the error
number. See section 4005 for error code retrieval procedures and definitions. See electrical schematic to assist in
fault isolation.
TRANSMISSION SHIFTER LOGIC INFORMATION

Shifter Wire Shifter Tower Shifter Shroud Harness Harness
Function Shifter Trans. ECM #
Color Connector Connector Wire # ped/cab #
power B+ black/red A A 19A 43 45
forward V yellow - B 25F 44 43
reverse R pink - C 25R 45 64
neutral N gray - D 25T 46 67
gear2(3-4) B2 green B - 25W 48 65
gear1(1-2) B1 blue C - 25Z 49 63
downshift DS purple D - 25Y 50 22
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the shifter are limit
switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In neutral N is high. In first gear,
B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low and B2 is high. In fourth gear, B1 and B2 are
high. Downshift, DS, is activated when the end of the shifter is engaged.
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES

Transmission ECM Transmission Transmission Transmission Trans/Cab
Clutch # Wire #
Function ECM Pin # Valve Valve Pin # Pin #
A1P1 56 Y1 K4 1 25K 16
A1P2 10 Y2 KR 2 25L 17
A1P3 32 Y3 K1 3 25M 18
A1P4 55 Y4 K3 4 25N 19
A1P5 9 Y5 KV 5 25P 20
A1P6 51 Y6 K2 6 25J 21
VPSI 12,13 all Y all K 7 25S 22
TEMP 39 TEMP none 8 36T 5
TEMP 46 TEMP none 9 36R 12
Section
6003
TRANSMISSION

6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FORWARD AND FIRST CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Clutch Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Clutch Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clutch Disc Clearance Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FORWARD AND FIRST CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Forward Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
First Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECOND AND REVERSE CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECOND AND REVERSE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Reverse Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SPUR GEAR BEARING END PLAY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPUR GEAR BEARING END PLAY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
THIRD AND FOURTH CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
THIRD AND FOURTH CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Third Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fourth Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CHARGE PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHARGE PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Reverse Idler (Countershaft) Bearing Preload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Output Shaft Bearing End Play Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Second / Reverse Clutch Bearing End Play Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Forward / First Clutch Bearing End Play Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Converter Bearing Preload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Speed Sensing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
HOW IT WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6003-3
SPECIAL TOOLS
A15355 A15350
PRESSING TUBE CAS-2266-1
1. COLLETT HOLDER CAS-2263-1
2. COLLET CAS-2263-2
A15348
PRESSING TUBE CAS-2267
A15347
1. SLOTTED NUT SOCKET CAS-2262

A15351
1. CLUTCH DISC ALIGNMENT SLEEVE CAS-2265-1

2. TUBE SPACER CAS-2265-2
A15356
TRANSMISSION ADAPTER PLATE CAS-10916
6003-4
A15344 A15354
CLUTCH SPRING PRESSING TUBE PULLER CAS-2268
6003-5
SPECIAL TORQUES
Transmission Cover......................................................................................................................................... 46 Nm
Oil Baffle Plate................................................................................................................................................. 23 Nm
Brake Rotor ..................................................................................................................................................... 46 Nm
Emergency Steering Cover .............................................................................................................................. 23 Nm
Parking Brake ................................................................................................................................................. 185 Nm
Clutch End Cap (all) ......................................................................................................................................... 46 Nm
Reverse Idler (Countershaft) ............................................................................................................................ 46 Nm
Output Drive Flange ......................................................................................................................................... 46 Nm
Filter Cover ....................................................................................................................................................... 23 Nm
Oil Pump Supply Flange ................................................................................................................................... 46 Nm
Converter Housing M12-8.8 Bolts .................................................................................................................... 79 Nm
Converter Housing M12-10.9 Bolts ................................................................................................................ 117 Nm
Converter Housing M8 Bolts............................................................................................................................. 34 Nm
Oil Pump Flange............................................................................................................................................... 79 Nm
Pump Shaft....................................................................................................................................................... 32 Nm
SPECIFICATIONS
Converter Charge Pump Maximum End Play................................................................................................0.04 mm
All Clutch Packs Disc Clearance ...........................................................................................................2.1 to 2.5 mm
Reverse Spur Gear Bearing End Play.................................................................................................0.0 to 0.05 mm
Second Spur Gear Bearing End Play ................................................................................................0.05 to 0.15 mm
First Spur Gear Oil Ring and Retaining
Ring Thickness (Smaller than Combined Dimension).....................................................................0.0 to 0.05 mm
Reverse Idler (Countershaft Bearing Preload) ....................................................................................0.0 to 0.10 mm
Final Drive Bearing End Play.................................................................................................................0.3 to 0.5 mm
Third/Fourth Clutch Bearing Preload .................................................................................................0.15 to 0.20 mm
Reverse/Second Clutch Bearing Preload ............................................................................................0.2 to 0.25 mm
Forward/First Clutch Bearing Preload ...............................................................................................0.15 to 0.20 mm
6003-6
TRANSMISSION DISASSEMBLY
STEP 1 STEP 4
A15356 A15053
Install the transmission adapter plate CAS-10916 on Tag all lines as to location and remove from the
the transmission. transmission.
STEP 2 STEP 5
BD07B001
BD07B009
Remove the mounting bolts and remove the valve
body.
STEP 3
STEP 6
BD07B010
BD07B002
Drain the transmission and remove the internal oil Remove the mounting bolts, remove the port plate
filter. from the transmission.
6003-7
STEP 7 STEP 10
A15055 A15060
Remove the torque converter and flexplate. Install alignment marks on the oil supply flange and
the converter housing for installation. Install the
STEP 8 puller CAS-2268 and remove the oil supply flange.
Discard the gasket.
STEP 11
A15057
A15336
STEP 9 Remove the check ball and spring.
STEP 12
A15210
Remove the seal and needle bearing from the A15065

cover. Discard the seal. Remove the converter housing.
6003-8
STEP 13 STEP 16
A15066 A15071
Remove the shim and oil control ring from the input Remove the rear bearing.
shaft.
STEP 17
STEP 14
A15073
A15068 Remove the converter control valve.
STEP 18
STEP 15
BD07B011
Remove the transmitter.

A15069
Remove the spur gear.

6003-9
STEP 19 STEP 22
BD07B012 BD07B015
Invert the transmission and remove the input shaft. Pull the bearing from the spur gear.
STEP 20 STEP 23
BD07B013 BD07B016
Place the input shaft in a vice with soft caps. Loosen

the cap screw and remove the retaining plate.
STEP 21
STEP 24
BD07B014
BD07B017
Remove the spur gear from the shaft and remove Remove the bearing and driver from the shaft, watch
the snap ring from the shaft. for shims when removed.
IMPORTANT: Put cap over bolt hole prior to
installing puller to protect the threads in the shaft.
6003-10
STEP 25 STEP 28
BD07B018 A15081
Remove the bearing from the driver, watch for shims. Install the puller CAS-2268 and remove the charge
pump.
STEP 26
STEP 29
STEP 195
BD07B023
Remove the screw in sleeve.

STEP 27
STEP 30
A15080
BD07B024
Remove the two (2) small socket head screws and Drill a hole in the plug, use a slide hammer to remove
the one (1) large socket head screw opposite each the plug.
other.
6003-11
STEP 31 STEP 34
BD07B025 BD07B028
Use a slide hammer and pull the shaft partially out. Remove the snap ring.
STEP 32 STEP 35
BD07B026 BD07B029
Use a soft faced hammer and drive the gear from the
housing.
STEP 33 STEP 36
BD07B030
BD07B027
Remove the soft plug, remove the retaining bolt from
Remove the bolts and cover. the idler shaft.
6003-12
STEP 37 STEP 40
BD07B031 A15086
Use a slide hammer and remove the idler shaft and Remove the brake rotor.
bearings from the housing.
STEP 41
STEP 38
A15087
BD07B032 Remove and discard the output shaft seal.
STEP 42
STEP 39
A15088
Remove and discard expansion plugs.

BD07B033
Remove the output speed transmitter.

6003-13
STEP 43 STEP 46
A15092 A15097
Remove the first forward clutch end cover. Remove the third/fourth clutch end cover.
STEP 44 STEP 47
A15094 A15098
Remove third/fourth clutch shims.
STEP 45 STEP 48
A15099
A15095
Remove and discard all oil control rings from all
Remove the second/reverse clutch shims. clutch shafts.
6003-14
STEP 49 STEP 52
A15101 A15105
Remove the snap ring and spacer washers from the Remove the cover mounting bolts. Install two (2)
output shaft. bolts in the threaded holes to force the cover off.
STEP 50 STEP 53
A15308 A15100
Remove companion flange.
STEP 54
STEP 51
A15110
Remove the upper oil baffle.

A15102
Install blocks between the output shaft companion

flange and housing.
6003-15
STEP 55 STEP 58
A15111 A15114
Remove the output shaft and gear. Remove reverse/second clutch pack.
STEP 56 STEP 59
A15112 A15115
Remove forward/first clutch pack.
STEP 57 STEP 60
A15116
A15113
Remove reverse idler (coun te rshaft) gea r and
Remove third/fourth speed clutch pack. Pull the bearing.
other clutch packs away to get clearance.
6003-16
STEP 61 STEP 64
A15117 BD07B035
Remove output shaft roller bearing and spacer. Remove the shaft from the housing.
STEP 62 STEP 65
A15208 A15211
Remove the transmission breather.
STEP 63
BD07B034
Remove the bearing cups from the housing bores.

6003-17
FORWARD AND FIRST CLUTCH DISASSEMBLY

STEP 66 STEP 69
A15120 A15169
Using bearing collet CAS-2263-3 and collet holder Remove the snap ring.
CAS-2263-1, remove the bearing from the first
clutch. STEP 70
STEP 67
A15122
Remove the spacer ring and lubrication ring.

A15121
STEP 71
STEP 68
A15123
Remove the ball bearing.

A15168
Remove the ball bearing.

6003-18
STEP 72 STEP 74
A15128 A15130
Remove the spur gear and bearing cone from the Remove the tapered roller bearing.
forward clutch.
STEP 73
A15129
869L92
Remove the bearing cups and spacer from the

spur gear.
6003-19
CLUTCH CARRIER DISASSEMBLY

STEP 75 STEP 78
A15131 A15134
Remove the clutch disc retaining ring. Remove the retainer and spring.
STEP 76 STEP 79
A15135
A15132
Remove the clutch backing plates, top friction plate Remove the spacer washer.
and adjustment steel disc. Remove remainder of
discs.
STEP 80
STEP 77
A15139
Using compressed air, remove the piston from each

clutch. Discard the O-rings from the piston.
A15133
U s in g t u b e CA S -2 2 6 4 , co m p r e ss th e s p ri n g .
Remove the retaining ring.
6003-20
STEP 81
A15142
Remove plugs from the shaft only if you plan to clean
the oil channels in the shaft.
6003-21
703L92
STEP 82 STEP 83
A15143 A15144
Install new O-rings on the piston. Lubricate with Install the 1.10 mm shim.
petroleum jelly. Install the piston on the first side of
the housing (shaft end with oil grooves). Be careful
not to cut O-rings when installed. Honey combed
side of piston faces out.
6003-22
STEP 84 STEP 87
A15145 A15126
Install the spring and retainer. The chamfered side of Install a steel disc and then a friction disc until there
the retainer faces out. are 12 steel and 13 friction discs in place. The last
steel disc must be the adjustment steel disc. Install
STEP 85 the backing plate. The raised contact surface side
must face out.
STEP 88
A15146
Using tool CAS-2264, compress spring and install

retaining ring.
A15149
STEP 86 Install the retaining ring.
A15147
Install the disc with friction material on one side only.

The side of the disc with no material goes against the
piston.
6003-23
CLUTCH DISC CLEARANCE ADJUSTMENT

STEP 89
A15152
A15151
Measure from the edge of the carrier housing to the Pry the backing plate up as high as possible and
face of the backing plate. measure from the edge of the clutch housing to the
face of the backing plate again.
The difference between the two dimensions must be
2.1 to 2.5 mm.
There are three (3) adjustment steel discs available
to set the correct clearance, 2.5 mm, 3.0 mm, or 3.5
mm thick. Use the disc required to get the correct
clearance.
6003-24

Forward Clutch
702L92
STEP 90 STEP 91
869L92 A15257
Install the bearing cups into the spur gear until tight Using tube CAS-2266-1 and adapter ring
against the gear shoulder. CAS-2263-3, install bearing on forward pack side of
shaft until tight against the shaft shoulder.
6003-25
STEP 92 STEP 95
A15162 A15165
A l i g n t h e c l u t c h d i s c s u s in g a l i g n m e n t t o o l Using press tube CAS-2266-1 and adapter ring

CAS-2265-1 and spacer CAS-2265-3. CAS-2263-3, press bearing on until tight against
spacer.
STEP 93
STEP 96
A15163
A15166
Install the spur gear until engaged with all clutch
discs. Apply compressed air to the inlet port on the Install tapered bearing using tube CAS-2266-1 and
shaft and observe the spur gear. If the ear goes up adapter ring CAS-2266-3. Install slotted nut on shaft.
and down, all clutch discs are not engaged. The
gear must not move when air is applied.
STEP 94
A15164
Install the spacer ring.

6003-26
FIRST CLUTCH
700L92
STEP 97 STEP 98
A15167 A15173
Turn clutch pack over to first (short) clutch side and Measure the thickness of the oil control ring.
insta ll the b all b e aring un til a ga in st the sh aft
shoulder.
6003-27
STEP 99 STEP 102
A15172 A15175
Measure the thickness of spacer and snap ring Using align ment too l C AS-22 65-1 and spa cer
together. This dimension must be 0.05 mm smaller CAS-2265-4, align the clutch discs.
than the oil control ring thickness. Select the correct
size spacer to get the correct combined thickness. STEP 103
Spacers come in 14.1, 14.2, and 14.3 mm sizes.
STEP 100
A15176
Install the spur gear until all discs are fully engaged.
Apply compressed air to the inlet port on the shaft
A15174 and observe the spur gear. If the gear goes up and
Install the spacer and oil control ring. down, all the clutch discs are not engaged. The gear
must not move when air is applied.
STEP 101
STEP 104
A15169
A15177
Install the snap ring in the spur gear.
Install the ball bearing.
6003-28
STEP 105 STEP 107
A15178 A15181
Install a 1.5 mm thick shim on the shaft. Install collet CAS-2263-5 on lower bearing with collet
holder CAS-2263-1. Apply a 100 000 N load with
STEP 106 press at the upper bearing to assure all parts are
seated.
A15179
Using tube CAS-2266-1 and step plate

CAS-2266-4, press tapered bearing on until tight
against shim.
6003-29
STEP 108
A15183
Install slotted nut on the shaft.
798L92
FORWARD / FIRST CLUTCH ASSEMBLY
6003-30
SECOND AND REVERSE CLUTCH DISASSEMBLY

STEP 109 STEP 111
A15184
A15186
Using collet holder CAS-2263-1 and collet Remove the shim and spacer.
CAS-2263-2, remove the tapered roller bearing from
the second clutch side. STEP 112
STEP 110
A15187
Using collet h older CAS-2263-1 and collet

A15185
CAS-2263-4, remove the tapered roller bearing.
Remove the spur gear and speed sensing ring. The
upper bearing will also come off. If necessary, grind STEP 113
rivets off and remove sensing ring. The spur gear
has no other parts serviced separately.
A15189
Using collet h older CAS-2263-1 and collet

CAS-2263-4, remove the tapered roller bearing from
the reverse clutch side.
6003-31
STEP 114 STEP 117
A15190 A15130
Remove the spur gear. Remove the roller bearing.
STEP 115 STEP 118
A15248 A15132
Remove the bearing cups and snap ring. Disassemble both clutch carriers. See the steps for
the Clutch Carrier Disassembly, 56 through 62 for
STEP 116 this procedure.
A15191
Remove the shim.

6003-32
STEP 119
A15132
Assemble both clutch carriers. See Clutch Carrier

Assembly steps 63 to 69. The reverse clutch has 12
steel discs including the adjustment disc, and 13
friction discs including the disc with friction material
only on one side. The reverse clutch side of the
housing is bigger than the second clutch side.
The second clutch has 8 steel discs including the
adjustment disc and 9 friction discs including the disc
with friction material only on one side.
6003-33
SECOND AND REVERSE CLUTCH ASSEMBLY

Reverse Clutch
704L92
STEP 120 STEP 121
A15161 A15162
Install the bearing against the shaft shoulder using Align all clutch discs usin g the alignment to ol
press tube CAS-2266-1 and step plate CAS-2266-3 CAS-2265-1 and spacer CAS-2265-3.
for the reverse clutch pack.
6003-34
STEP 122 STEP 123
A15169 A15249
Install the snap ring into the spur gear. Install a bearing cup tight against the gear bore
shoulder.
6003-35
SPUR GEAR BEARING END PLAY PROCEDURE

STEP 124
A15253
A15252 Install a bearing cup tight against the gear bore

shoulder.
Take the difference between the two dimensions.
This is the reference dimension.
EXAMPLE:
Dimension 1 25.95 mm
Reference # 4.10 mm
740L92
Install the lower bearing cone. Support the bearing

on the inner race. Measure from the spur gear to the
bearing inner race, Dimension 1.
6003-36
731L92 732L92
Measure the upper bearing assembly as shown for plus or minus adjustment. Add or subtract this dimension to the
reference dimension to get spacer size needed. If the bearing inner race is above the outer race, you will add the
difference between the two to the referenced dimension.
Spacer sizes available in mm: 3.8, 3.85, 3.9, 4.0, 4.15, 4.2, 4.25, 4.3, 4.4, and 4.5.
STEP 125 STEP 127
A15257 A15258
Install lower bearing on shaft against shaft shoulder Install the spur gear until all clutch discs are fully
using tube CAS-2266-1 and step plate CAS-22-66-3. engaged. Apply compressed air to the inlet port on
the shaft and observe the spur gear. If the gear goes
STEP 126 up and down, all the clutch discs are not engaged.
The gear must not move when air is applied.
A15254
Install the upper bearing cup into the spur gear

against the snap ring.
6003-37
STEP 128 STEP 130
A15259 A15261
Install adjustment spacer with the oil control notches Install the outer bearing on the shaft using tube
up. CAS-2266-1 and step plate CAS-2266-2.
STEP 129 STEP 131
A15260 A15262
Install the upper bearing using tube CAS-2266-1 and Install washer and slotted nut.
step plate CAS-2266-4.
6003-38
Second Clutch
701L92
STEP 132
A15265
If removed, install sensing ring. Install lower bearing

into spur gear using press tube CAS-2266-1 and step
plate CAS-2266-2 to support the bearing.
6003-39
SPUR GEAR BEARING END PLAY PROCEDURE

STEP 133 STEP 135
A15266 A15269
Install sleeve and 3.55 mm shim on lower bearing Align all th e clutch discs usin g alignment to ol
race. Install the upper bearing. CAS-2265-1 and spacer CAS-2265-2.
STEP 134 STEP 136
A15264 A15270
Press bearing assembly together. Install a dial Install the lower bearing against the shaft shoulder
indicator on press and indicate to the spur gear. using tube CAS-2266-1 and step plate CAS-2266-2.
Move the spur gear up and down and check end
play. End play must be 0.05 to 0.15 mm. Select the
correct size shim for the correct end play.
6003-40
STEP 137 STEP 140
A15271 A15275
Install the spur gear until all clutch discs are fully Install the outer bearing on the shaft using tube
engaged. Apply compressed air to the inlet port on CAS-2266-1 and step plate CAS-2266-2.
up and down all the clutch discs are not engaged. STEP 141
The gear must not move when air is applied.
STEP 138
A15276
Support the clutch assembly lower bearing on the

inner race. Apply a 100 000 N load with the press to
A15272 assure the parts are seated.
Install the sleeve and shim.
STEP 139
A15274
Install the upper bearing using tube CAS-2266-1 and

6003-41
STEP 142
A15277
Install the slotted nut.
796L92
6003-42
THIRD AND FOURTH CLUTCH DISASSEMBLY

STEP 143 STEP 146
A15193 A15200
Using holder CAS-2263-1 only, remove the bearing. Turn the clutch over. Using holder CAS-2263-1 and
collet CAS-2263-5, remove the other bearing.
STEP 144
STEP 147
A15194
Remove the shim and upper bearing. A15202
Remove spur gear and upper bearing.

STEP 145
STEP 148
A15198
Remove the three (3) rings. A15203
Remove the spacer.

6003-43
STEP 149 STEP 152
A15204 A15207
Remove the lower bearing. Press the lower bearing and sleeve from the shaft.
Do no press on the bearing, only on the sleeve.
STEP 150
STEP 153
A15205
Press the shaft from the clutch. A15219
Remove the piston ring from the shaft.

STEP 151
STEP 154
A15220
Remove the clutch packs from the spur gear. A15213
Disassemble both clutch packs. See Clutch Carrier

Disassembly steps 56 through 62 for this procedure.
6003-44
STEP 155
The third clutch has 8 steel discs including the
with friction material on one side.
The fourth clutch has 7 steel discs including the
with friction material only on one side.
A15213
Assemble both clutch packs. See Clutch Carrier

Assembly steps 63 through 69 for this procedure.
THIRD AND FOURTH CLUTCH ASSEMBLY

Third Clutch
699L92
6003-45
STEP 156 STEP 159
A15220A A15224
Install the oil control ring on clutch shaft. Lock the Install the spur gear on the third side of the clutch
ring ends together. pack (long side of carrier) until all clutch discs are
fully engaged. Apply compressed air to the inlet port
STEP 157 on the shaft and observe the spur gear. If the gear
goes up and down, all the clutch discs are not
engaged. The gear must not move when air is
applied.
STEP 160
A15222
Press the sleeve and lower bearing onto the clutch

shaft so the bearing is against the shaft ridge.
STEP 158
A15225
Install the shaft into the clutch pack assembly.
STEP 161
A15223
Align all clutch discs on the third clutch (long side of

carrier) using aligning tool CAS-2265-1.
733L92
Install three (3) rings as shown in illustration.

6003-46
STEP 162 STEP 163
A15229 A15230
Install the upper bearing and washer. Install the tapered roller bearing against the upper
bearing using tube CAS-2267.
Fourth Clutch
703L92
6003-47
STEP 164 STEP 167
A15231 A15234B
Alig n c lu tch discs o n fo urth clutch side us in g Install the oil control spacer.
alignment tool CAS-2265-1 and spacer CAS-2265-3.
STEP 168
STEP 165
A15233
A15234 Install the upper ball bearing.
Install the ball bearing against the shaft shoulder.
STEP 169
STEP 166
A15236
A15234A Install the tapered bearing against the upper bearing.
Install the spur gear until all clutch discs are fully
engaged. Apply compressed air to the inlet port on
up and down, all clutch discs are not engaged. The
gear must not move when air is applied.
6003-48
STEP 170 STEP 171
A15237 A15237A
Press assembly together to a load of 100 000 N. Install the spacers and slotted nuts on the shaft.
Press only on the inner races of the two (2) bearings.
794L92
FOURTH/THIRD CLUTCH ASSEMBLY
CHARGE PUMP DISASSEMBLY

STEP 172 STEP 173
A15279 A15280
Remove the shaft from the pump. Do not lose shims Remove the cover from the pump. If necessary, drive
that may be on the shaft. the needle bearing from the cover.
6003-49
STEP 174 STEP 176
A15281 A15283
Mark the gear set for assembly later and remove it Remove the bearing.
from the coupling with the square key.
STEP 177
STEP 175
A15284
A15282 Measure from the pump housing to the surface of the
Remove the snap ring, drive coupling, and bearing. If gears. If there is more than 0.05 mm of end play,
n ece ss ar y, re mov e the thr ee rin gs in side th e replace the pump assembly. The pump housing,
coupling. c o v e r , a n d g e a r s e t a r e o n l y s e r v i ce d a s a n
assembly.
6003-50
CHARGE PUMP ASSEMBLY
742L92
STEP 178 STEP 180
A15282 A15280
Install the three rings inside the coupling and the Install the needle bearing in the cover and the cover
bearing on the coupling. Install the coupling and snap on the pump housing.
ring.
STEP 179
A15281
Install the gear set into the housing with a square

key.
6003-51
STEP 181
A15279
Install the shaft with shim. Apply Loctite 242 to screw

and tighten to a torque of 32 Nm.
799L92
CHARGE PUMP
6003-52
TRANSMISSION ASSEMBLY
STEP 182 STEP 184
A15208 A15289
Install all bearing cups, spacers, and snap rings into Install the first and forward clutch pack assembly.
the transmission housing.
STEP 185
STEP 183
A15290
A15116 I n s ta ll t h e s e c o n d a n d r e v e r s e fo u r th c lu t c h
Install the reverse idler (countershaft) gear with assembly.
bearings and shim.
STEP 186
793L92
A15291
Install the third and fourth clutch assembly. Move the

other clutch packs to help install the clutches. Install
and lock together all oil control rings on the clutch
shafts.
6003-53
759L92
OUTPUT SHAFT GROUP
STEP 187 STEP 188
A15112 A15292
Install the lower baffle plate. Install the shim and bearing for the output shaft.
STEP 189
Install the control valve assembly. See Section 6001
for procedure.
6003-54
Reverse Idler (Countershaft) Bearing Preload Procedure

STEP 190
A15286 A15288
Measure from the upper shoulder to the lower Install the reverse idler (countershaft). Measure from
shoulder of the reverse idler (counters haft) the housing to the countershaft (Dimension 3). Select
Dimension 1. the correct shim size needed from the following
procedure:
EXAMPLE:
Dimension 3 +0.60 mm
Dimension X 54.55 mm
Dimension X -54.55 mm
Difference 2.56 mm
Bearing Preload +0.04 mm
Shim Size Needed 2.60 mm
743L92
Preload must be within 0 to 0.10 mm.
STEP 191
A15287
Assemble the gear and both bearings. Measure

between the outside of both inner races (Dimension
2). A15294
Install the output gear.

6003-55
STEP 192 STEP 194
A15295 A15297
Install the output shaft. The longer splined end goes Install the cover without bearing cups. Tighten the
into the gear. bolts to a torque of 46 Nm.
STEP 193
A15296
Install the upper oil baffle. Tighten the bolts to a

torque of 23 Nm.
6003-56
Output Shaft Bearing End Play Procedure

STEP 195 STEP 196
A15300 A15302
Measure from the case surface to the shoulder on Install the correct shim.
the output shaft (Dimension 1).
STEP 197
A15298
A15303
Measure from the case surface to the shoulder in the
case bore (Dimension 2). Subtract Dimension 2 from Install the bearing on the output shaft.
Dimension 1. Subtract 0.4 mm from your difference
for the shaft end play. Select a shim of the correct STEP 198
size.
EXAMPLE:
Dimension 2 -50.40 mm
Difference 2.80 mm
Subtract for the Play -0.40 mm
A15304
Install the correct number / size shims and snap ring

so the bearing will not move up or down.
6003-57
STEP 199 STEP 200
A15305 A15308
Install the seal so the lip is to the inside. Apply RTV Tighten all the slotted nuts on the clutch packs to a
sealant between the outer diameter of the seal and torque of 550 Nm.
the housing.
STEP 201
A15306
Install bearing cup for the second / reverse and third /

fourth clutch assemblies.
792L92
6003-58
Second / Reverse Clutch Bearing End Play Procedure

STEP 202 EXAMPLE:
Dimension 1 7.58 mm
Difference 0.63 mm
Shim Needed 1.80 mm
STEP 203
A15310
Clamp the bearing cup in place. Measure from the

bearing cup to the cover surface (Dimension 1).
A15097
A15312
Measure from the mounting surface of the end cap to

the shoulder inside the cap (Dimension 2).
47L92
Install the correct shim in the end cap and hold in

place with grease. Install the end cap with a new
O-ring and tighten the bolts to a torque of 46 Nm.
Make sure the cap ports face the correct direction.
STEP 204
Duplicate step 183 for the third / fourth clutch pack.
A15095
Select the correct size shim using the procedure

here:
6003-59
Forward / First Clutch Bearing End Play Procedure

STEP 205 STEP 207
A15315 A15317
Install the bearing cup on the forward / first clutch Measure from the end of the end cap to the inner
bearing cone. Measure from the cover surface to the shoulder of the cap (bearing mounting surface) for
bearing cup (Dimension 1). Dimension 3.
Select the correct shim size from the following
STEP 206 procedure:
A15316
Measure from the end cap mounting flange to the

end of the cap (Dimension 2).
745L92
EXAMPLE:
Subtract Dimension 4 from Dimension 1.
Difference 1.00 mm
6003-60
STEP 208 STEP 210
A15221 A15320
Install the correct shim and bearing cup into the end Install all new expansion plugs until flush with the
cap. Install the end cap with a new O-ring and tighten housing. The lips must be toward the inside of the
the bolts to a torque of 46 Nm. housing. Apply Loctite 277 to sealing surfaces of
each plug.
STEP 209
STEP 211
A15318
Install the reverse idler (countershaft). Be sure the A15321
spring pin in the bottom of the shaft aligns with the Install the brake rotor. Tighten the bolts to a torque of
hose in the housing. Tighten the bolt to a torque of 46 46 Nm. Install the bolt locking washer.
Nm.
STEP 212
A15322
Install the parking brake caliper. Tighten the bolts to

a torque of 185 Nm.
6003-61
STEP 213 STEP 216
BD07B036 BD07B039
Install idler shaft gear and layshaft and align. Heat Remove the guide bolt, use Loctite 243 on the
the components. threads, install and torque the retaining bolt to 46 Nm
(34 pound-feet).
STEP 214
STEP 217
BD07B037
Install and aligning screw. BD07B040
Use Loctite 262 on sealing plugs, install plugs until

STEP 215 flush with housing.
STEP 218
BD07B038
Install idler shaft.

A15323
Apply Loctite 221 to the area around the openings on

the side of the pump and install into the transmission.
6003-62
STEP 219 STEP 222
STEP 195 STEP 198
Install the pump flange. Tighten the bolts to a torque Install the filter and cover with a new O-ring. Tighten
of 79 Nm. the bolts to a torque of 23 Nm.
STEP 220
A15325
Install the output shaft seal with the lip inward. Apply
RTV sealant to outer diameter of seal and housing
after installed.
STEP 221
A15326
Install the companion flange. Tighten the bolts to a

torque of 46 Nm. Install the locking washers on bolts.
6003-63
746L92
INPUT GROUP
STEP 223 STEP 224
BD07B041 BD07B042
Install the three V-rings into the recess of the shaft, Install a 2 MM. (0.078 inch) shim and bearing.
install the key.
6003-64
STEP 225 STEP 228
BD07B043 BD07B046
Install a 2 MM. (0.078 inch) shim. Install a snap ring on the shaft, install the input gear.
STEP 226 STEP 229
BD07B044 BD07B047
Install the shaft and bearing, use Loctite 243 on the Install the snap ring onto the shaft.
threads of the bolt, install and torque the bolt to 32
Nm (23.5 pound-feet). STEP 230
STEP 227
BD07B048
Install the input shaft into the housing, align key into
BD07B045 the keyway by turning the shaft.
Press a new bearing onto the spur gear.
6003-65
STEP 231 STEP 234
STEP 199 A15330
Install the bearing cup into the converter housing. Install the spur gear into the housing.
STEP 232 STEP 235
A15073 A15331
Install the converter control valve. Install the drive shaft.
STEP 233 STEP 236
A15329 A15332
Install the bearing cone into the cup. Install the bearing cone using tube CAS-2266-1 and
6003-66
STEP 237
A15333
Install the bearing cup.

6003-67
Converter Bearing Preload Procedure

STEP 238
STEP 206 A15338
Install converter housing. Tighten the bolts to a Measure from the bottom of the housing to the
torque of 34 Nm (M8 bolts), 79 Nm (M12-8.8 bolts) bearing outer race locating surface (Dimension 3).
and 117 Nm (M12-10.9 bolts). Determine shim size needed by using the following:
Measure from the bearing outer race (cup) to the EXAMPLE:
flange mounting surface (Dimension 1). Dimension 2 65.37 mm
STEP 239
Dimension X 60.87 mm
Difference 1.23 mm
STEP 240
A15337
A15335
Install the oil control ring on the drive shaft. Lock the
ends of the ring together.
751L92
Install the gasket on the flange and measure from the

gasket to the bottom of the oil supply housing
(Dimension 2).
6003-68
STEP 241 STEP 244
A15366 A15341
Install the relief valve spring and ball. Install the oil supply housing. Align the marks you
made before removal. The openings in the housing
STEP 242 must alig n w ith th e op enings in the con verte r
housing.
STEP 245
A15340
Install the correct shim. Apply grease on shim to hold

in place.
A15342
STEP 243 Install the cover. Tighten the bolts to a torque of 46

Nm.
A15339
Apply Loctite 221 to the area around the two ports.

6003-69
STEP 246 STEP 247
A15055 BD07B003
Install the flexplate on the converter and tighten the Install pipe connectors (1 - 4), install plug (5) and
bolts to a torque of 46 Nm. Apply Loctite 270 to torque to 40 Nm (29.5 pound feet), and install plug
threads of the bolts. Install a new sealing ring on the (6) and torque to 6 Nm (53 pound inch).
shaft of the converter. Install the converter.
STEP 248
BD07B004
Install new O-ring and tighten plug to 80 Nm (59

pound feet).
797L92 STEP 249

INPUT ASSEMBLY
BD07B005
Install two aligning studs (M8) and new gasket.

6003-70
STEP 250 STEP 252
BD07B006 BD07B008
Install the duct plate and torque mounting bolts to 23 Install 6 M6 x 100 MM. and 17 M6 x 76 MM. bolts
Nm (17 pound feet). and torque to 12 Nm (106 pound inch).
NOTE: M6 x 100 MM. bolts are located at the
STEP 251 arrows.
BD07B007
Install two aligning studs (M6) and new gasket.

6003-71
Speed Sensing Adjustment

STEP 253 STEP 254
BS07B001
1. ENGINE 2. TURBINE 3. INTERNAL
Location of sensor.
BS07B002
Output speed sensor (4).

6003-72
STEP 255 STEP 256
BD07B049
Measure dimension (I) on the transmitter from

contact face to the screw-in face.
Dim. (I) e.g.... 30.00 MM.
STEP 257
Turn the input shaft until a tooth tip is centered in the
bore of the gauge plug hole.
STEP 258
BS07B003
1. ENGINE 4. X = 0.5 +0.3 MM.

2. TURBINE 5. X = 0.5 +0.3 MM.
3. INTERNAL 6. X = 0.3 ±0.1 MM.
Gap X must be determined for each of the speed

sensors 1, 2, and 3.
BD07B050
Install the plug gauge making sure that the gauge is

fully seated. Loosen the set screw and push the
plunger against the gear tooth, tighten the set screw.
NOTE: The tool shown is not offered, use a depth
mike or caliper in this procedure.
6003-73
STEP 259 STEP 261
Calculation of needed shims as below.
Example A
Dimension II 30.10 mm
Dimension A 29.50 mm
Example B
Dimension I 30.00 mm
Dimension A -29.50 mm
Dimension S (shims) 0.50 mm
STEP 262
BD07B052
Install shim (s) as required, apply Loctite 574 to the

threads.
STEP 263
BS07B004
Install transmitter and torque to 30 Nm (22 pound
feet).
Example of correctly installed gauge, dimension II.
NOTE: The tool shown is not offered, use a depth STEP 264
mike or caliper in this procedure. Repeat the procedure for turbine and internal speed
transmitters.
STEP 260
BD07B051
Measure dimension (II) on the gauge from contact

face to the screw-in face.
Dim. (II) e.g.... 30.10 MM.
6003-74
STEP 265 STEP 267
BD07B056
Measure dimension (II) on the transmitter from

contact face to the mounting face.
Dim. (I) e.g.... 40.00 MM.
BS07B005 STEP 268

Calculation of needed shims as below.
1. SPUR GEAR 3. HOUSING
2. TRANSMITTER Example A
Dimension X for the output speed transmitter is 1.0 + Dimension I 39.70 mm
0.5 MM. Dimension X -1.20 mm
Instal. Dimension 38.50 mm
STEP 266
Example B
Dimension II 40.00 mm
Instal. Dimension -38.50 mm
Dimension (shims) 1.50 mm
BD07B055
Determine dimension from housing face (3) to spur

gear (1).
Dim (I) e.g.....39.70 MM.
6003-75
STEP 269 STEP 270
BD07B057 BD07B058
Install required shims, lubricate O-ring with Install and torque the mounting screw to 23 Nm (17
Molydisulfide grease. pound feet).
6003-76
HOW IT WORKS
764L92
1. INPUT GEAR 6. REVERSE IDLER (COUNTERSHAFT) GEAR

2. FORWARD CLUTCH AND GEAR 7. FOURTH CLUTCH AND GEAR
3. FIRST CLUTCH AND GEAR 8. THIRD CLUTCH AND GEAR
4. REVERSE CLUTCH AND GEAR 9. OUTPUT GEAR
5. SECOND CLUTCH AND GEAR
POWER FLOW
Gears 1, 2, 4, 6, and 7 are in constant mesh. When SECOND GEAR FORWARD - Energize M3 which
converter turns, all gears are running. permits oil flow to forward clutch. Energize M4 which
permits oil flow to second clutch and dumps third
clutch to reservoir.
Gears 3, 5, 8, and 9 are in constant mesh only with
each other.
(Poppet valves are inside the valve body)
FIRST GEAR FO RWARD - Energize M3 which
permits oil flow to forward clutch. Energize M2 which
positions poppet valve (M2) to redirect oil flow from
M3 poppet to second clutch. Energize M4 which
permits oil flow to through poppet valve (M4) to
858L92 poppet valve (M2).
FOURTH GEAR FORWARD ONLY - You energize FIR ST G EAR REVERSE - Ener gize M1 wh ich
M5 solenoid which locks up fourth clutch. The fourth permits oil flow to reverse clutch. Energize M2 to
clutch now drives the carrier, which drives the third redirect oil flow from poppet valve (M4) to poppet
gear clutch, and in turn, third gear which drives the valve (M2) and out to first clutch (also dumps third
outer gear. Third gear is locked hydraulically at this clutch). Energize M4 to permit oil flow to poppet
time. (No solenoids needed). valve (M2).
THIRD GEAR FORWARD - Energize M3 which
permits oil flow to forward clutch. Third clutch is still
hydraulically locked up.
6003-77
SECOND GEAR REVERSE - Energize M1 which THIRD GEAR REVERSE - Energize M1 wh ich
permits oil flow to reverse clutch. Energize M4 which permits oil flow to reverse clutch. Third clutch is still
permits oil flow through M4 poppet valve to M2 hydraulically locked up.
poppet valve which is open to second clutch and also
dumps third clutch oil.
782L92A
6003-78
NOTES
Section
6004
FRONT AND REAR AXLE

6004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISASSEMBLY OF DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DISASSEMBLY OF THE BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ASSEMBLY OF DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Determine Shim Thickness for a Perfect Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Adjust Rolling Moment of Drive Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6004-3
SPECIAL TOOLS
Differential bearing cone puller collet set..................................................................................................... CAS2839
Differential bearing cone puller collet set.................................................................................................... CAS2840
Pinion seal installer...................................................................................................................................... CAS2841
Pinion locknut wrench.................................................................................................................................. CAS2842
Pinion bearing puller collet set..................................................................................................................... CAS2843
Puller body and forcing screw ..................................................................................................................... CAS2844
Forcing screw, nut, and trust washers......................................................................................................... CAS2845
Pinion shaft lifting bail.................................................................................................................................. CAS2846
Differential assembly holding bracket set ..................................................................................................380001562
Planetary ring gear puller ..........................................................................................................................380001563
Planetary bearing puller collet set .............................................................................................................. CAS2849
Brake housing puller..................................................................................................................................380001564
Differential bearing preload wrench ...........................................................................................................380001565
Brake housing outer bearing cup installer ................................................................................................... CAS2852
Brake housing inner bearing cup installer .................................................................................................380001751
Pinion outer bearing cup installer ................................................................................................................ CAS2854
Pinion inner bearing cup installer ................................................................................................................ CAS2855
Locknut socket and nuts.............................................................................................................................. CAS2856
Differential lifting bracket ............................................................................................................................. CAS2857
Pinion depth gauge set................................................................................................................................ CAS2858
Wheel end guide stud set ......................................................................................................................... 380001752
Puller body and screw .............................................................................................................................. 380001575
Support bracket .........................................................................................................................................380001576
Slide hammer adapter ............................................................................................................................ CAS10846-3
Slide hammer ..............................................................................................................................................OEM4252
Handle (included in CAS1773 or CAS1716)............................................................................................ CAS1716-3
Replacer ..................................................................................................................................................... CAS2205
Puller plate (included in CAS40040)............................................................................................................ CAS2510
Magnetic base with indicator .....................................................................................................................380001725
Heat gun ....................................................................................................................................................380001544
Lifting sling.................................................................................................................................................380001579
Pulling attachment ..................................................................................................................................... 380001578
Engine stand..............................................................................................................................................380001580
Holding bar ................................................................................................................................................380001546
Step plate (included in 380001539) ...........................................................................................................380001539
Step plate (included in 380001539) ...........................................................................................................380001541
Drive plate (included in OEM6231).................................................................................................................... 27555
6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015
6004-6
LUBRICATION
1� 1
2� 2�
1� 1�
5� 3�
3� 5�
3� 4� 4�
3�
BS00M069 BS00M070
1. BRAKE BLEEDER 3. OIL DRAIN HOLE (OUTPUTS) OIL 5. OIL FILLER HOLE
2. BLEEDER 4. DRAIN HOLE (AXLE CASING)
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a changed braking
behavior.
A wear measurement has to be made on both wheel ends.
Remove screw plug, actuate brake and determine dimension “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).
6004-7
WHEEL END AND BRAKES

Disassembly STEP 3
STEP 1
BD00M238
Pry the cover off the wheel end.

BD00M235
Fasten the axle on a stand. STEP 4
STEP 2
BD03B008
Use 380001582 slide ha mmer and 380 001545

adapter, remove the slotted pin from wheel end lock
BD00M236
nut.
STEP 5
BD00M237
BD03B009
Loosen the screw plugs and drain the oil from the Using 380001571 locknut socket and 380001576
axle casting. support bracket, loosen and remove the locknut.
6004-8
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).
6004-9
STEP 12 STEP 15
BD03B012
Remove the snap rings from the planet gear shaft BD03B015
using 380001585 snap ring pliers. Using suitable puller, remove planetary ring gear
from brake housing.
STEP 13
STEP 16
BD03B013
Remove the planet gear using 380001563 gear

puller and 380001539 step plate. BD03B016
Remove O-rings from the annular grooves of the ring

STEP 14 gear.
STEP 17
BD03B014
Remo ve the b earing fro m th e plane ta ry usin g

380001757 collet set, 380001575 puller body and BD03B017
screw, and 8061 step plate. Remove O-ring from recess of the brake housing.
6004-10
STEP 18 STEP 21
BD03B021
BD00M253 Use compressed air to raise piston out of the brake
Remove the brake disc pack from the brake housing. housing.
STEP 19 STEP 22
BD03B019
Drive slotted pins in the support shim until they are BD00M257
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.
6004-11
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
Pull the pin out of the support shim and remove the and U-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
BD03B023
Press the gripping rings off of the pins.
Using 38001564 puller bridge and 380001542 step
plate, remove the brake housing from the wheel end
shaft.
6004-12
STEP 30 STEP 32
BD03B024
Use acceptable lifting equipment and lift the brake BD00M267
housing from the wheel end shaft. Remove the shaft seal from the brake housing.
STEP 31 STEP 33
BD00M266 W270-2R037
If necessary drive both bearing outer rings out of the Pull bearing inner from the output shaft.
brake housing.
STEP 34
BD00M269
If the wheel end pressure ring needs to be replaced,

remove the pressure ring from the wheel end shaft.
6004-13
Assembly
WARNING: Always wear heat protective gloves
to prevent burning your hand when handling
STEP 35 heated parts.
SM121A
STEP 38
W270-2R007
Insert wheel bolt into the output shaft until contact.
STEP 36 BD00M273
Heat the bearing inner ring and install it onto the

wheel end shaft.
STEP 39
BD00M271
Install a new pressure ring 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.
W270-2R008
Press bearing sheet over the collar of the output shaft.

NOTE:
6004-14
STEP 41 STEP 42
BD03B024
BD03B027 Use acceptable lifting equipment and install the
Use a solution of 50% water and 50% mineral spirits brake housing over the wheel end shaft until contact.
to wet the outer diameter of the shaft seal. Using
380001574 install the shaft seal with the sealing lip WARNING: Always wear heat protective
showing to the oil chamber. See illustration below. gloves to prevent burning your hand when
handling heated parts.
SM121A
STEP 43
BS00M073
SHAFT SEAL
BD00M277
1. BRAKE HOUSING
2. SHAFT SEAL Heat the bearing inner ring and install it into the
* GREASE FILLING brake housing until contact.
6004-15
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 5. U-RING

2. GUIDE RING 6. SUPPORT RING
3. SUPPORT RING 7. WHEEL END SHAFT
4. U-RING
BD00M280
Install the guide ring, support rings and U-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.
6004-16
STEP 47
BD00M281
Insert the pins into the assembly fixture until contact.
STEP 48
BS00M074
1. PIN 4. SUPPORT SHIM

2. GRIPPING RINGS 5. RETAINING RING
3. CUP SPRINGS X. 10.5 MM +0.3 (0.41 IN +0.02 )
STEP 50
BD00M282
1. GRIPPING RINGS
Press the gripping rings onto the pins until contact on

the assembly fixture.
ATTENTION: Observe the installation position, install
the gripping rings with the orifices offset by 180 to each BD00M284
other. Insert the assembled pins into the support shim and
install the snap ring.
STEP 49
STEP 51
BD00M283
Install the cup springs onto the pins. See illustration BD00M285
below. Insert the assembled support shim into the piston.
6004-17
STEP 52 STEP 54
1
BD00M286 BD00M288
1. SPLINE
Install the circlip into the brake housing.
Drive the stop bolt into the planet carrier. Then coat
STEP 53 the spline with anti-corrosive antiseize.
STEP 55
BD03B028
BD00M289
Insert the planet carrier into the spline of the wheel

end shaft until contact.
STEP 56
BD03B034
1. BRAKE HOUSING 4. SUPPORT SHIM

2. CIRCLIP 5. PISTON
X INSTALLATION DIMENSION
3. SLOTTED PIN
4.0 - 0.5 MM
Drive slotted pins into the bores of the support shim
to lock the circlip.
W270-2R009
Mount outer and inner disks (lining disks with paper

or sinter lining).
NOTE: Quantity and arrangement of the disks please take
related spare parts list.
6004-18
Version with additional damping disks STEP 59
STEP 57
BD03B016
Grease both O-rings.
STEP 60
W270-2R010
WARNING: When mounting damping disks

(outer disks coated on one side, see arrows)
pay attention to the position of the coated
side (see sketch left).
SM121A
STEP 58
BD03B030
Install two aligning dowels in the brake housing,

install ring gear onto the brake housing.
NOTE: Make sure alignment is correct on ring gear.
BD03B029
Insert O-ring into the recess of the brake housing.

6004-19
WARNING: Always wear heat protective WARNING: Always wear heat protective
gloves to prevent burning your hand when gloves to prevent burning your hand when
handling heated parts. handling heated parts.
SM121A SM121A
STEP 61 STEP 63
BD00M292 BD00M294
Install the bearings with the big radius showing to the Heat the bearing inner rings and install into the
planet carrier (downwards). planet gears.
STEP 62 STEP 64
BD00M293 BD03B031
Put the planet gears onto the bearing inner rings. Install the snap rings on the planet gear shafts using
380001585 snap ring pliers.
6004-20
Adjust end play of sun gear shaft 0.5 to STEP 67
2.0 mm (0.02 to 0.08 inch)
STEP 65
BD00M298
Insert the sun gear shaft onto the stub shaft until
contact.
BD00M296
Determine dimension I, from the mounting face of the STEP 68

brake housing up to the face of the stop bolt.
Dimension I e.g. . . . . . . . . . . . 67.90 mm (2.67 inch)
STEP 66
BD00M299
Determine dimension II from the face of the sun gear

shaft up to the mounting face of the axle casing.
Dimension II e.g. . . . . . . . . . . . 63.00 mm (2.5 inch)
BD00M297 Example:
Insert the stub shaft into the spline of the axle bevel
Dimension I 67.90 mm (2.67 inch)
gear until contact.
Dimension II 63.00 mm (2.5 inch)
Difference 4.90 mm (0.17 inch)
Required end play e.g. 1.10 mm (0.04 inch)
Difference = shim e.g. s 3.80 mm (0.13 inch)
6004-21
STEP 69 STEP 72
BD00M245 BD00M300
Insert the sun gear shaft into the planet carrier. Install the washers and bolts by hand.
Tightening torque . . . . . . . 390 Nm (288 pound-feet)
STEP 70
STEP 73
BD00M244
Install the determined shim(s), e.g. S. = 3.80 mm BD03B033

(0.14 inch) into the sun gear shaft with grease. Install the locknut by hand and tighten it using
380001571 locknut socket and 380001576 support
STEP 71 bracket.
Tighten torque . 1500 +200 Nm (1106 +147 pound-feet)
STEP 74
BD03B032
Install O-ring and hold into place with grease, install

output housing onto axle.
BD00M302
Secure the locknut with the slotted pin.

6004-22
STEP 75 STEP 76
BD00M303 BD00M304
1. O-RING
Insert the cover into the wheel end.
Install an O-ring on the cover.
6004-23
LEAKAGE TEST OF THE BRAKE HYDRAULICS

1. Open the bleeder.
2. Slowly actuate the HP-pump until oil flows out of the bleeder.
3. Close the bleeder egein.
4. Slowly pressurize the HP-pump with > 10 bar and hold the pressure for some seconds.
NOTE: The brake piston extends and the cylinder chamber fills up with oil. The air accumulates in the upper section of the
cylinder chamber.
5. Loosen the shut-off valve on the HP-pump.
NOTE: The reversing piston presses the air from the upper section of the cylinder into the brake line.
6. Open the bleeder again.
7. Slowly actuate the HP-pump until oil flows out of the bleeder.
ATTENTION: Repeat procedure Item 3 - 7- until -at Item 7- from the beginning of the actuation no more air exist from
bleeder.
NOTE: Then pressurize the brake temporarily (5x) with p = 100 bar max.
High Pressure Test

STEP 77 Low Pressure Test
Reduce test pressure to p = 5 bar (72.5 psi) and
close the shutoff valve again.
During a 5 minute testing time a pressure drop is not
allowed.
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.
6004-24
DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES

STEP 1 STEP 3
BD00M235 BD00M241
Fasten the axle on a stand. Use acceptable lifting equipment to hold the wheel
end in place. Loosen and remove the bolts.
STEP 2
STEP 4
BD00M236 BD03B032
Separate the wheel end from the axle housing.

Remove 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).
6004-25
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 the
axle casing. STEP 10
STEP 7
BD01F072
Loosen an d remove both adjusting nuts u sing

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

carrier out of the axle casing. STEP 11
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.
6004-26
STEP 12 STEP 13
BD00M401 BD00M402
Loosen the bolts and take off both bearing brackets. Remove both bearing outer rings from the differential
carrier.
NOTE: Make an alignment mark between the bearing
bracket and the housing.
STEP 14
ATTENTION: Loosen the bolts by hand only.
BD00M403
U se a c ce p ta b le liftin g e q uip me n t a nd lift th e

differential out of the differential carrier.
6004-27
DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL

STEP 15 STEP 18
W270-2R011 W270-2R013
Pull bearing iner ring from the differential housing. Loosen cap screws and remove released housing
cover.
STEP 16
STEP 19
W270-2R012
Pull bearing inner ring from the housing cover. BD00M407
Remove all the single parts from the differential

STEP 17 housing.
STEP 20
BD00M406
Place the differential in a press to prevent it from

turning. Remove the bolts and the released housing BD00M408
cover. Press off the ring gear from the differential housing.
6004-28
DISASSEMBLY OF DRIVE PINION

STEP 21 STEP 24
BD00M409 BD00M412
Heat the pinion shaft locknut with a hot air gun. Remove the shaft seal from the differential carrier.
NOTE: Locknut is held with Loctite Type No. 262.
STEP 25
STEP 22
W270-2R015
Press drive pinion out of the axle drive housing by

W270-2R014
means of two-armed puller (S) and remove the
Loosen slotted nut and remove the washer behind it.
released bearing inner ring.
STEP 23 STEP 26
BD00M411
W270-2R016
Pull the input yoke from the drive pinion shaft.
Take off spacer ring and pull bearing inner ring from
the drive pinion.
6004-29
STEP 27 STEP 30
BD00M414 W270-2R019
If necessary drive out both bearing outer rings from Loosen pipe union.
the differential carrier.
STEP 31
STEP 28
W270-2R020
W270-2R017 Loosen hexagon screw and remove released cooling
Loosen both pipe unions (also see arrow). pipe from the axle casing.
STEP 29
W270-2R018
Loosen hexagon srew.

6004-30
STEP 32 STEP 35
BD00M334 BD00M337
Remove the screw plug with the vent valve from the Disconnect the pipe union and remove the released
axle casing. brake tube from the axle casing.
STEP 33 STEP 36
BD00M335 BD00M338
Loosen and remove the hexagon screw from the Remove the vent valve from the connection part.
axle.
STEP 37
STEP 34
BD00M339
BD00M336 Loosen the connection part and remove it from the
Loosen and remove the union screw from the axle. axle. Repeat steps 33 to 37 for the other wheel end.
6004-31
ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER

STEP 38 STEP 41
1� 2�
3�
4�
1�
BD00M340 BD00M343
1. O-RING
1. VENT 2. CONNECTION 3. O-RING 4. RECTANGULAR
VALVE PART RING Install an O-ring into the groove of the brake tube.
Assemble the part as shown in the photo above.
STEP 42
STEP 39
2
1�
BD00M344
1. BRAKE TUBE
BD00M341
2. UNION SCREW
Install the connection part on the axle casing.
Tightening torque . . . . . . . . 130 Nm (96 pound feet) Insert the brake tube into the axle casing, assembling
the connection part through the union screw.
STEP 40
BD00M342
Install the union screw with a new O-ring on the axle.

Tightening torque . . . . . . 150 Nm (110 pound-feet)
6004-32
STEP 43 STEP 46
BD00M345 W270-2R021
Fasten the brake tube with the hexagon nut and Install connection socket.
union nut. Tightening torque . . . . . . . . . 80 Nm (59 pound-feet)
Tightening torque . . . . . . . . 100 Nm (73 pound-feet)
STEP 47
STEP 44
W270-2R022
BD00M346 P l a c e c o o l i n g p ip e i n t o t h e a x l e c a s i n g a n d
Tightening torque . . . . . . . . . 80 Nm (60 pound-feet) preliminarily fasten union or union hut by hand.
NOTE: Repeat steps 38 to 44 for the other wheel
end. STEP 48
STEP 45
W270-2R023
Place connection tube into the axle casing and

MD00M348 preliminary fasten it by hand.
Install the screw plug on the axle casing.
6004-33
STEP 49 STEP 52
W270-2R024 W270-2R027
Fasten collection tube by means of hexagon screw Install vent valve.

and washer.
Tightening torque (M8/8.8) . 23 Nm (17 pound-feet)
STEP 50
W270-2R025
Fasten cooling pipes by means of hexagon screw

and washer.
Tightening torque (M8/8.8) . 23 Nm (17 pound-feet)
STEP 51
W270-2R026
Finally fasten all unions of the cooling pipes.

6004-34
ASSEMBLY OF DIFFERENTIAL CARRIER

NOTE: If the ring gear or drive pinion are damaged, both Example A:
parts have to be replaced together. For new installation of a
Dimension A (= Measuring 225.00 mm
complete bevel gear set pay attention to the same pair
pin + stop washer (8.858 inch)
number of drive pinion and ring gear.
5.60 mm
Dimension B
(0.220 inch)
Determine Shim Thickness for a mm
Perfect Tooth Contact Pattern Dimension C
(0.590 inch)
245.60 mm
NOTE: Make the following measuring steps at maximum Results in Dimension X
(9.669 inch)
accuracy. In exact measurements result in a faulty tooth
contact pattern and require a repeated disassembly and
assembly of the drive pinion as well as of the differential. STEP 54
STEP 53
BD00M350
Determine Dimension I (bearing width).

Dimension I e.g. . . . . . . . . . . 42.65 mm (1.680 inch)
W270-2R028
Install adapter pieces (1) and preliminary fasten the

bearing bracket by means of hexagon screws.
Then install stop washer (4) and measuring pin (3)
and assemble measuring shaft (2) (see sketch).
Determine the gap between the measuring shaft and
the measuring pin with a feeler gauge.
Dim. B e.g. . . . . . . . . . . . . . . . 5.60 mm (0.220 inch)
6004-35
STEP 55 STEP 57
BD00M351 W270-2R030
1. 202.0 +0.05
Undercool bearing outer ring and insert it into the
Read Dimension II (dimension for pinion). bearing bore until contact.
Dimension II e.g. . . . . . . . . . . 202.05 mm (7.95 inch)
Example B: STEP 58
42.65 mm
Dimension I
------(1.680 inch)
+ 202.05 mm
Dimension II
(7.95 inch)
s 244.70 mm
Results in Dimension Y
-----(9.63 inch)
Example C:
Dimension X 245.60 mm (9.670 inch)
Dimension Y - 244.70 mm (9.63 inch)
Difference = Shim e.g. s 0.90 mm (0.04)
Install the Drive Pinion

W270-2R031
Undercool bearing outer ring on the input flange side

and insert it until contact.
STEP 56
STEP 59
BD00M352
Place the determined shim e.g. S. =0.90 mm (0.04 BD01F065

inch) into the bearing bore in the differential carrier. Press the bearing inner ring on the drive pinion shaft
using 380001552 and 380001542 step plate.
6004-36
Adjust Rolling Moment of Drive STEP 62

Pinion Bearing
STEP 60
W270-2R032
Press dust protection o n the inpu t flange until

contact.
BD00M356
Install the spacer ring on the pinion shaft. STEP 63

NOTE: As per experience the required rolling movement
is obtained by use of the spacer ring [e.g. s=8.10 mm (0.31
inch)] available at disassembly.
However, a later checking of the rolling movement must be
done.
WARNING: Always wear heat protective

gloves to prevent burning your hand when
handling heated parts.
SM121A
STEP 61
BD00M359
Install the input yoke on the pinion shaft.
STEP 64
BD00M357
Insert the assembled drive pinion into the differential

carrier and install the heated bearing inner ring.
BD00M360
Install the washer on the pinion shaft.

6004-37
STEP 65 STEP 68
W270-2R033 W270-2R034
Unscrew slotted nut by hand and tighten it. Install shaft seal with the sealing lip showing to the oil
Tightening torque . . . . . 1200 Nm (885 pound-feet) chamber (downwards).
NOTE: When tightening rotate the drive pinion in both ATTENTION: Just before the installation wet the outer
directions several times. diameter of the shaft seal with a solution of 50% water and
50% mineral spirits. Fill the space between the sealing and
STEP 66 dust lip with grease.
STEP 69
BD00M362
Check rolling movement. Rolling movement should

be 3.5 to 4.5 Nm (2.58 to 3.31 pound-feet). W270-2R035
Assemble input flange and finally fasten it by means

NOTE: For new bearings it should be tried to achieve the of washer and slotted nut.
maximum value of the rolling movement. Tighten torque . . . . . . . . 1200 Nm (885 pound-feet)
ATTENTION: If the required rolling movement is not ATTENTION: Apply Loctite, Type No. 262, onto the
obtained, correct it with an adequate spacer ring, according thread of the locknut.
to the following indications:
Rolling movement too low - install a thinner spacer ring.
Rolling movement too high - install a thicker spacer ring.
STEP 67
Then loosen the slotted nut again and pull input
flange from the drive pinion.
6004-38
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL

STEP 70 STEP 73
BD00M427 BD00M430
Place bo th thrust washers into the d ifferential Insert the axle bevel gear and slide the splined shaft
housing. into the clutch discs.
STEP 71 STEP 74
BD00M428 BD00M431
Starting with an outer clutch disc install alternately Assemble the differential spider and insert it into the
the outer and inner clutch discs. differential housing.
ATTENTION: Thickness of the disc pack must be
identical on both sides. STEP 75
STEP 72
BD00M432
Insert the second axle bevel gear.

BD00M429
Insert the pressure ring into the differential housing.

6004-39
STEP 76 Determine the Disc Clearance
STEP 78
BD00M433
Insert the second pressure ring into the differential

housing. BD00M435
Determine dimension I, from the mounting face of the

STEP 77 differential housing to the plane face of the outer
clutch disc.
Dimension I e.g. . . . . . . . . . . 49.30 mm (1.94 inch)
STEP 79
BD00M434
Starting with an inner clutch disc install alternately

the inner and outer clutch disc.
ATTENTION: The thickness of the clutch disc pack must
be identical on both sides. BD00M436
Determine dimension II, from the contact surface of

the outer clutch disc to the mounting face of the
housing cover.
Dimension II e.g. . . . . . . . . . . 48.95 mm (1.92 inch)
49.30 mm
Dimension I
-------(1.94 inch)
+ 48.95 mm
Dimension II
-------(1.92 inch)
0.35 mm
Difference = Disc clearance
------(0.01 inch)
NOTE: If the required disc clearance is not obtained,
correct it with the adequate outer clutch discs [s=2.7,
s=2.9, s=3.0, s=3.1 or s=3.3 mm (0.106, 0.114, 0.118,
0.122, 0.129 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.
6004-40
STEP 80 STEP 83
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 81 STEP 84
BD00M438 BD00M441
Put the housing cover in place on the differential Use acceptable lifting equipment and insert the
housing. Heat the ring gear and install onto the differential into the differential carrier.
differential housing.
STEP 85
STEP 82
BD00M442
BD00M439 Place the bearing outer ring into the differential
Put the differential in a press to prevent it from carrier.
turning and install the bolts on the ring gear.
Tightening torque . . . . . . . 390 Nm (287 pound-feet)
ATTENTION: Use new locking bolts.
6004-41
STEP 86 STEP 89
BC00M443 BD00M446
Install the adjusting nut by hand on the differential Install both bearing brackets and install the bolts and
carrier. washers.
Tighten torque . . . . . . . . . 390 Nm (287 pound-feet)
STEP 87
ATTENTION: Apply Loctite Type No. 262 onto threads
of the bolts.
Adjust Backlash and Bearing

Preload
STEP 90
BD00M444
Install the ring gear sided bearing outer ring.
STEP 88
BD00M447
Place a dial indicator right-angled at the outer

diameter 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
diameter 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
using a dial indicator against a tooth on the ring gear.
BD00M445 NOTE: Rotate the differential several times and recheck
Install the adjusting nut by hand on the differential the backlash.
carrier.
6004-42
STEP 91
W270-2R036
Determine bracket width and correct it on both

adjusting nuts, if required.
Bracket width . . . . . . . 448-0.05 mm (17.6-0.002 inch)
Section
6005
DRIVE SHAFTS, CENTER BEARING,

AND UNIVERSAL JOINTS

6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CENTER O REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SLIDING YOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6005-3
SPECIAL TORQUES
Center, Rear and Front Drive Shaft Bolts............................................................95 to 108 Nm (70 to 80 pound feet)
Carrier Bearing Bolts ..................................................................................... 149 to 163 Nm (110 to 120 pound feet)
Lock Nut for Yoke on Front Drive Shaft ......................................................... 339 to 375 Nm (250 to 275 pound feet)
6005-4
7�
6� 8� 9�
1�
16�
5� 15�
5� 5�
3�
6� 8� 9�
4�
11� 12� 13� 14�
5� 5�
18�
19� 10�
2�
17
W270-2R002
1. FRONT DRIVESHAFT 11. WASHER

2. REAR DRIVESHAFT 12. CLAMP
3. CENTER DRIVESHAFT 13. WASHER
4. ELBOW 14. NUT
5. BOLT 15. HOSE
6. BOLT 16. BRACKET
7. FRONT AXLE 17. REAR AXLE
8. WASHER 18. FRONT CHASSIS
9. NUT 19. TRANSMISSION
10. NUT
6005-5
FRONT DRIVE SHAFT

1. Remove the cap screws that fasten the center 1. Apply antiseize compound to the bearing area of
drive shaft to the yoke (4) at the rear of the front the front drive shaft (1), refer to Figure 1.
drive shaft. Use a prybar to dise ngage the
2. Put the front drive shaft (1) into position on the
universal joint from the yoke (4) and move the
machine.
center drive shaft out of the way.
3. Fasten the front drive shaft (1) to the universal
2. Loosen the lock nut (8) and set screw (9) in the
joint (3) with cap screws (2). Tighten the cap
center bearing (13) of the housing (12).
screws (2) to 95 to 108 Nm (70 to 80
3. Remove the self-locking nut (11) and flat washer pound-feet).
(10) that fasten the yoke (4) to the rear of the
4. Apply antiseize compound to the splines on the
front drive shaft (1).
4. Make an alignment mark on the yoke (4) and the
5. Install the yoke (4) so that the alignment marks
end of the front drive shaft (1) to make sure that
are aligned. If a new front drive shaft has been
the yoke is installed correctly.
installed, make sure this yoke is parallel with
5. Use an acceptable puller and remove the yoke yoke at the other end of the front drive shaft.
(4) from the end of the front drive shaft (1).
6. Install the self-locking nut (11) and flat washer
6. Remove paint or rust from the rear of the front (10) that fasten the yoke to the front drive shaft.
drive shaft (1) and apply WD40 or similar oil to Tighten the self-locking nut to 339 to 373 Nm
loosen any rust between the inner race and the (250 to 275 pound-feet).
7. Align the set screw (9) with the slot in the front
7. Remove the cap screws (2) that fasten the drive shaft (1).
universal joint (3) to the front drive shaft (1).
8. Tighten the set screw (9) until it bottoms out in
8. Use a prybar to disengage the front drive shaft the slot, loosen the set screw (9) one full turn.
(1) from the universal joint (3) and remove the
9. Hold the set screw (9) so it will not turn, tighten
front drive shaft (1). If necessary, use a brass
the lock nut (8).
hammer to drive the front drive shaft (1) out of
the center bearing. 10. Engage the universal joint of the center drive
shaft with the yoke (4).
11. Install the cap screws that fasten the center drive
shaft to the yoke (4). Tighten the cap screws to
6005-6
B910790J
1. FRONT DRIVE SHAFT 7. NUT 13. CENTER BEARING

2. CAP SCREW 8. LOCK NUT 14. NIPPLE
3. UNIVERSAL JOINT 9. SET SCREW 15. ELBOW
4. YOKE 10. WASHER 16. HOSE
5. BOLT 11. SELF-LOCKING NUT 17. CLAMP
6. LOCK WASHER 12. HOUSING
6005-7
CENTER BEARING
1. Remove the hardware (10 and 11) that holds the NOTE: The center bearing (13) and housing (12) are not
clamp (17) for the lubrication hose (16). serviced separately. If the center bearing (13) is worn or
damaged or if the housing (12) has cracks, a new housing
2. Remove the lock nut (8) from the end of the
(12) and center bearing (13) must be used.
lubrication hose (16).
1. Apply antiseize compound to the bearing area of
3. Remove the lubrication hose (16).
the front drive shaft (1).
4. Remove the cap screws that fastens the center
2. Install the housing (12) so that the lubrication
drive shaft to the yoke (4) at the rear of the front
fitting is to the right.
drive shaft (1). Use a prybar to disengage the
universal joint from the yoke. Move the center 3. Install the bolts (5), lock washers (6), and nuts
drive shaft out of the way. (7) that hold the housing (12). Tighten the nuts
(7) to 149 to 163 Nm (110 to 120 pound-feet).
5. Loosen the lock nut (8) and set screw (9) in the
center bearing (13). 4. Apply antiseize compound to the splines on the
6. Remove the self-locking nut (11) and flat washer
(10) that fasten the yoke (4) to the rear of the 5. Install the yoke (4) so that the alignment marks
front drive shaft (1). are aligned. If a new front drive shaft (1) has
been installed, make sure this yoke (4) is parallel
7. Make an alignment mark on the yoke (4) and the
with the yoke (4) at the other end of the front
end of the front drive shaft (1) to make sure that
drive shaft (1).
the yoke (4) is installed correctly.
6. Install the self-locking nut (11) and flat washer
8. Use an acceptable puller and remove the yoke
(10) that fasten the yoke (4) to the front drive
(4) from the end of the front drive shaft (1).
shaft (1). Tighten the self-locking nut (11) to 339
9. Remove paint or rust from the rear of the front to 373 Nm (250 to 275 pound-feet).
drive shaft (1) and apply WD40 or similar oil to
7. Align the set screw (9) with the slot in the front
loosen any rust between the inner race and the
drive shaft (1).
front drive shaft.
8. Tighten the set screw (9) until it bottoms out in
10. Remove the nuts (7), lock washers (6), and bolts
the slot, loosen the set screw (9) one full turn.
(5) that hold the housing (12).
9. Hold the set screw (9) so it will not turn, tighten
11. Install two longer bolts, approximately 3 inches
the lock nut (8).
(75 mm) to hold the housing (12) during removal.
Use an acceptable puller to remove the housing 10. Engage the universal joint at the front of the
(12). center drive shaft with the yoke (4).
11. Install the cap screws that fasten the center drive
shaft to the yoke (4). Tighten the cap screws to
12. Install the 45 degree elbow (15) and the nipple
(14) in the housing (12).
13. Install the lubrication hose (16).
14. Install the lock nut (8) to end of the lubrication
hose (16).
15. Install the hardware (10 and 11) that holds the
clamp (17) for the lubrication hose (16).
16. Lubricate the center bearing (13).
6005-8
B910790J
1. FRONT DRIVE SHAFT 7. NUT 13. CENTER BEARING

2. CAP SCREW 8. LOCK NUT 14. NIPPLE
3. UNIVERSAL JOINT 9. SET SCREW 15. ELBOW
4. YOKE 10. WASHER 16. HOSE
5. BOLT 11. SELF-LOCKING NUT 17. CLAMP
6. LOCK WASHER 12. HOUSING
6005-9
CENTER OR REAR DRIVE SHAFT

1. Remove the cap screws (2) that hold both 1. Lubricate the center or the rear drive shaft (1 or
universal joints (3). 8) with the grease.
2. Use a prybar to disengage the rear universal 2. Engage the front universal joint (3) with the yoke
joint (3) from the yoke (4). (4) and install the cap screws (2). Tighten the
ca p s cre ws (2) to 95 to 10 8 N m (7 0 to 8 0
3. Hold the drive shaft (1 or 8) and disengage the
pound-feet).
front universal joint (3) from the yoke (4) and
remove the drive shaft. 3. Engage the rear universal joint (3) with the yoke
(4) and install the cap screws (2). Tighten the
cap screws to 95 to 108 Nm (70 to 80
pound-feet).
SLIDING YOKE
1. Make an alignment mark on the sliding yoke (5) 1. Install the retainer (7) on the drive shaft (1 or 8).
and the drive shaft (1 or 8) so that the parts are
2. Install the sliding yoke (5) so that the alignment
assembled correctly.
ma r k s a re a lig n e d . If a n e w p a rt is b e in g
2. Remove the retainer (7) from the sliding yoke (5). installed, the yokes must be parallel.
3. Remove the sliding yoke (5). 3. Turn the retainer (7) onto the sliding yoke (5) and
tighten the retainer (7).
4. Clean the parts in cleaning solvent. Inspect the
splines for damage and wear. 4. Lubricate the sliding yoke.
UNIVERSAL JOINT
1. Remove the cap screws (2) that fasten the NOTE: The bearing race and journal that make up the
universal joint (3) to the drive shaft (1 or 8) or the universal joint are not serviced separately. If the bearing
yoke (4). race or the journal is worn or damaged, a new universal
joint (3) must be used.
2. Remove the universal joint (3).
1. Clean the slots in the yoke (4) or the drive shaft
(1 or 8). Clean the tabs on the universal joint (3).
2. Install the universal joint (3) and install the cap
screws (2). Tighten the cap screws (2) to 95 to
108 Nm (70 to 80 pound-feet).
3. Lubricat the universal joints.
6005-10
B910791J
1. CENTER DRIVE SHAFT 3. UNIVERSAL JOINT 5. SLIDING YOKE 7. RETAINER

2. CAP SCREW 4. YOKE 6. GREASE FITTING 8. REAR DRIVE SHAFT
Section
6006
WHEELS AND TIRES

6006-2
TABLE OF CONTENTS
WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6006-3
WHEELS AND BOLTS

General Information Torque Specification
The wheel bolts must be tightened after every 20 Tighten the wheel bolts to 298 Nm (220 pound-feet)
hours of operation until the wheel bolts stay tight: in the sequence shown in Figure 1. Then a final
torque of 640 to 720 Nm (475 to 530 pound-feet) in
A. If the machine is new.
the same sequence.
B. If a wheel has been removed and installed.
TIRE PRESSURES
PRESSURE (bar)
WORK TRAVEL
MODEL FRONT REAR FRONT REAR
26.5R25 GP-2B 4.00 (58) 2.75 (39.8) 2.75 (39.8) 2.75 (39.8)
26.5R25 XHA 4.25 (61.6) 2.00 (29) 2.00 (29) 2.00 (29)
26.5R25 XLDD2 4.25 (61.6) 2.00 (29) 2.00 (29) 2.00 (29)
26.5R25 RL-5K 4.00 (58) 2.75 (39.8) (**) (**)
26.5R25 XLDD1 4.25 (61.6) 2.00 (29) 2.00 (29) 2.00 (29)
26.5R25 XMINE D2 4.25 (61.6) 2.00 (29) 2.00 (29) 2.00 (29)
750/65 R25 XLD (*) 4.25 (61.6) 2.00 (29) 2.00 (29) 2.00 (29)
26.5R25 RT-5C 4.00 (58) 2.75 (39.8) 2.75 (39.8) 2.75 (39.8)
26.5R25 GP-4B 4.00 (58) 2.75 (39.8) 2.75 (39.8) 2.75 (39.8)
26.5X25 L3 20PR 2.40 (34.8) 1.50 (21.7) 1.50 (21.7) 1.50 (21.7)
26.5R25 RT-3B 4.00 (58) 2.75 (39.8) 2.75 (39.8) 2.75 (39.8)
(*) The pressure can be increased 0.5 bar when the working conditions do not require particular floating capabilities.
(**) It is suggested to load the machine on a trailer for road transit.
6006-4
CHANGING TIRES
1. Have a qualified tire mechanic service the split
The split rim wheels used on this machine rim wheels used on this machine.
can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and 2. The correct tire equipment, especially a tire
stand at the front or rear of the tire. inflation cage, is required. Using the wrong
procedure for a split rim wheel can result in
When inflating a tire off the machine, put death.
the w hee l in a tire in fla tio n cag e. Th e IMPORTANT: When installing a Michelin tire, lubricate
retaining ring and rim can come off with the tire with a tire mounting lubricant and inflate the tire to
enough force to result in death to a person 551 kPa, 5.5 bar (80 psi) to make sure that the tire is seated
in front of the rim. on the rim. Then decrease the pressure to the specified
48-44 pressure.
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and 4. Tighten the wheel bolts to 298 Nm (220
axle flange are clean and free of dirt and grease. pound-feet) in the sequence shown in Figure 1.
Th e n tig h te n t he wh e e l b o lts in th e s a me
2. Install the wheel, hardened washers and wheel
sequence to 640 to 720 Nm (475 to 530
bolts.
pound-feet).
3. Use a hand wrench (not an impact) to tighten the
w h e e l b o lts to p u ll th e w h e e l a g a in s t t h e
planetary housing. DO NO T use an impact
wrench to tighten the wheel bolts.
BC06A079
FIGURE 1. WHEEL BOLT TORQUE SEQUENCE
Section
6007
TRANSMISSION CONTROL VALVE

6007-2
TABLE OF CONTENTS
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6007-3
CONTROL VALVE
Disassembly STEP 4
STEP 1
BD06A010
Loosen and remove the cap screws, remove the

BD06A007 cover. Remove the opposite cover.
Mark the installation position of the wiring harness to
the valve block. STEP 5
STEP 2
BD06A011
BD06A008
Remove the wiring harness.
Loosen and remove the cap screws that secure the
distribution plate and intermediate plate to the valve STEP 6
body, remove the intermediate plate and distribution
plate.
STEP 3
BD06A012
Loosen and remove the retaining plate cap screws,

remove the retaining plates and solenoids.
BD06A009
Remove the wiring harness retaining clamp.

6007-4
STEP 7 STEP 9
BD06A013 BD06A015
Loosen and remove two cap screws, install two Remove the components.
adjusting screws. Loosen and remove the remaining
cap screws. STEP 10
STEP 8
BD06A016
Remove the op po site sole noids, housing, and

BD06A014
components.
Separate the housing from the valve body by equally
loosening the adjusting screws.
6007-5
Inspection Assembly
1. Clean all metal parts in cleaning solvent. NOTE: Apply clean engine oil (15W-40) to pistons and
springs, orifices, new O-rings, and filter screens before
2. Immerse end housings, valve housing, valve
assembly.
plate, and distribution plate in cleaning solvent
a nd ag ita te cle a nin g s o lve nt . W E AR EYE STEP 11
PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign
matter from interior of housings and plates and to
ensure that all bores are clear of foreign matter.
3. WEAR EYE PROTECTION WHEN USING
COMPRESSED AIR. Use compressed air to
ensure that orifices are clear of foreign matter.
4. Check filter screens for blockage, rips, or tears.
Replace if any of these conditions are seen.
5. Inspect the plates, housings and covers for
corrosion, cracks, breaks, chipping or other
damage. Check bores in housings for deep BD06A017
scratches, gouges, and other damage. Replace
Place the valve body on the bench with the orifices up.
a housing or cover if any of the above conditions
are seen.
STEP 12
6. Check pressure regulators for cracks, breaks, or
other damage. Check connector contacts for
looseness or signs of corrosion. Replace a
pressure regulator if any of these conditions are
seen. Check resistance of pressure regulators
using a multimeter. Replace a pressure regulator
if resistance is not 17 to 21 ohms.
7. Check wiring harness connectors for signs of
breaks, cracks, or other damage. Check contacts
for foreign matter or corrosion. Check harness
wiring for signs of broken or cracked insulation
and broken or frayed wiring at connection to
connectors. Replace wiring harness if any of BD06A018
these conditions are seen. 1. VIBRATION DAMPER 3. PRESSURE REDUCING

2. PISTONS VALVE
8. Check springs for cracks, breaks, distortion, or
signs of permanent set. Replace a spring if any Install components in positions shown.
of these conditions are seen.
STEP 13
9. Inspect pistons for cracks, breaks, chipping,
grooves, or other damage. Replace if any of
these conditions are seen.
BD06A019
Preload the compression springs of the pistons,

install a roll pin of a diameter of 5.0 mm (0.20 inch).
6007-6
STEP 14 STEP 17
BD06A020 BD06A023
Install the adjusting screws, gasket, and housing Install the cap screws and torque in a criss cross
cover. pattern to 7.5 Nm (66.3 pound-inch).
STEP 15 STEP 18
BD06A021 BD06A024
Tighten the adjusting screws equally until the cover is Install the solenoids and secure them with the
flush on the valve body. retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
STEP 16 NOTE: Install the retaining plate with the neck towards
valve body, install controllers with connectors as shown.
STEP 19
BD06A022
P us h th e p is to n s d o w n th r o ug h th e p re s s ur e
controller wholes and remove the roll pins.
BD06A025
1. VIBRATION DAMPER 3. MAIN PRESSURE VALVE

2. PISTONS
Install components in positions shown.

6007-7
STEP 20 STEP 23
BD06A026 BD06A028
Preload the compression springs of the pistons, install Install the wiring harness with connector on side of
a roll pin of a diameter of 5.0 mm (0.20 inch). Install valve body marking made during disassembly.
the adjusting screws, gasket, and housing cover. Connect wiring harness to the solenoids.
STEP 21 STEP 24
BD06A023 BD06A029
Install the cap screws and torque in a criss cross Install the gasket, install the wiring harness plug in
pattern to 7.5 Nm (66.3 pound-inch). the cover. Install the cap screws and torque in a criss
cross pattern to 7.5 Nm (66.3 pound-inch).
STEP 22
STEP 25
BD06A027
Install the solenoids and secure them with the BD06A030
retaining plates and cap screws. Torque the cap Install the wiring harness retaining clamp.
screws to 5.5 Nm (48.5 pound-inch).
NOTE: Install the retaining plate with the neck towards
valve body, install controllers with connectors as shown.
6007-8
STEP 26 STEP 28
BD06A031 BD06A033
Install the screens into the bores of the intermediate Install the distribution plate, install the cap screws
plate towards the distribution plate. and torque in a criss cross pattern to 9.5 Nm (84
pound-inch).
STEP 27
STEP 29
BD06A032
Install two adjusting screws. Place the intermediate BD06A034
plate with the screens facing up. Install new o-rings on the plugs, install and torque
plugs to 6 Nm (53 pound-inch).
SECTION INDEX
BRAKES
Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7001

Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7008
Section
7001
REMOVAL AND INSTALLATION

OF BRAKE COMPONENTS

7001-2
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7001-3
BC05M136
1. FRONT AXLE 5. FRONT ACCUMULATOR

2. PARKING BRAKE ACCUMULATOR 6. BRAKE PUMP
3. BRAKE VALVE 7. FAN VALVE
4. REAR ACCUMULATOR 8. REAR AXLE
COMPONENT LOCATION ILLUSTRATION
7001-4
BRAKE VALVE
1. Park the machine on a level surface and lower 1. Install the brake valve (1) in the cab or canopy.
the loader bucket to the floor. Stop the engine. Refer to the illustration on page 5.
2. Put blocks on both sides of each tire to prevent 2. Remove the plugs from the hydraulic lines and
machine movement. connect the hydraulic lines to the brake valve (1).
3. Make sure the brake accumulators are 3. Stop the vacuum pump and remove.
completely discharged. Push down and release 4. Connect all of the electrical connections.
the brake pedals at least 30 times.
5. Turn the master disconnect switch to the ON
4. Turn the master disconnect switch to the OFF position.
position.
6. Bleed the brake system. See Section 7002.
5. Remove the cab skirts located under the cab or
canopy. 7. Install the cab skirts.
6. To release the pressure on the parking brake 8. Check the hydraulic reservoir oil level and add oil
accumulator, the line at the accumulator must be as required. See Section 1002 for the correct oil.
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect
couplings in each brake circuit to release any
pressure in the brake circuit.
8. Clean the brake valve (1) and lines, refer to the
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake
valve (1).
10. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump
11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
12. Remove the brake valve (1).
7001-5
1�
6�
2 7�
3�
9�
4� 10
8�
5�
BC05M137
1. BRAKE VALVE 6. FRONT BRAKE LINE

2. FRONT ACCUMULATOR LINE (REAR AXLE) 7. REAR BRAKE LINE
3. PARKING BRAKE LINE 8. REAR ACCUMULATOR (FRONT AXLE)
4. BRAKE PUMP INPUT 9. RETURN TO TANK
5. BRAKE VALVE DISCHARGE TO FAN VALVE 10. PARKING BRAKE ACCUMULATOR
BRAKE VALVE ILLUSTRATION
7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

1. Park the machine on a level surface and lower 1. Mount the accumulators (1) in the accumulators
the loader bucket to the floor. Stop the engine. clamps (7), do not tighten clamps at this time.
Refer to illustration on page 7.
2. Put blocks on both sides of each tire to prevent
machine movement. 2. Connect the tubes to both brake accumulators
(1) and tighten.
3. Make sure the service brake accumulators (8)
and the parking bra ke accu mula tor (1 ) are 3. Tighten accumulator clamp studs (7) to 17Nm
completely discharged. Push down and release (13 pound feet).
the brake pedal at least 30.
4. Install the parking brake accumulator (2) into the
4. Turn the master disconnect switch to the OFF bracket.
position.
5. Install the nut (3) and tighten.
5. Remove the left cab skirt located under the cab
6. Connect the line to the parking brake
or canopy to gain access to accumulators.
accumulator (2).
6. To release the pressure on the parking brake
7. Stop the vacuum pump and remove.
accumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to 8. Install the left cab skirt.
catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect position.
couplings in each brake circuit to release any
pressure in the brake circuit.
11. Refer to Section 7008 and perform the Parking
8. Clean the brake accumulators (1), parking brake
Brake Test Procedure.
accumulator (2) and lines. Refer to illustration on
page 7. 12. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
9. Put identification tags on the line that is
connected to the parking brake accumulator (2).
reservoir. Start the vacuum pump.
11. Disconnect the tubes from both brake
accumulators (1).
12. Loosen the clamp stud (8) on the accumulator
clamp (7).
13. Remove the accumulators (1) from the
accumulator clamps (7).
14. Install plugs in the tubes.
15. Disconnect the hose from parking brake
accumulator (2).
16. Remove the nut (3), remove the parking brake
accumulator (2).
17. Install a plug in the hose.
7001-7
BC05M138
1. BRAKE ACCUMULATORS 5. TUBE FRONT BRAKE ACCUMULATOR

2. PARKING BRAKE ACCUMULATOR 6. TUBE REAR BRAKE ACCUMULATOR
3. MOUNTING NUT 7. CLAMP ACCUMULATOR
4. HOSE PARKING BRAKE ACCUMULATOR 8. CLAMP STUD
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION
7001-8
BRAKE PUMP
1. Park the machine on a level surface and lower 1. Install the brake pump (1), mounting bolts (2)
the loader bucket to the floor. Stop the engine. and washers. Refer to the illustration on page 9.
2. Put blocks on both sides of each tire to prevent 2. Torque mounting bolts (2) to 57 to 65 Nm (42 to
machine movement. 48 pound feet).
3. Turn the master disconnect switch to the OFF 3. Remove the plugs or caps and connect the lines
position. to the brake pump (1).
4. Clean the brake pump (1) and lines, refer to the 4. Stop the vacuum pump and remove.
5. Put identification tags the lines that are position.
connected to the brake pump (1).
7. Check the hydraulic reservoir oil level and add oil
reservoir. Start the vacuum pump.
as required. See Section 1002 for the correct oil.
7. Disconnect the lines from the brake pump (1)
and put plugs in each line.
8. Remove the mounting bolts (2) and washers
from the brake pump (1) and remove the brake
pump (1).
7001-9
5�
3�
4
1�
2�
W270-3R003
1. BRAKE PUMP 4. FAN VALVE HOSE

2. MOUNTING BOLTS (2) 5. SUCTION HOSE
3. PRESSURE HOSE
BRAKE PUMP ILLUSTRATION
7001-10
NOTES
Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING

7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7002-3
SPECIFICATIONS
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......................................................................... 157 to 167 bar (2277 to 2420 psi)
Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2755 to 2842 psi)
Brake warning pressure switch (normally closed) opening set point ..................96.5 to 110.3 bar (1400 to 1600 psi)
Brake redundant pressure switch (normally closed) opening set point ..............................................62 bar (900 psi)
Brake light pressure switch (normally open) closing set point.............................................................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)
SPECIAL TOOLS
G
94L95
380001737 NITROGEN CHARGING KIT USED TO CHECK AND
CHARGE THE ACCUMULATOR WITH NITROGEN.
BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER
7002-4
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM

NOTE: The hydraulic brake schematic is included in the 8. Stop the engine. Push and release the brake
hydraulic schematic. Refer to the rear pocket of this several times while reading the pressure on the
manual. gauges. Each push and release of the pedal will
resu lt in a slight dr op in pr essure , b ut not
1. Check the oil level in the hydraulic reservoir; add
necessarily equal on the two gauges.
oil as necessary.
9. As the lowest pressure reaches 106 to 115 bar
2. Push and release the brake pedal many times
(1530 to 1670 psi) the brake warning lamp and
with the engine stopped to remove all hydraulic
alarm buzzer must actuate. If the warning lamp
pressure from the brake system until there is no
and alarm buzzer fail to work, test the low brake
pressure on the pedal.
pressure warning switches and electrical circuit.
3. Install two 207 bar (3000 psi) pressure gauges to If the warning lamp and alarm buzzer actuate at
front and rear hydraulic brake accumulator test a higher or lower pressure than specified, test
ports. The test ports are located behind the left the low brake pressure warning switches and
cab skirt across from the transmission mounted replace as needed.
on the diagnostic panel. If your loader does not 10. After the low brake pressure light activates,
have a diagnostic panel, refer to page 7 for the press the brake pedal eight more times.
locations of the test ports.
11. Record the readings on the pressure gauges.
4. Make sure that the pressure gauge hoses are The pressure gauges should read at or above
long enough so the gauges can be read while 48 to 59 bar (700 to 850 psi).
sitting in the operators seat.
12. If the pressures are at or above 48 to 59 bar (700
NOTE: The gauges can not be connected to the test ports to 850 psi), the test is complete.
if hydraulic pressure remains in the system. 13. If the pressures are not within the required
5. Start the engine. Run the engine at low idle while specifications, then the brake system must be
re ad in g t he p re ssu re g au ge s. The a larm s bled.
(buzzer, master warning light and brake pressure 14. After bleeding the brake system, perform the
warning light) s hould s hut of f when the brake system check again.
accumulator with the lowest pressure reaches
96.5 to 110.3 bar (1400 to 1600 psi). 15. Continue to slowly push and release the brake
pedal several times until the gauge pressure
6. After the alarms stop, run the machine at high sud denly drops to zer o. The last pressu re
idle to finish charging the accumulators. The reading before the drop to zero is the nitrogen
pressure must increase on both gauges until 190 charge pressure in the accumulator. Test the
to 196 bar (2757 to 2843 psi) is reached. This is pressure in both accumulators. If the pressure is
the accumulator valve cut-out pressure. It is below 48 to 59 bar (700 to 850 psi), charge or
normal for the pressure to drop slightly once the replace the accumulator(s) (see page 5).
cut-out pressure is reached.
NOTE: Nominal temperature of 20° C (68° F), colder
7. With the engine running at high idle, push and temperature will reduce pressure, hotter temperature will
release the brake pedal rapidly while reading the increase pressure.
drop in pressure on the gauges. The pressure
drops ma y not be equal, but as the lowest
pressure reaches 157 to 167 bar (2277 to 2420
psi), the system pressure must start to increase.
This is the valve cut in pressure.
NOTE: The brake cut-in and cut-out pressures of the
brake system charge valve are factory preset and are not
adjustable.
NOTE: If the pressure on one of the pressure gauges is
lower than specified, the problem can be a bad accumulator
valve.
7002-5
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is
completely discharged by doing the following: E
C
A. Stop the engine.
B. Push down and release the brake pedal many
times to release the pressure.
F�
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.
D� B� A�
4. Turn the stem out of valve F until the stem stops.
94L95
5. Remove the cap screws and guard from the NITROGEN CHARGING KIT
accumulator.
8. Make sure that valve D is open.
6. Remove the cap from the accumulator valve
9. Turn the stem into valve F and read the pressure
stem.
gauge E.
7. Connect valve F to the accumulator valve stem.
10. The pressure must be 53.5 to 57 bar (775 to 825
psi). If the pressure is too lo w, charge th e
accumulator with dry nitrogen.
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator according 5. If the pressure increases above 57 bar
to the instructions in Checking the Nitrogen Charge in the (825 psi), quickly open and close valve D and
Accumulator. Keep the nitrogen charging kit connected to read gauge E. If the pressure is still too high,
the accumulator. close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
1. Close (turn counterclockwise) valve A and open
pre ssu re sho wn o n ga ug e E is the cha rge
valve B. Close valves C and D.
pressure.
2. Turn the stem out of valve F until the stem stops
6. Connect valve F to the accumulator valve stem.
moving. Disconnect valve F from the
Turn the stem into valve F until the stem stops
accumulator valve stem.
m o v in g a n d o p e n v a l v e D t o c h a r g e t h e
3. Connect the nitrogen charging kit to a dry accumulator.
nitrogen tank.
7. After the accumulator stops charging, turn the
4. Slowly turn valve A clockwise and read gauge E stem out of valve F until the stem stops moving.
until the pressure is 53.5 to 57 bar (775 to 825
8. Close valve B and disconnect the nitrogen
psi). Stop turning valve A.
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
Ins tall the guard and cap screws on the
accumulator.
7002-6
BLEEDING THE BRAKE SYSTEM

1. Check the level of hydraulic fluid in the reservoir. 8. Start the engine and run at low idle.
Add fluid to the reservoir if necessary.
9. Push the brake pedal all the way down and
IMPORTANT: If machine is equipped with quick-attached slowly release for one cycle.
components, disconnect them from machine prior to
10. Close all four wheel end bleed screws.
proceeding.
11. Fully depress the brake pedal three times in 5
second cycles.
12. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
bubbles). Close the bleed screw.
13. Open the bleed screw on the right front axle.
Repeat step 12.
1 14. Open the bleed screw on the left rear axle.
Repeat step 12.
15. Open the bleed screw on the right rear axle.
BD03A092
Repeat step 12.
1. SAFETY LINK 16. Replace all bleed screws, caps and plugs.
17. Check the hydraulic fluid and add as necessary.
2. Raise loader arms and install the safety link (1)
for safe access to the front axle bleed screws.
4. Keep the engine speed at low idle until both
brake accumulators are fully charged.
NOTE: This will be approximately 30 seconds after the
low brake pressure light goes out.
5. Stop the engine.
6. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).
7. Remove the plastic and rubber caps from each
wheel end and slowly open all four bleed screws.
NOTE: Attach a hose to the bleed screws to prevent
spilling any fluids.
7002-7
BRAKE MODULATION PRESSURE CHECK
1�
2�
3
4�
W270-3R004
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
Testing the Brake Modulation 11. The rear axle brake pressure should read 74 to
81 bar (1070 to 1170 psi).
Pressure
12. If the pressures are not within the specified
1. Make sure the hydraulic accumulator cut-in and r a n g e , it w i ll b e n e c e s s a r y t o a d ju s t t h e
cut-out pressures are correct. Refer to page 4 of modulation pressures.
this section.
2. Stop the engine. Pump the brake pedal until
there is no pressure in the brake system.
3. Remove the cab skirts to gain access to the
brake test ports.
4. Connect two 207 bar (3000 psi) pressure gauges
to the front axle test port (1) and the rear axle
test port (2).
to the front brake accumulator test port (4) and
the rear brake accumulator test port (3).
6. Start the engine.
7. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
the gauges rise above 170 bar (2645 psi).
8. Apply and hold the brakes for 10 to 15 seconds.
9. Make a note of the pressure on the gauges for
the front and rear axles.
10. The front axle brake pressure should read 76 to
83 bar (1100 to 1200 psi). This is the modulation
pressure for the front axle.
7002-8
Adjusting the Brake Modulation 2. Turn the adjusting bolt (2) to adjust the
modulation pressure.
Pressure
NOTE: The rear brake modulation pressure cannot be
NOTE: The adjusting bolt to adjust the modulation adjusted separately from the front brake modulation
pressure is located in the cab, under the brake pedal. pressure.
3. Repeat steps 5 through 10 in the Testing the
Brake Modulation Pressure procedure.
4. Repeat these steps until the brake modulation
pressure is within the specified range.
2�
1
BD00N121
1. TAMPER RESISTANT COVER

2. ADJUSTING BOLT
1. Remove the tamper resistant cover (1).
NOTE: This is a tamper resistant cover and it will be
necessary to install a new cover after the modulation
pressure is adjusted.
7002-9
CHECKING THE BRAKE SYSTEM
1�
2�
3
4�
W270-3R004
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
1. Check the level of the hydraulic fluid in the 7. Stop the engine.
reservoir, add as needed.
8. Push the brake pedal down slowly, allowing for
full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal down. The
low brake pressure light should activate when
the pressure reaches 96.5 to 110 bar (1400 to
1600 psi). After the low brake pressure light
activates, press the brake pedal eight more
times.
10. Record the readings on the pressure gauges.
The pressure gauges should read at or above
W270-1R006
53.5 to 57 bar (775 to 825 psi).
1. ARTICULATION LOCK 11. If the pressures are at or above 53.5 to 57 bar
2. Install the articulation lock before doing this test. (775 to 825 psi), the test is complete.
3. Remove the left side cab skirt to gain access to 12. If the pressures are not within the required
the brake accumulator test ports. specifications, then the brake system must be
bled.
4. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20 13. After bleeding the brake system, perform the
pumps). brake system check again.

to the test ports 3 and 4.
6. Start the engine and let idle until both the front
and rear accumulators 3 and 4 are fully charged.
The accumulators are fully charged at 190 to 196
bar (2755 to 2842 psi).
7002-10
1�
3� 2�
3�
1�
2� 4�
30� 5�
31�
32� 6�
14� 5�
33� 21�
5� 30�
34�
2� 7�
35� 29�
5� 8�
36
9�
27� 15�
28� 10�
26� 15�
11�
16� 14�
24� 25� 12�
14�
17�
5�
19�
23� 15� 18�
2�
22� 5� 13�
5�
21� 20�
BC05G011
BRAKE VALVE EXPLODED VIEW
7002-11
1. CAP SCREW (T 22 NM (16 LB-FT)) 13. CAP (T 60 NM (44 LB-FT)) 25. CHECK VALVE
2. O-RING 14. SPOOL 26. CARTRIDGE
3. BUSHING 15. PLUG (T 10 NM (88.5 LB-IN)) 27. PLUG (T 60 NM (44 LB-FT))
4. SLEEVE 16. PLUG (T 60 NM (44 LB-FT)) 28. JET
5. SPRING 17. PLUG (T 22NM (16 LB-FT)) 29. WVI UNIT
6. SPRING RETAINER 18. VALVE SEAT 30. PLUG (T 60 NM (44 LB-FT))
7. SPRING RETAINER 19. THROTTLE SCREW 31. PLUG (T 100 NM (74 LB-FT))
8. CIRCLIP 20. PLUG (T 22NM (16 LB-FT)) 32. RV UNIT
9. SHAFT SEAL 21. CAP 33. SPRING RETAINER
10. SLEEVE LVE 22. SLEEVE 34. SLEEVE
11. GUIDE RING 23. SPRING RETAINER 35. THRUST RING
12. O-RING 24. SLEEVE 36. SLEEVE LVV
7002-12
NOTES
Section
7004
BRAKE ACCUMULATORS

7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7004-3
SPECIAL TOOL
C� E�
F�
G
D� B� A
94L95 BC04A001
380001737 NITROGEN CHARGING KIT 380001168 ACCUMULATOR CHARGING ADAPTER
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Remove cover from accumulator charge port. 6. Connect valve F to the valve stem on the
Loosen the Allen screw in the charge port. adapter.
NOTE: Do not turn the Allen screw more than 1/8 of a 7. Turn the T-handle inward on valve F to engage
turn or gas will escape uncontrolled. the pin in the valve stem, open valve G.
2. Install adapter on accumulator, use the 8. Open valve D and check the charge pressure on
380001737 nitrogen charging kit to discharge the gauge E.
accumulator, refer to illustrations above. The tool
9. To discharge the accumulator, partially open
must be disconnected from the nitrogen tank.
valve B. The accumulator charge will bleed down
3. Close valves B, C and D. through the regulator.
4. Adjust the regulator A to the minimum pressure 10. Once the accumulator is fully discharged,
setting by turning the knob counterclockwise. disconnect valve F from the valve stem and
remove adapter.
5. Turn the T-handle on valve F fully out.
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is 5. Remove the cap from the accumulator. Loosen
completely discharged by doing the following: the Allen screw in the charge port.
A. Stop the engine. NOTE: Do not turn the Allen screw more than 1/8 of a
turn or gas will escape uncontrolled.
B. Push down and release the brake pedal 21
times to release the pressure. 6. Connect adapter to accumulator.
2. Connect a drain hose to the test connector in 7. Connect valve F to the adapter valve stem.
each brake circuit to release any pressure in the
8. Make sure that valve D and G are open.
brake circuit.
9. Turn the stem into valve F and read the pressure
3. Close valves B and C on the nitrogen charging
gauge E.
kit, refer to the illustration.
NOTE: See chart below for pressure readings.
4. Turn the stem out of valve F until the stem stops.
10. If the pressure is too low, charge the
accumulator with dry nitrogen.
7004-4
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator according 6. Connect valve F to the adapter valve stem. Turn
to the instructions in Checking the Nitrogen Charge in the the stem into valve F until the stem stops moving
Accumulator. Keep the nitrogen charging kit connected to and open v alve G and D to charge the
the accumulator. accumulator.
1. Close (turn counterclockwise) valve A and open 7. After the accumulator stops charging, turn the
valve B. Close valves C, D, and G. stem out of valve F until the stem stops moving
and close valve G.
2. Turn the stem out of valve F until the stem stops
moving. Disconnect valve F from the adapter 8. Close valve B and disconnect the nitrogen
valve stem. charging kit from the adapter valve stem, remove
the adapter.
3. Connect the nitrogen charging kit to a dry
nitrogen tank. 9. Torque the Allen screw to 20 Nm (15 lb-ft), install
the cover on the accumulator valve stem.
4. Slowly turn valve A clockwise and read gauge E
until the pressure is equal to charge pressure
required for accumulator being charged. Stop
TEMPERATURE CHARGE PRESSURE
turning valve A.
0° C 32° F 51.2 BAR 743 PSI
5. If the pressure increases above required 5° C 41° F 52.2 BAR 757 PSI
pressure, quickly open and close valve D and 10° C 50° F 53.1 BAR 770 PSI
read gauge E. If the pressure is still too high, 15° C 59° F 54.1 BAR 784 PSI
close valve A (turn counterclockwise) a small 20° C 68° F 55.0 BAR 798 PSI
amount and quickly open and close valve D. The 25° C 77° F 55.9 BAR 811 PSI
pre ssure sho wn o n ga uge E is the cha rge 30° C 86° F 56.9 BAR 825 PSI
pressure. 35° C 95° F 57.8 BAR 839 PSI
40° C 104° F 58.8 BAR 852 PSI
TEMPERATURE/CHARGE PRESSURE BRAKE

ACCUMULATOR
Section
7008
PARKING BRAKE

7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7008-3
PARKING BRAKE
Disassembly STEP 6
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wh eel cho cks on ea ch wheel to pre vent
machine movement.
STEP 3
BD07A212-01
Loosen and remove the cover from the parking

brake.
STEP 7
Start the machine and run the engine at low idle with
the bucket resting on the ground.
IMPORTANT: It will be necessary to have an assistant
help for this procedure. An operator must be present in the
cab at all times to apply the service brakes and shut down
W270-1R006 the machine in the event of mechanical failure.
Install the articulation lock.
STEP 8
STEP 4
Disengage the parking brake.
Pump the brake pedal at least 30 times to discharge
the accumulators. NOTE: Hydraulic pressure will not be applied to the
parking brake until the parking brake rocker switch is
STEP 5 turned off, the service brakes applied and the transmission
is put into gear.
A. Place the parking brake rocker switch in the
OFF position.
B. Apply the service brake and put the machine
into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.
BD07A211-01
Remove bolts from bracket attached to frame and

secure out of the way.
7008-4
STEP 9 Inspection
1. Clean and inspect all parts for wear and damage.
2. Inspect the brake disc for wear and damage.
3. Replace all parts that are worn or damaged.
Assembly
STEP 1
BD07A213-01
Loosen the jam nut, turn adjusting bolt

counterclockwise until the brake pads are loose.
STEP 10
BD07A216-01
Install the two brake pads in the parking brake

assembly.
STEP 2
BD07A215
Remove the retainer pins and brake pins.
STEP 11
BD07A215-01
Install the brake pins and retainer pins.
STEP 3
Start the machine and run the engine at low idle with
the bucket resting on the ground.
IMPORTANT: It will be necessary to have an assistant
BD07A216-01 help for this procedure. An operator must be present in the
Remove the two brake pads from the parking brake cab at all times to apply the service brakes and shut down
assembly. the machine in the event of mechanical failure.
7008-5
STEP 4 STEP 6
Disengage the parking brake. Install the cover on the parking brake.
NOTE: Hydraulic pressure will not be applied to the
parking brake until the parking brake rocker switch is STEP 7
turned off, the service brakes applied and the transmission Perform the Parking Brake Te st Procedure as
is put into gear. described in this section.
A. Place the parking brake rocker switch in the
OFF position. STEP 8
B. Apply the service brake and put the machine Remove the articulation lock.
into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.
STEP 5
BD07A213-01
Turn the adjusting bolt clockwise until both brake

pads contact the brake disc, then turn the adjusting
bolt counterclockwise one turn. Tighten the jam nut
to secure the adjusting bolt.
7008-6
PARKING BRAKE TEST PROCEDURE

STEP 1 STEP 5
While testing, the machine must be on a clear level
surface with the bucket in the travel position.
WARNING: Always know the location of all

workers in your area. Warn them before you
start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015
STEP 2
Start the machine and run the engine at low idle in
third gear neutral. BD06F141-01
1. ESCAPE
STEP 3 2. ENTER
3. PARK BRAKE SWITCH
Place the Transmission-Auto switch to the manual
position. Press and hold the enter key (2) for 2 to 3 seconds
until the instrument cluster monitor display changes to
STEP 4 the select screen.
Pla ce the Parking Bra ke switch (3 ) to the O N NOTE: If you press the escape key (1) it will back up one
position. step.
STEP 6
BD07B060-01
Use the up or down arrow to select “Config”, press the

enter key (2).
7008-7
STEP 7 STEP 9
BD07B061-01 BD07B063-01
Use up or down arrow and highlight “Park Brake”, Monitor will display “Test Park Brake Engage 3rd
press the enter key to select the park brake menu. Manual” if all conditions are met to test the brake.
NOTE: If all conditions are not met to test the brake the
STEP 8 monitor will display the condition that needs corrected prior
to proceeding.
STEP 10
Shift the gear selector into third gear forward and
slowly increase the engine speed to high idle.
STEP 11
Monitor will display “Test Park Break Ready”.
STEP 12
Verify that the machine does not move.
BD07B062-01
STEP 13
Display come up “Test Park Brake Confirm Please”
press enter. Reduce the engine speed to low idle and return the
transmission neutral display will go back to “Engage
3rd manual”.
STEP 14
Shift the gear selector to third gear reverse and
slowly increase the engine speed to high idle display
will go to “Ready”.
7008-8
STEP 15
Verify that the machine does not move.
STEP 16
Reduce the engine speed to low idle and return the
transmission to neutral.
STEP 17
BD06F141-01
Press the escape switch on the key pad to exit the test
mode.
STEP 18
If any machine movement was detected, the parking
brake must be adjusted, see procedures this section.
SECTION INDEX
HYDRAULICS
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004
Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
Ride Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014
r
Section
8001
REMOVAL AND INSTALLATION

OF HYDRAULIC COMPONENTS

8001-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader Control Valve Line Connections Top Of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Loader Control Valve Line Connections Bottom Of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Joystick and 2 Lever Hose Color Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Joystick and 1 Lever Hose Color Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Joystick Hose Color Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Bucket Cylinder Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8001-3
REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE

Removal STEP 5
Release the pressure in the ride control accumulator
STEP 1 with the bleeder valve in the ride control valve, see
Park the machine on a level surface. ride control valve remove page 33.
STEP 2 STEP 6
Loosen the filler cap on the reservoir to release any
pressure in the reservoir.
STEP 7
Attach a vacuum pump to the hydraulic reservoir,
turn on the pump.
STEP 8
BD03A092
Raise the lift arms and install the safety link on the lift
arm cylinder.
STEP 3
Stop the engine and apply the parking brake.
IMPORTANT: Pump the brake repeatedly to be sure the
brake accumulators have no hydraulic pressure, then move
COVER
the loader control valve back and forth several times to
Loosen and remove the top bolts and washers,
release any hydraulic pressure in the pilot control circuit.
loosen the bottom bolts that fasten the access cover
plate for the loader control valve. Remove the cover
STEP 4 plate.
Place the master disconnect switch in the OFF
position.
8001-4
ÎÛßÎ ÑÚ ÓßÝØ×ÒÛ
BC05M094
1. 2 SPOOL VALVE 5. YELLOW BLACK BLACK (HOSE PILOT 9. 4 SPOOL VALVE

RAISE)
2. RED BLACK BLACK (HOSE PILOT 6. 3 SPOOL VALVE 10. GREEN WHITE BLACK (HOSE FOURTH
LOWER) SPOOL PILOT)
3. GREEN BLACK BLACK (HOSE PILOT 7. RED WHITE BLACK (HOSE THIRD 11. GREEN WHITE BLACK (HOSE FOURTH
DUMP) SPOOL PILOT) SPOOL PILOT)
4. ORANGE BLACK BLACK (HOSE PILOT 8. RED WHITE BLACK (HOSE THIRD
ROLLBACK) SPOOL PILOT)
HYDRAULIC VALVE PILOT LINE CONNECTIONS
NOTE: When disconnecting hydraulic fittings, plug hoses STEP 10

and cap fittings to prevent entry of foreign matter into Tag and disconnect the load sensing hose (not
hydraulic system. shown) from the LS port on the top of the control
valve.
STEP 9
Disconnect the hoses (2,3, 4, 5, if equipped 7, 8, 10, STEP 11
and 11) from the remote control valve(s) at the loader Tag and slowly disconnect the pilot accumulator
control valve (1, 6, or 9). Refer to the illustration on hose (not shown) from the from the ACC port on the
page 4 for color coding. top of the control valve.
NOTE: Line 7, 8, 10, and 11 will need to be tagged as left
or right side of the valve.
8001-5
18�
14�
20�
19�
16� 12�
17� 13�
15
W270-6R005
12. ELBOW ROD END LEFT LIFT 15. ROD END BUCKET 18. U BOLT (2)
13. ELBOW CLOSED END RIGHT LIFT 16. RETURN PORT 19. NUT (4)
14. CLOSED END BUCKET 17. INLET PORT 20. WASHER (4)
LOADER CONTROL VALVE LINE CONNECTIONS TOP OF VALVE
STEP 12 STEP 14
Remove the tilt cylinder “U” bolts (18) from the frame. Loosen and remove right lift cylinder line from elbow
(13).
STEP 13
Loosen and remove tilt cylinder lines (14 and 15). STEP 15
Loosen and remove left lift cylinder line from elbow
(12).
8001-6
22�
21�
23�
24�
25
W270-6R006
21. CLAMP 24. CLAMP

22. ROD END RIGHT LIFT 25. TUBE TILT CYLINDER ROD PLATED
23. CLOSED END LEFT LIFT
LOADER CONTROL VALVE LINE CONNECTIONS BOTTOM OF VALVE
STEP 16 STEP 17
Loosen clamp (24), disconnect tube (23) from the Loosen clamp (21), disconnect tube (22) from the
loader valve. loader valve. Disconnect tube (25).
8001-7
STEP 18 Installation
Attach lifting equipment to loader control valve.
IMPORTANT: Before installing, replace all O-rings on the
fittings, tubes, and hoses.
STEP 19
STEP 20
BC05M096
Loosen and remove the three bolts and washers that
BC05M096
hold the loader control valve to the valve mounting
plate. Remove the loader control valve. Install and align the loader control valve with the
valve mounting plate.
STEP 21
Install the bolts and washers that fasten the loader
control valve to the valve mounting plate. Tighten the
bolts.
STEP 22
Connect tube (22) to the loader valve, tighten the
clamp (21 ) lea ving a 3 0 mm (1 ¼ inch ) sp ace
between tube spud and clamp, refer to illustration on
page 6.
STEP 23
Connect tube (23) to the loader valve, tighten the
clamp (24 ) lea ving a 3 0 mm (1 ¼ inch ) sp ace
between tube spud and clamp. Connect tube (25).
STEP 24
Install and tighten the supply and return lines (16 and
17), refer to illustration on page 5.
STEP 25
Connect and tighten to elbow (12) the left lift cylinder
line.
STEP 26
Connect and tighten to elbow (13) the right lift
cylinder line.
STEP 27
Install and tighten tilt cylinder lines (14 and 15).
STEP 28
Install the tilt cylinder line “U” bolts (18).
8001-8
STEP 29 STEP 34
Connect the hoses (2,3, 4, 5, if equipped 7, 8, 10, Run engine at half throttle.
and 11) to the remote control valve(s) on the loader
control valve (1, 6, or 9). Refer to the illustration on STEP 35
page 4 for color coding. Slo w ly a n d co mp let ely e xte n d a nd re tra ct a ll
cylinders at least 10 times to remove any air from the
STEP 30 circuits.
Connect the load sensing hose (not shown) and the
pilot accumulator hose (not shown) to the top of the STEP 36
control valve. Stop the engine and check for leaks.
STEP 31 STEP 37
Turn off and disconnect the vacuum pump from the Install the access cover on the front of the machine.
reservoir.
STEP 38
STEP 32
Check the level of the hydraulic oil and add hydraulic
Place the master disconnect switch in the ON oil as required. Refer to Section 1002 for the correct
position. oil.
STEP 33
BD03A092
Raise the loader arms and remove the safety link.

8001-9
REMOTE CONTROL VALVE

Removal STEP 44
STEP 39
parking brake.
IMPORTANT: With the engine NOT running, pump the
brake repeatedly to be sure the brake accumulators have no
hydraulic pressure, put the ignition switch in the ON
position then move the loader control valve back and forth
several times to release any hydraulic pressure in the pilot
control circuit, turn ignition switch OFF.
STEP 40 BD06F208
Place the master disconnect switch in the OFF Open and remove the access panel.
position.
STEP 45
STEP 41
Unlatch and open the right hand side access door.
STEP 42
Lift the access door up and remove the access door
from the pins.
STEP 43
BD06F210
Disconnect the electrical connectors for the remote

control valve.
STEP 46
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.
W270-8R016
Unlatch and open the compartment door on the right

hand side.
8001-10
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install STEP 51
plugs in the hoses and caps on the fittings. Install new O-rings on the adapters for the remote
control valve.
STEP 48
Loosen and remove the screws and washers holding STEP 52
the hydraulic control tower cover. Remove the cover. Install the remote control valve and screws in the
hydraulic control tower and tighten the screws.
STEP 49
Loosen and remove the screws that fasten the STEP 53
remote control valve to the hydraulic control tower. Install the cover over the remote control valve and
install the screws and washers.
STEP 50
Remove the remote control valve from the hydraulic STEP 54
control tower. Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 11, 12, and 13 as necessary.
STEP 55
Turn off the vacuum pump and disconnect from the
STEP 56
BD06F210
Connect the electrical connectors for the remote

control valve.
STEP 57
Place the master discon nect switch in the ON
position.
STEP 58
Start the engine and run the engine at low idle.
STEP 59
Check to see that the remote control valve works
correctly.
8001-11
STEP 60 STEP 62
Check for hydraulic oil leakage at the remote control
valve.
STEP 61
Check the level of hydraulic oil in the reservoir and
add as required.
BD06F2081
Install and close the access panel.
STEP 63
W270-8R016
Close the right hand compartment door.

8001-12
3�
7�
4�
8�
6� 5�
1�
2�
7� 8
7� 5�
1� 2�
8� 3�
6� 4�
W270-6R008
1. PILOT TANK HOSE 4. ORANGE BLACK BLACK (ROLLBACK) 7. GREEN WHITE BLACK (4TH SPOOL)
2. PILOT PRESSURE HOSE 5. GREEN BLACK BLACK (DUMP) 8. RED WHITE BLACK (3RD SPOOL)
3. YELLOW BLACK BLACK (RAISE) 6. RED BLACK BLACK (LOWER)
JOYSTICK AND 2 LEVER HOSE COLOR CODING
8001-13
7�
1�
4� 6�
7� 5� 3�
4� 2�
1�
6� 3�
5�
3
7� 7� 7� 7�
2� 1� 2� 1�
3� 6� 3� 6�
4� 5� 4� 5�
W270-6R009 W270-6R010
1. PILOT TANK HOSE 1. PILOT TANK HOSE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK BLACK (LOWER) 3. RED BLACK BLACK (LOWER)
4. ORANGE BLACK BLACK (ROLLBACK) 4. ORANGE BLACK BLACK (ROLLBACK)
5. YELLOW BLACK BLACK (RAISE) 5. YELLOW BLACK BLACK (RAISE)
6. GREEN BLACK BLACK (DUMP) 6. GREEN BLACK BLACK (DUMP)
7. RED WHITE BLACK (3RD SPOOL) 7. RED WHITE BLACK (3RD SPOOL)
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING
8001-14
5�
4� 1�
5� 6�
2� 4�
6� 1�
3�
3�
2
7� 7� 7� 7�
2� 1� 2� 1�
3� 6� 3� 6�
4� 5� 4� 5�
W270-6R011 W270-6R012

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING
8001-15
NOTES
8001-16
REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP
7�
15� 7�
10� 8�
4�
5� 16�
6�
4� 8�
5�
2�
1�
3�
12�
11�
14� 9�
13
W270-6R007
1. PUMP MAIN HYDRAULIC 5. SPLIT FLANGE 9. BOLT 13. LOADER HIGH PRESSURE
2. MOUNT BOLTS 6. TUBE 10. CLAMPS 14. STEERING PRIORITY MANIFOLD
3. DRAIN HOSE 7. HOSE SUCTION 11. SPLIT FLANGE 15. CLAMPS
4. BOLT 8. HOSE CASE DRAIN 12. TUBE PUMP DISCHARGE 16. FITTINGS
8001-17
Removal STEP 73
Connect lifting equipment to hydraulic pump (1).
NOTE: When disconnecting hydraulic fittings, plug hoses
Take up all slack in lifting equipment. Remove four
and cap fittings to prevent entry of foreign matter into
mounting bolts (2) and washers securing pump to
hydraulic system.
transmission. Pull hydraulic pump from transmission
and remove from loader. Remove and discard O-ring
STEP 64 from pump.
bucket to the floor. Stop the engine and apply the Installation
parking brake.
NOTE: Install new O-rings where required.
STEP 65
Place the master disconnect switch in the OFF STEP 74
position. Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
STEP 66 four washers and bolts (2) to secure pump (1) to
Loosen the filler cap on the reservoir to release any transmission, tighten the bolts. Disconnect lifting
air in the reservoir. Connect a vacuum pump to the equipment from pump.
STEP 75
STEP 67 Connect pump pressure hose (13) to steering priority
Refer to Section 9007 and remove the ROPS cab or manifold (14).
ROPS canopy.
STEP 76
STEP 68 Connect drain hose (3).
Remove eight bolts (4) and washers. Remove four
split flanges (5). Disconnect tubes (6) with suction STEP 77
hoses (7) from hydraulic pump. Remove and discard Install and connect case drain hoses (8).
O-ring face seals from flange heads of tubes.
STEP 78
STEP 69 Install suction hoses (7), tighten clamps (10) to 10 to
Loosen clamps (10). Tag and disconnect suction 11 Nm (90 to 100 pound inches).
hoses (7) from hydraulic reservoir and remove from
machine. STEP 79
Install four split flanges (5). Install eight bolts (4) and
STEP 70 washers, tighten bolts (4) to 73 to 90 Nm (53.8 to
Tag and disconnect case drain hoses (8) from fittings 66.3 pound feet).
(16); remove hoses (8). Remove and discard O-ring
face seals from fittings. STEP 80
Refer to Section 9007 and install the ROPS cab or
STEP 71 ROPS canopy.
Tag and disconnect drain hose (3). Remove and
discard O-ring face seals from fittings. STEP 81
Turn off the vacuum pump and disconnect from the
STEP 72 hydraulic reservoir.
Tag and disconnect pump pressure hose (13) from
steering priority manifold (14). Remove and discard STEP 82
O-ring face seals from flange heads of hoses. Place the master discon nect switch in the ON
position.
8001-18
STEP 83 STEP 84
Start the engine and run the engine at low idle for two Stop the engine and check for hydraulic oil leakage
minutes. at the hydraulic pump.
NOTE: If any unusual vibration is heard coming from the
pump, stop the machine immediately and check for STEP 85
obstructions in the pump suction line. Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
8001-19
REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS

Removal STEP 91
NOTE: The photo’s may vary from your machine, the
procedure is the same.
STEP 86
parking brake.
STEP 87
Pump the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, then move
the loader control lever back and forth several times
BD01D709
to release any hydraulic pressure in the pilot control
circuit. Loosen and remove the bolt, washer and spacer that
hold the pivot pin for the yoke.
STEP 88
STEP 92
Relieve the pressure in the ride control accumulator
with the manual bleeder valve located in the ride
control valve.
STEP 89
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 90
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 93
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.
8001-20
STEP 97
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 98
BD01D710
Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.
STEP 95
BD01D714
Use a proper lifting device and position the lift

cylinder on the machine.
STEP 99
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 96
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.
8001-21
STEP 100 STEP 103
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 104
STEP 101
BD01D709
BD01D708 Align the pivot pin with the yoke and install the
Remove the caps and plugs and connect the hoses spacer, washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 105
STEP 102 SLOWLY extend and retract the piston rod three
If the yoke of the lift cylinder is not aligned with the times to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 106
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 107
Check the level of hydraulic oil in the reservoir and
ad d a s re qu ir ed . Tigh ten the fille r ca p o n th e
8001-22
REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER
W270-5R015
1. BRACKET 6. BOLTS 11. WASHER

2. WASHER 7. WASHERS 12. WIRING HARNESS GAURD
3. BOLT 8. PROXIMITY SWITCH 13. BOLT
4. TARGET BAR 9. GAP 3.2 - 5 MM (0.125 - 0.197 INCH) 14. WASHER
5. PROXIMITY SWITCH BRACKET 10. BOLT 15. BUCKET CYLINDER
BUCKET CYLINDER PROXIMITY SWITCH
8001-23
Removal STEP 112

NOTE: The photo’s may vary from your machine, the
procedure is the same.
STEP 108
parking brake.
STEP 109
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 110 BD01D697
Loosen and remove the two bolts (6) and washers

(7) that fasten the proximity switch bracket (5) to the
cylinder (15). Remove the proximity switch bracket
(5) and proximity switch (8).
STEP 113
Remove bolts and washers(10 and 11), remove bolts
and wahsers (13 and 14), remove the wiring harness
gaurd (12) with wiring harness.
STEP 114
BD01D694
Disconnect the proximity switch connector from the

wiring harness connector.
STEP 111
BD01D699
Disconnect the hoses from each side of the bucket

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D695
Loosen and remove the two bolts (3) and washers

(2) that fasten the bracket (1) to the cylinder (15).
Remove the bracket (1) with target bar (4).
8001-24
STEP 115 STEP 118
BD01D700 BD06H199
Use a cceptab le equ ipme nt to h old the b ucket Remove the pivot pin from the head end of the
cylinder. bucket cylinder.
NOTE: It is not necessary to remove the grease line from
STEP 116 the pivot pin unless the pivot pin is to be replaced.
STEP 119
BD01D698
Loosen and remove the bolt, washer and spacer that

fasten the pivot pin from both ends of the bucket
BD06H200
cylinder.
Raise the bucket cylinder and remove the cylinder
from the machine.
STEP 117
BD01D701
Remove the pivot pin from the rod end of the bucket
cylinder.
8001-25
STEP 120
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 121
BD01D699
Conn ect the hose s to each sid e of the bu cke t

cylinder.
STEP 125
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD01D706
engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 122 STEP 126

Install the pivot pin and stop the engine.
STEP 127
BD01D704
Install the pivot pin to the head end of the bucket

cylinder.
BD01D698
STEP 123 Install the spacer, washer and bolt that fasten the
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
pivot pin to the front frame. Tighten the bolt.
STEP 128
NOTE: If a new pivot pin is being installed, connect the
Install the wiring harness gaurd (12) with wiring
grease line to the pivot pin.
harness, install and tighten bolts and washers (10
and 11), bolts and wahsers (13 and 14), refer to
illstation on page 22.
8001-26
STEP 129 STEP 131
BD01D697 BD01D694
Install the two bolts (6) and wahsers (7) that fasten Connect the proximity switch connector to the wiring
the proximity switch bracket (5) to the bucket cylinder harness connector.
(15).
STEP 132
STEP 130 See Section 9006 for the adjustment procedure for
adjusting the proximity switch.
STEP 133
Start and run the engine at low idle.
STEP 134
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 135
Lubricate the pivot pins with molydisulfide grease.
BD01D695
STEP 136
Install the bracket (1) with target bar (4). Install and
Check the level of the hydraulic oil in the reservoir
tighten the two bolts (3) and washers (2) that fasten
and add as required. Tighten the filler cap on the
the bracket (1) to the cylinder (15).
8001-27
REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATORS

Removal STEP 139
STEP 137
parking brake.
STEP 138
With the engine NOT running, pump the brake
repeatedly to be sure the brake accumulators have
no hydraulic pressure, move the loader control lever
back and forth several times to release any hydraulic
pressure in the pilot control circuit. BD06A218
Relieve the pressure in the ride control accumulators
with the manual bleeder valve located on the side of
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.
STEP 140
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
8001-28
BC06A217
1. BOLT (3) 9. BRACKET 17. NUT (2)

2. WASHER (3) 10. RIGHT ACCUMULATOR 18. WASHER (2)
3. RIDE CONTROL VALVE 11. U-BOLT 19. BRACKET
4. RIGHT ACCUMULATOR TUBE 12. BRACKET 20. LEFT ACCUMULATOR
5. LEFT ACCUMULATOR TUBE 13. WASHER (2) 21. U-BOLT
6. HOSE TO LEFT CYLINDER 14. NUT (2) 22. BRACKET
7. HOSE TO RETURN TUBE 15. WASHER (2) 23. WASHER (2)
8. HOSE TO RIGHT CYLINDER 16. NUT (2) 24. NUT (2)
STEP 141 STEP 143

Disconnect the tube (4 or 5) from the elbow at the Loosen and remove the two nuts (16 or 24) and
accumulator (10 or 20). Install a plug in the tube and washers (15 or 23) that fasten the accumulator
a cap on the fitting. bracket (12 or 22) to the front frame.
STEP 142 STEP 144

Loosen and remove the two nuts (14 or 17) and Remove the ride control accumulator (10 or 20) from
washers (13 or 18) that fasten the accumulator the machine.
bracket (9 or 19) to the front frame.
8001-29

Turn off and disconnect the vacuum pump from the
STEP 145 hydraulic reservoir.
Place the ride control accumulators (10 or 20) in
position on the front frame. STEP 150
Refer to Section 8013, Charging The Accumulator
STEP 146 With Nitrogen and charge the accumulators.
Install the two nuts (16 or 24) and washers (15 or 23)
that fasten the accumulator bracket (12 or 22) to the STEP 151
front frame. Tighten the nuts. Refer to Section 8002 Testing the Ride Control and
test the ride control system, check for leaks.
STEP 147
Install the two nuts (14 or 17) and washers (13 or 18) STEP 152
that fasten the accumulator bracket (9 or 19) to the Check the level of the hydraulic oil in the reservoir
front frame. Tighten the nuts. and add as required. Tighten the filler cap on the
STEP 148
Remove the caps and plugs and install the tubes (4
or 5) to the elbows on the ride control accumulators.
8001-30
RIDE CONTROL VALVE

Removal STEP 156
With the engine NOT running, pump the brake
STEP 153 repeatedly to be sure the brake accumulators have
Park the machine on a level surface and apply the no hydraulic pressure, then move the loader control
parking brake. lever back and forth several times to release any
hydraulic pressure in the pilot control circuit.
STEP 154
STEP 157
BD03A092
BD06A218
Raise the loader arms and install the safety link.
Relieve the pressure in the ride control accumulators
with the manual bleeder valve located on the side of
STEP 155
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.
STEP 158
release any pressure in the reservoir. Connect a
pump.
STEP 159
Place the master disconnect switch in the OFF
position.
BD06A213
Remove the access cover. STEP 160

Disconnect the electrical connector from the ride
control valve.
8001-31
BC06A217
1. BOLT (3) 9. BRACKET 17. NUT (2)

2. WASHER (3) 10. RIGHT ACCUMULATOR 18. WASHER (2)
3. RIDE CONTROL VALVE 11. U-BOLT 19. BRACKET
4. RIGHT ACCUMULATOR TUBE 12. BRACKET 20. LEFT ACCUMULATOR
5. LEFT ACCUMULATOR TUBE 13. WASHER (2) 21. U-BOLT
6. HOSE TO LEFT CYLINDER 14. NUT (2) 22. BRACKET
7. HOSE TO RETURN TUBE 15. WASHER (2) 23. WASHER (2)
8. HOSE TO RIGHT CYLINDER 16. NUT (2) 24. NUT (2)
STEP 161 STEP 163

Tag and disconnect the hoses (6, 7, and 8) and tubes Remove the ride control valve from the machine.
(4 and 5) from the ride control valve. Install a plug in
the hoses and caps on fittings. STEP 164
Remove and discard all O-rings.
STEP 162
Loosen and remove the three bolts (1) and washers
(2) that fasten the ride control valve to the frame.
8001-32

Stop the engine and check for hydraulic oil leakage
STEP 165 at the ride control valve.
Install the ride control valve in position on the front
frame. STEP 175
STEP 166
Install the washers (2) and bolts (1) through the
frame and into the ride control valve. Tighten the
bolts.
STEP 167
BD06A213
Install the access cover.
STEP 176
BD06A218
Tighten the accumulator manual bleeder valve

located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).
STEP 168
Lubricate and install new O-rings.
STEP 169 BD03A092
Connect the tubes (4 and 5) and hoses (6, 7, and 8) Raise the loader arms and remove the safety link.
to the ride control valve.
STEP 177
STEP 170 Check the level of the hydraulic oil in the reservoir
Connect the electrical connector to the ride control and add as required. Tighten the filler cap on the
valve. hydraulic reservoir.
STEP 171 STEP 178

Turn off the vacuum pump and disconnect from the Refer to Section 8002 and perform the Ride Control
hydraulic reservoir. Test Procedure.
STEP 172
Place the master disconnect switch in the ON
position.
STEP 173
Start and run the engine at low idle for two minutes.
8001-33
REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE
BC06A214
1. SOLENOIDS 3. INLET 5. FAN SUPPLY

2. OUTLET 4. FAN RETURN 6. FAN VALVE
8001-34
Removal STEP 185

Tag and disconnect the fan valve outlet hose (2) from
STEP 179 the fan reversing valve. Install a plug in the hose and
Park the machine on a level surface and lower the a cap on the fitting.
bucket to the ground. Stop the engine and apply the
parking brake. STEP 186
Tag and disconnect the fan valve inlet hose (3) from
STEP 180 the fan reversing valve. Install a plug in the hose and
With the engine NOT running, pump the brake a cap on the fitting.
repeatedly to be sure the brake accumulators have
no hydraulic pressure, then move the loader control STEP 187
lever back and forth several times to release any
hydraulic pressure in the pilot control circuit.
8
7�
STEP 181
release the air pressure in the reservoir. Connect a
pump.
STEP 182
D isc on n e ct th e e le ct rica l co n n ec to r fr o m t h e
solenoids (1) on the fan reversing valve.
W270-6R015
7. NUT AND WASHER 8. REAR AXLE TRUNNION MOUNT

STEP 183
Loosen and remove the nuts and washers (7).
Tag and disconnect the fan supply hose (5) from the
fan reversing valve. Install a plug in the hose and a
cap on the fitting. STEP 188
Remove the fan reversing valve from the machine.
STEP 184
Tag and disconnect the fan return hose (4) from the STEP 189
fan reversing valve. Install a plug in the hose and a Remove and discard all O-rings from the fittings.
cap on the fitting.
8001-35

Connect the fan supply hose (5) to the fitting on the
STEP 190 fan reversing valve.
Lubricate and install new O-rings in the fittings.
STEP 197
STEP 191 Connect the electrical connector to the solenoids (1)
Place the fan reversing valve into position on the on the fan reversing valve.
machine.
STEP 198
STEP 192 Turn off the vacuum pump and disconnect from the
Install the washers and nuts (7). Tighten the nuts. hydraulic reservoir.
STEP 193 STEP 199

Connect the fan valve inlet hose (3) to the fitting on Check the level of the hydraulic oil in the reservoir.
the fan reversing valve.
STEP 200
STEP 194 Start the engine and run the engine at low idle for two
Connect the fan valve outlet hose (2) to the elbow on minutes.
the fan reversing valve.
STEP 201
STEP 195 Stop the engine and check for hydraulic oil leakage
Connect the fan return hose (4) to the fitting on the at the fan reversing valve.
fan reversing valve.
STEP 202
NOTESCheck the level of the hydraulic oil in the
reservoir and add as required. Tighten the filler cap
on the reservoir.
8001-36
NOTES
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS

8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TESTING AND ADJUSTING PUMP 1 DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting Pump 1 Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING PUMP 2 DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting Pump 2 Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TESTING AND ADJUSTING THE LOADER RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Timing Cycle of Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8002-3
SPECIFICATIONS
Manufacturer ....................................................................................................................................... Bosch-Rexroth
Pump 1 (closest to transmission) .....................................................................169.5 L/min at 250 bar, at 2100 r/min
(44.8 gpm at 3626 psi, at 2100 r/min)
Pump 2 (furthest from transmission) ................................................................169.5 L/min at 250 bar, at 2100 r/min
(44.8 gpm at 3626 psi, at 2100 r/min)
Combined pump flow...........................................................................................339 L/min at 250 bar, at 2100 r/min

(89.6 gpm at 3626 psi, at 2100 r/min)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Circuit relief valve pressure setting

Auxiliary A and B port.................................................................................................................290 bar (4200 psi)
Bucket A and B port ...................................................................................................................290 bar (4200 psi)
Pilot accumulator pressure ............................................................................................13 to 15 bar (188 to 218 psi)
Steering relief valve pressure setting ............................................................................................ See Section 5002
Accumulator pressure .................................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.
8002-4
SPECIAL TOOLS
633L95 B877168V
380001741 PRESSURE FITTING KIT 380001740 FLOWMETER FITTING KIT
632L95 B877895M
380001742 PRESSURE FITTING KIT 380001726 HAND PUMP
B785789M B877558M
380001731 FLOWMETER 380001739 PRESSURE FITTING KIT
8002-5
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and

damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Fill the hydraulic reservoir with the hydraulic
No oil specified in Section 1002.
Is the oil level correct?.
Yes
Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.
Problems in All Circuits

Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for See Page 15. Do the flow meter test of the
No hydraulic pump.
contaminated oil. Is the oil contaminated?
Yes
See Section 8003 and clean or replace the

oil.
Problem in All Loader Circuits

See Page 10 and check the pressure setting
Adjust the limit pressure. See page 10 in this
of the limit pressure in the loader control No section.
valve. Is the pressure setting correct?
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.
8002-6
Problem in a Single Loader Circuit

Start an d ru n the e ng in e at full th rottle. The loader control valve is damaged. See
Operate the control for the bad circuit. Does No Section 8005 and repair the loader control
the cylinder move in both directions? valve
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 18. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of control valve and check for worn or
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes
See Page 13. Do the Steering Pump Limit

Pressure Test and Adjustment
Problem in the Ride Control

L ift ar ms r a pid ly a nd c o n tin uo u sly s ink See the Ride Control Test Procedure page
towards the ground. No 19 in this section.
Yes
Check the manual bleed valve for the ride

control accumu la tor to be sure that it is
closed.
8002-7
TESTING AND ADJUSTING PUMP 1 DIFFERENTIAL PRESSURE

Pressure Check STEP 3
After heating oil to operating temperature, lower
STEP 1 bucket to the ground, turn off the engine, and turn
key to “RUN” position and operate joystick and
relieve the pressure in the hydraulic system and pilot
accumulator. Turn ignition switch to OFF.
WARNING: Before doing any maintenance on

the hydraulic system, make sure that all hydraulic
pressure has been released by operating the
control levers several times and the hydraulic
reservoir air pressure has been released. Failure to
do so could cause serious injury.
CSM120
STEP 4
W270-1R006
Install articulation lock.
WARNING: Keep clear of this area when engine

is running. Machine could pivot unless the
transport and service link is in its LOCKED position.
After servicing is completed, unlock the transport
and service link and secure in place on the rear
frame.
SA069
BS06N368
STEP 2 1. PUMP 2 LOAD SENSE PRESSURE TAP

Make sure that the temperature of the hydraulic oil is 2. PUMP 1 LOAD SENSE PRESSURE TAP
at least 54°C to 57°C (129°F to 135°F). The following 3. PUMP 1 LOAD SENSE PRESSURE ADJUSTMENT
is the procedure for heating the hydraulic oil. 4. PUMP 1 MAIN LINE PRESSURE TAP (G1)
To measure the oil temperature with the 6. PUMP 2 MAIN LINE PRESSURE TAP (G2)
instrument cluster: 7. STEERING RELIEF PRESSURE ADJUSTMENT
A. Press the down arrow key until the info screen 8. PUMP 2 LOAD SENSE PRESSURE ADJUSTMENT
with temperatures that need to be monitored Connect two 69 bar (1000 psi) test gauges. One to
are on. pump 1 main line pressure tap G1 (4) on the bottom
To heat the hydraulic oil do the following: left face of the priority valve. And the other to pump 1
load sense pressure tap (2) on the top of the pump
A. Apply the service brake. closest to the transmission.
B. Start the engine and run at high idle. IMPORTANT: Do not steer or operate loader controls
C. Hold the bucket control lever in the while the gauges are connected, gauges could be damaged.
R O L L B A C K p o s i ti o n w h il e r a is i n g a n d
lowering the lift arms from ground level to full STEP 5
height. Start the engine and run at low idle.
D. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to
135°F).
8002-8
STEP 6 Adjusting Pump 1 Differential
Make sure all of the controls are in the neutral Pressure
position and record the readings on the test gauges
located on test ports (2) and (4).
STEP 10
STEP 7
Subtract the reading of the test port (2) from the
reading of the test port (4).
STEP 8
The difference between the two readings should be
28 to 31bar (405 to 450 psi).
STEP 9
If this reading is more or less than specified, it will be
necessary to adjust the pump load-sense pressure. BS06N368
1. PUMP 2 LOAD SENSE PRESSURE TAP

3. PUMP 1 LOAD SENSE PRESSURE ADJUSTMENT
4. PUMP 1 MAIN LINE PRESSURE TAP (G1)
7. STEERING RELIEF PRESSURE ADJUSTMENT
The load-sense adjusting screw (3) is directly below

th e lo a d- se n se p r e ssu re ta p . Tu rn th e sc re w
clockwise to increase the load-sense pressure.
Turning the screw counterclockwise will decrease the
load-sense pressure.
NOTE: One turn of the adjustment screw will change the
pressure approximately 16 bar (230 psi).
8002-9
TESTING AND ADJUSTING PUMP 2 DIFFERENTIAL PRESSURE


CSM120
STEP 4
W270-1R006

frame.
SA069
BS06N368

A. Press the down arrow key until the info screen
with temperatures that need to be monitored Connect two 69 bar (1000 psi) test gauges. One to
are on. pump 2 main line pressure tap G2 (6) on the top left
To heat the hydraulic oil do the following: face of the priority valve. And the other to pump 2
load sense pressure tap (1) on the top of the pump
A. Apply the service brake. furthest from the transmission.
B. Start the engine and run at high idle. IMPORTANT: Do not steer or operate loader controls
C. Hold the bucket control lever in the while the gauges are connected, gauges could be damaged.
height. Start the engine and run at low idle.
D. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to
135°F).
8002-10
STEP 6 Adjusting Pump 2 Differential
Make sure all of the controls are in the neutral Pressure
position and record the readings on the test gauges
located on test ports (1) and (6).
STEP 10
STEP 7
Subtract the reading of the test port (1) from the
reading of the test port (6).
STEP 8
The difference between the two readings should be
27 to 30 bar (391 to 435 psi).
STEP 9
necessary to adjust the pump load-sense pressure. BS06N368

The load-sense adjusting screw (8) is directly below

th e lo a d- se n se p r e ssu re ta p . Tu rn th e sc re w
clockwise to increase the load-sense pressure.
Turning the screw counterclockwise will decrease the
load-sense pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).
8002-11
TESTING AND ADJUSTING THE LOADER RELIEF PRESSURE


CSM120
STEP 4
W270-1R006

frame.
SA069
BS06N368

with temperatures that need to be monitored NOTE: Make sure that the differential pressures are
are on. correct for the pump 1 and pump 2 prior to proceeding.
To heat the hydraulic oil do the following: Connect a 345 bar (5000 psi) test gauge to pump 1
A. Apply the service brake. main line pressure tap G1 (4).
B. Start the engine and run at high idle. STEP 5

C. Hold the bucket control lever in the Start the engine and run at high idle.
height. Roll the loader bucket back against the stops (or fully
D. Continue this procedure until the temperature retract the bucket cylinder if the if the unit does not
of the hydraulic oil is 54° to 57°C (129° to have a bucket) and maintain this position.
135°F).
8002-12
STEP 7 Adjusting the Loader Limit
Record the reading on the test gauge. Pressure
STEP 8
Reading should be 248 to 255 bar (3595 to 3700 psi).
STEP 9
necessary to adjust the loader relief pressure.
BS06H193
STEP 10
Turn the screw (1) clockwise to increase the loader
relief. Turning the screw counterclockwise will
decrease the loader relief pressure.
NOTE: 1/4 turn of the adjustment screw will change
the pressure approximately 35 bar (500 psi).
8002-13
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE


CSM120
STEP 4
W270-1R006

frame.
SA069
BS06N368

A. Press the down arrow key until the info screen 8. PUMP 2 LOAD SENSE PRESSURE ADJUSTMENT
with temperatures that need to be monitored NOTE: Make sure that the differential pressures are
are on. correct for the pump 1 and pump 2 prior to proceeding.
To heat the hydraulic oil do the following: Connect a 345 bar (5000 psi) test gauge to pump 1
A. Apply the service brake. main line pressure tap G1 (4), located on the bottom
left of the priority valve.
B. Start the engine and run at high idle.
C. Hold the bucket control lever in the STEP 5
R O L L B A C K p o s i ti o n w h il e r a is i n g a n d Start the engine and run at high idle.
lowering the lift arms from ground level to full
height. STEP 6
D. Continue this procedure until the temperature Steer hard in either direction over relief pressure.
of the hydraulic oil is 54° to 57°C (129° to Maintain this position.
135°F).
8002-14
STEP 7 Adjusting the Steering Limit
Record the reading on the test gauge. Pressure
STEP 8
Reading should be 239 to 243 bar (3465 to 3525 psi).
STEP 9
necessary to adjust the steering limit pressure.
BS06N368

STEP 10
The steering priority valve is located on the hydraulic
pump closest to transmission, the adjusting valve is
located on the transmission side of the priority valve.
Turning the screw clockwise to increase the limit
pressure. Turning the screw counterclockwise will
decrease the limit pressure.
8002-15
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE

NOTE: This pressure is factory preset and is not STEP 6
adjustable. Open the right side compartment to gain access to
the loader control handle.
Pressure Check
STEP 7
STEP 1 Attach a gauge capable of reading 70 bar (1000 psi)
to the test port under loader control handle.
Make sure that the temperature of the hydraulic oil is
at least 54°C to 57°C (129°F to 135°F). The following
is the procedure for heating the hydraulic oil. STEP 8
To measure the oil temperature with the Start and run the machine at low idle, hold the bucket
instrument cluster: control lever in the ROLLBACK position to increase
the system pressure.
with temperatures that need to be monitored STEP 9
are on.
A pressure reading of 29 to 40 bar (420 to 580 psi)
To heat the hydraulic oil do the following: should be obtained, if pressure is not as specified do
the following steps.
A. Start the engine and run at full throttle.
B. Hold the bucket control lever in the STEP 10
Lower the bucket to the ground and turn off the
en gin e. Tur n the ignition sw itch to th e “RU N”
height.
position.
C. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to STEP 11
135°F). Operate the pilot controls several times until the
gauge pressure suddenly drops to zero. The last
STEP 2 pressure reading before the drop to zero is the
Raise lift arms to the top and turn off the engine. Turn nitrogen charge pressure in the accumulator. If the
the ignition switch to the “RUN” position. pressure is below 13 to 15 bar (188 to 218 psi),
replace the accumulator. If accumulator test is good,
STEP 3 go to next step.
Repeatedly put the loader control lever into “FLOAT”
position and back to neutral. STEP 12
Replace the pilot controls, see section 8001, retest
STEP 4 the system, if test fails go to next step.
The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down. STEP 13
Replace the loader control valve, see section 8001,
NOTE: If 10 full actuations cannot be made, an internal
retest the system.
hydraulic leak exists, proceed to next step.
STEP 5
Start machine and lower the bucket to the ground
and turn off the engine. Turn the ignition switch to the
“R U N” p o sitio n , o p e ra te th e p ilo ts co n tro ls a
minimum of 30 strokes to relieve any pressure in the
system.
8002-16
PUMP FLOW TEST

Timing Cycle of Loader STEP 2
Disconnect the load sense hose (7) and install a cap
NOTE: If you perform a cycle time test on the loader and
on the fitting at the loader valve (14) for the load
it meets specifications you do not need to do the pump flow
sense hose fitting (not shown).
test.
NOTE: This is the line that returns to the pump
STEP 1 compensator valve.
Make sure that the temperature of the hydraulic oil is
at least 54°C to 57°C (129°F to 135°F). The following STEP 3
is the procedure for heating the hydraulic oil. Connect a “T” fitting (10) into the loader control valve
inlet hose (6) and to the flow meter inlet hose (11).
To measure the oil temperature with the
instrument cluster:
STEP 4
A. Press the down arrow key until the info screen Use a union (9) and connect an in line needle valve
with temperatures that need to be monitored (8) to the open port in the “T” fitting (10), connect the
are on. load sense hose (7) to the needle valve (8).
To heat the hydraulic oil do the following:
A. Start the engine and run at full throttle. STEP 5
Make sure that the flow meter valve and the installed
B. Hold the bucket control lever in the
needle valve are in the open position. Start and run
the engine at high idle, slowly close the flow meter
valve until a pressure reading of 103 bar (1500 psi) is
height.
obtained.
C. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to STEP 6
135°F). Using the temperature gauge on the flow meter,
continue to run the engine at high idle until the
STEP 2 temperature of the hydraulic oil is at least 52°C to
Start engine and run at high idle, with bucket empty 60°C (125°F to 140°F).
and rolled back on the ground (to get the cylinders all
the way down). raise to full height. STEP 7
Run the engine at low idle, fully open the flow meter
STEP 3 valve.
Specification for loader cycle time from ground to full
height is 7 second s. Anyth ing over 7 seconds STEP 8
indicates a problem and pump flow test should be Open the needle valve (8) and operate the engine at
performed. 2100 rpm. At 0 bar (0 psi) the flow should be 352 to
362 L/min (93.0 to 95.6 gpm).
Pump Flow Test STEP 9
NOTE: The pump differential pressure must be set before Close the flow meter valve slowly and read the flow
attempting any other tests. Refer to page 7 of this section. at 34.5 bar (500 psi) @ 2100 rpm. The flow should be
348 to 358 L/min (91.9 to 94.6 gpm).
STEP 1
Connect the flow meter (3) by disconnecting the inlet STEP 10
hose (6) from connector (13), install a cap on the Close the flow meter valve slowly and read the flow
connector (13). Refer to illustration on page 17. at 3600 psi @ 2100 rpm. The flow should read 334 to
344 L/min (88.2 to 90.9 gpm).
STEP 11
If any of the pump flow readings are not within
specifications, the pump may be out of calibration and
Technical Support Services should be contacted.
8002-17
Í»» ²±¬»
BS06N556
1. HYDRAULIC RETURN MANIFOLD 6. HOSE 11. FLOW METER INLET HOSE

2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP
3. FLOW METER 8. NEEDLE VALVE 13. CONNECTOR STR THD 30 MM ORFS X M42 ORB
4. PUMP 9. UNION 14. LOADER VALVE
5. PRIORITY VALVE 10. T FITTING
NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.
8002-18
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Remove the safety strut and lower the bucket to the
STEP 1 floor. Shut off the engine. Find an easy place to
Circuit relief valves are located as shown below. disconnect the line for the circuit to be tested.
STEP 5
Connect the hand pump to the disconnected line that
goes to the loader control valve.
STEP 6
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21°C (70°F).
STEP 7
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEP 8
Compare the reading to the specifications on Page 3.
STEP 9
If the pressure is not correct, adjust the circuit relief
valve.
Adjustment
BS03B022
1. CIRCUIT RELIEF VALVES STEP 1

2. PUMP LIMIT PRESSURE ADJUSTMENT
3. BUCKET SPOOL Loosen the lock nut. Turn the adjustment screw
4. LIFT SPOOL clo ckwise to incre ase th e p ressure or
5. AUXILIARY SPOOL counterclockwise to decrease the pressure.
6. LOADER CONTROL VALVE
NOTE: One turn of the adjusting screw will change the
pressure approximately 138 bar (2000 psi).
STEP 2
Raise the lift arms and install the safety link on the lift
STEP 2
arm cylinder.
Check the pressure again. Repeat the adjustment as
necessary.
STEP 3
Loosen and remove the bolts and washers that
fasten the access cover plate for the loader control
valve. Remove the cover plate.
8002-19
TESTING THE RIDE CONTROL

STEP 1 STEP 6
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP 2
Install the articulation lock, start the machine, STEP 7
activate the parking brake.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
STEP 3 their stops, place the pilot control lever in the neutral
With the pilot controller in neutral, set the ride control position.
rocker switch on the right side console to the “Always
On” position and observe the switch lamp, the lamp STEP 8
should illuminate.
Set the ride control rocker switch to the “Always On”
position. The lift arms should rise 15 to 30 cm (6 to
STEP 4 12 inches) with an empty bucket.
Set the ride control rocker switch to the “Off” position
and observe the switch lamp, the lamp should go out. NOTE: Test results will be for a machine with a empty
factory bucket and no attachments.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not illuminate STEP 9
see section 4002 and troubleshoot the electrical system for
If there is little or no lift arm raise, the test may have
the ride control.
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
STEP 5
Raise the lift arms to the top of their travel and dump NOTE: If test was done to slowly repeat in the allotted
the bucket. time.
NOTE: Keep rocker switch in the “Off” position during STEP 10

this steps 5, 6, 7.
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator, see section 8013.
8002-20
HYDRAULIC COMPONENT LOCATIONS
2
1�
4� 5� 7�
3� 6�
9�
8�
24� 23� 22� 21� 20� 19� 17� 16� 14� 13� 12� 11� 10�
18� 15�
W270-6R017
1. PILOT CONTROL VALVE 13. STEERING CYLINDER

2. PILOT PRESSURE DIAGNOSTIC COUPLER 14. BRAKE ACCUMULATORS
3. BRAKE LIGHT PRESSURE SWITCH 15. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
4. BRAKE WARNING PRESSURE SWITCH 16. PARKING BRAKE CYLINDER
5. BUCKET CYLINDER (TILT CYLINDER) 17. STEERING PRESSURE DIAGNOSTIC COUPLER
6. PILOT PRESSURE ACCUMULATOR 18. STEERING PRIORITY VALVE
7. LOADER CONTROL VALVE 19. AUXILIARY STEERING PRESSURE SWITCH
8. LIFT CYLINDER 20. REAR BRAKE CYLINDER
9. RIDE CONTROL ACCUMULATOR 21. FAN VALVE
10. FRONT BRAKE CYLINDER 22. AUXILIARY STEERING PUMP AND MOTOR
11. RIDE CONTROL ACCUMULATOR BLEEDER VALVE 23. HYDRAULIC COOLER
AND RIDE CONTROL VALVE (OPTIONAL)
12. FRONT AND REAR AXLE BRAKE PRESSURE 24. FAN DRIVE MOTOR
DIAGNOSTIC COUPLERS
8002-21
28�
27�
26�
25�
30� 29�
42� 41� 40� 39� 38� 35� 33� 32� 31�
36� 34�
37
W270-6R018
25. RIDE CONTROL ACCUMULATOR 34. AUXILIARY STEERING PRESSURE SWITCH

26. LIFT CYLINDER 35. PUMP PRESSURE DIAGNOSTIC COUPLER
27. HYDRAULIC RESERVOIR BREATHER 36. LOAD SENSING DIAGNOSTIC COUPLER
28. HYDRAULIC RESERVOIR 37. IMPLEMENT HYDRAULIC PUMP
29. HYDRAULIC COOLER 38. HYDRAULIC FILTER
30. AUXILIARY STEERING PUMP AND MOTOR 39. STEERING CYLINDER
31. REAR BRAKE CYLINDER 40. PARKING BRAKE ACCUMULATOR
32. BRAKE HYDRAULIC PUMP 41. BRAKE AND ACCUMULATOR CHARGING VALVE
33. AUXILIARY STEERING PRIORITY VALVE 42. FRONT BRAKE CYLINDER
8002-22
NOTES
Section
8003
CLEANING THE HYDRAULIC SYSTEM

8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8003-3
SPECIAL TOOLS
806128
380001733, fitting kit.
806127
380001727, filter unit, portable.
TR98H032
380001728, vacuum pump.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hyd raulic syste ms o pera te with some
contamination. The design of the components in this If your machine has any of these problems, check
hydraulic system permits efficient operation with a the hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. b e fo u nd by sig h t, to uc h , o r od o r. Visib le
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
t e s ti n g in a la b o r a t o r y . E x a m p l e s o f t h e D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.
8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
19. Decrease the engine speed to low idle.
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
22. Stop the engine.
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.
8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
oil as re quired. Se e Sec tion 100 2 fo r
specifications.
8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39-4
17. Start the engine and run the engine at low idle.
NOTE: Any attachment or part of an attachment that is 18. Slowly and completely extend all cylinders. As
raised must be supported with acceptable equipment to the piston rod comes in/out of the cylinder, oil will
prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that is
release pressure in the hydraulic circuits. raised must be supported with acceptable equipment to
4. Loosen and remove the filler cap from the prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. oil as required.
See Section 1002 for specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.
8003-8
NOTES
Section
8004
HYDRAULIC PUMP

8004-2
TABLE OF CONTENTS
PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8004-3
PUMP SPECIFICATIONS
Manufacturer .................................................................................................................................................. Rexroth
High pressure pump (steering pump next to transmission) .............170 L/min at 20 680 kPa, 207 bar, at 2000 r/min
(44.6 U.S. gpm at 3000 psi at 2000rpm)
Low pressure pump output ..............................................................170 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(44.5 U.S. gpm at 3000 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts ..................................................................................................165 Nm (121.5 pound-feet)
Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet)
Control piston plug ..............................................................................................................90 Nm (66 pound-feet)
PREPARING THE EQUIPMENT PUMP FOR USE

Do the following procedure any time you install a new 4. Repeat Step 3 for three minutes.
or overhauled equipment pump:
5. Increase the engine speed to full throttle and
1. Start and run the engine at half throttle for three repeat Steps 3 and 4.
minutes.
6. Stop the engine and check for leaks.
2. With the engine running at half throttle, move the
7. Replace the hydraulic filter.
bucket control lever into roll back position. Hold
the bucket control lever in this position until the
bucket stops moving.
3. Hold the bucket control lever in the roll back
position for five seconds. Then put the bucket
control lever in the NEUTRAL position for five
seconds.
8004-4
EQUIPMENT PUMP
7� 8� 9�
6� 5�
5� 4�
4�
3
10�
2� 11�
1�
12� 24�
13� 23�
22�
21�
20�
19�
18�
17�
15�
14� 16�
30
29�
15� 28�
27�
26�
25�
BC06F550
1. SNAP RING 11. TAPERED BEARING 21. PRESSURE PINS

2. SEAL 12. BEARING RACE 22. BACKUP PLATE
3. MAIN BODY 13. SHIM 23. SPRING
4. O-RING 14. SPRING 24. SNAP RING
5. PLUG 15. HALF BEARING 25. PORT PLATE
6. CONTROL VALVE 16. SWASH PLATE 26. SHIM
7. CAP SCREW 17. PISTONS 27. TAPERED BEARING
8. PISTON ROD 18. RETAINING PLATE 28. BEARING RACE
9. CONTROL PISTON 19. BALL 29. DOWEL PIN
10. SHAFT 20. CYLINDER 30. END COVER
8004-5
Disassembly STEP 3
STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.
STEP 2
BC06F552
Remove the control valve.
STEP 4
BC06F551
Put alignment marks on the end cover and housing.
BC06F553
Remove the four bolts.

8004-6
STEP 5 STEP 6
BC06F555
BC06F554
Remove the end cover. Use a suitable bearing race puller and pull the
bearing race from the end cover.
NOTE: Watch for the flow plate, it can be stuck to either
the end cover or pump body. NOTE: Do not damage the sealing surfaces.
8004-7
STEP 7 STEP 9
BC06F558
Remove plug, pull control piston using a suitable tool

as shown.
NOTE: Do not use a magnet to pull the piston.
STEP 10
BC06F556
Remove the bearing and shim.
STEP 8
BC06F559
Remove the piston rod and swash plate. Turn the

swash plate slightly to break it free from the bearings.
BC06F557
Remove the rotary group from the housing in a

horizontal position.
8004-8
STEP 11 STEP 14
BC06F560
Remove the bearing and spring.
STEP 12
BC06F563
Use a suitable bearing race puller and pull the

bearing race from the housing.
STEP 15
BC06F561
Remove the shaft and bearing.
STEP 13
BC06F564
Remove the shim and plug.
BC06F562
Remove the retaining ring an seal.

8004-9
Inspection STEP 19
STEP 16
Clean all parts in cleaning solvent. Be careful not to
remove the alignment marks made during
disassembly.
STEP 17
BC06F567
Check the bearing surface.
STEP 20
BC06F565
Che ck fo r we ar on th e splin es, seal are as for

grooves, bearing areas for scaring, and key set.
STEP 18
BC06F568
Check that the retaining plate is free of grooves and

that there is no sign of wear.
STEP 21
BC06F566
Check the surface that the pistons contact for

grooves and scaring.
BC06F569
Check the sliding surface for scratches or metal

deposits, check the tightness of the cup on the
piston.
NOTE: If a piston needs to be replaced, all of the pistons
must be replaced.
8004-10
STEP 22 STEP 24
BC06F572
BC06F570
Check the cylinder bores and splines for damage. Check cylinder surface for grooves, wear, embedded
particles. Check flow plate for scratches or wear.
STEP 23
STEP 25
BC06F571
BC06F573
Check ball for grooves and wear.
Che ck mo unting su rface for the flo w plate for
damage.
8004-11
Assembly STEP 27
STEP 26
BC06F574 BC06F575
Install the plug in the housing and tighten to 127 Nm Put the shaft and bearing in the housing.
(93.5 pound-feet). Install shim and press in the
bearing race. STEP 28
BC06F576
Press in a new race into the end cover.

8004-12
STEP 29 STEP 31
BC06F579
Install the seal and retaining ring.
STEP 32
BC06F577
Install the end cover, 4 bolts and hand tighten.
STEP 30
BC06F578
A bearing pre load of 0.05 mm (0.002 inch) must be

ob ta in ed , a dd r em ove sh ims fro m b ea r in g a s
required.
BC06F580
Put new bearings in the housing. Install the reaction

spring.
8004-13
STEP 33 STEP 34
BC06F582
Install the piston into the housing with flat surface

out. Lubricate the O-ring and install the plug, tighten
the plug to 90 Nm (66 pound-feet).
STEP 35
BC06F581
Install the swash plate into the housing, work the

swash p late from side to sid e to seat it in th e
bearings and spring. Install the piston rod.
BC06F583
Use grease to hold the pressure pins into position,

install the spacer, spring and snap ring.
8004-14
STEP 36 STEP 39
BC06F584
Use a suitable compressor, compress the spring and

install the snap ring.
STEP 37
BC06F585 BC06F587
Place the ball onto the pressure pins, install the Hold the pistons in the rotating housing using an
pistons into the retaining plate. O-ring, install the rotating group into the housing,
remove the O-ring.
STEP 38
BC06F586
Lubricate the piston and retaining plate with clean oil,

install the piston into the rotating housing.
8004-15
STEP 40 STEP 41
BC06F588
Use the shim that was required for the bearing pre
load in step 30. Install the shim and bearing onto the
shaft.
BC06F589
Install a new O-ring on the end cover, place the flow

plate onto the rotating group with aligning notch up.
Place the end cover onto the housing, make sure
that the aligning pin in the end cover aligns with the
slot in the flow plate.
8004-16
STEP 42 STEP 43
BC06F591
Use new O-rings, install and tighten the control valve.
BC06F590
Instal and tighten the four bolts to 165 Nm

(121.5 pound-feet).
Section
8005
LOADER CONTROL VALVE

8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8005-3
SPECIFICATIONS
Manufacturer .................................................................................................................................................. Rexroth
Special Torques
End plate mounting bolts.................................................................................................. 70 Nm (51.5 pound feet)
Pressure relief, flow limit, and pilot pressure reducing valves.................. 20 to 25 Nm (177 to 221 pound inches)
Allen head plugs..............................................................................................................240 Nm (177 pound feet)
Allen head locking screw................................................................................................100 Nm (73.7 pound feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches)
Anticavitation valves.......................................................................................................100 Nm (73.7 pound feet)
Combination anticavitation and circuit relief .................................................................200 Nm (147.5 pound feet)
Circuit relief valve pressure setting
Auxiliary A and B port ................................................................................................................290 bar (4206 psi)
Bucket A and B port ...................................................................................................................290 bar (4206 psi)
Main relief valve .................................................................................................248 to 252 bar (3596 to 3654 psi)
8005-4
3�
4�
2�
22�
10�
10
16�
10�
8�
9� 21�
13�
10� 12� 20�
11� 19�
1�
10�
14� 15�
21�
17� 17�
W270-6R013
1. HOUSING 7. NOT USED 13. CONE 19. ANTICAVITATION AND CIRCUIT RELIEF
2. PLATE 8. PRESSURE RELIEF VALVE 14. REGENERATION CHECK VALVE 20. PILOT PRESSURE REDUCING VALVE
3. BOLT 9. FLOW LIMIT VALVE 15. LOCKING SCREW 21. ANTICAVITATION AND CIRCUIT RELIEF
4. WASHER 10. O-RINGS 16. LOAD SENSE SHUTTLE CHEK 22. ANTICAVITATION VALVE
5. NOT USED 11. LOCKING SCREW 17. LOCKING SCREW
6. NOT USED 12. SPRING 18. NOT USED
2 SPOOL VALVE HOUSING CONFIGURATION
8005-5
25�
24�
10�
23�
32�
31� 27
26�
10�
10�
28�
29�
30�
32�
31�
33�
29
25�
10�
32�
10�
30�
27� 26� 28�
W270-6R014
23. COVER 27. CAP NUT 31. SPRING RETAINER

24. BOLT 28. BOLT 32. SPRING
25. PISTON 29. COVER 33. SPOOL
26. JAM NUT 30. ADJUSTING ROD
2 SPOOL VALVE SPOOL CONFIGURATION
8005-6
3�
4�
35�
34�
35�
BS03C036
34. HOUSING 35. ANTICAVITATION AND CIRCUIT RELIEF

3 SPOOL MOUNTING CONFIGURATION
8005-7
36�
4� 37�
2�
34�
35
35�
BS03C035
36. NUT 37. STUD

4 SPOOL MOUNTING CONFIGURATION
8005-8
25� 27�
26�
29�
30�
10� 10�
31�
32�
31� 28�
33�
29� 31�
25 32�
10
10�
30�
27�
26� 28�
BS03C037
3 AND 4 SPOOL VALVE SPOOL CONFIGURATION
8005-9
DISSASEMBLY
STEP 1 STEP 6
Remove valve from machine, see section 8001. Remove pressure relief valve (8).
STEP 2 STEP 7
Remove bolts (24), cover (23), spring retainers (31), Remove flow limit valve (9).
and spring (32).
STEP 8
STEP 3 Remove locking screw (11), spring (12), and cone
Remove bolts (28), covers (29), spring retainers (31), (13).
and springs (32).
STEP 9
STEP 4 Remove regeneration check valve (14).
Use wooden dowel or brass drift and push spools
(33) from housing (1). STEP 10
IMPORTANT: Do not force spools from housing, if Remove locking screw (15).
spool binds work back and forth until spool comes
out freely. STEP 11
NOTE: Repeat steps 3 and 4 for 3 and 4 spool valve Remove load sense shuttle check valve (16).
configuration.
STEP 12
STEP 5 Remove locking screws (17).
Remove anticavitation valves (19, 21, and 22).
STEP 13
NOTE: Repeat step for 3 and 4 spool anticavitation
Remove pilot pressure reducing valve (20).
valves (35).
STEP 14
Remove bolts (3) and washers (4), remove plate (2)
from housing (1).
NOTE: For 4 spool configuration remove nut (36)
from stud (37), remove housings (34) from housing
(1).
8005-10
STEP 15 STEP 17
2�
1�
2�
1�
1�
1�
BS03C025 BS03C027
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING

Remove and discard O-rings and thrust rings from Remove and discard O-rings and thrust ring from
pilot pressure reducing valve (20). locking screw (15).
STEP 16
2� STEP 18
1�
2�
1�
1
1� 3
1�
BS03C026 2�
1. O-RINGS 2. THRUST RINGS BS03C028
Remove and discard O-rings and thrust rings from 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL
flow limit valve (9).
Remove and discard O-rings, thrust ring, and spool
seal from anticavitation valve (22).
8005-11
STEP 19
1�
2�
1�
1�
2�
2
BS03C029
1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (8).
STEP 20
1�
2�
1�
2�
2�
1�
BS03C030

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (19).
8005-12
STEP 21
1�
2�
1�
1�
BS03C031
1. O-RINGS 2. COIL
Remove and discard O-rings and thrust rings from anticavitation valve (18).
8005-13
STEP 22
3�
4
2� 1�
1�
1�
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (21 and 35).
8005-14
INSPECTION
1. Discard all O-rings, thrust rings, and spool seals. 4. Check the parts of the pressure relief valve,
anticavitation valves, and the anticavitation and
2. Clean all parts in cleaning solvent.
circuit relief valves. Use new parts as necessary.
3. Check the spools and the spool bores for
Inspect the other parts of the control valve. If any of
damage and wear.
the parts are damaged, install new parts.
ASSEMBLY
STEP 1
3�
4
A
2� 1�
1� See Note
1�
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (21 and 35). Torque relief valve (A)
into anticavitation valve to 200 Nm (147.5 pound feet).
NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is
in direction of arrow.
8005-15
STEP 2
1�
1�
2�
1�
2�
2�
1� A
BS03C030

Install new O-rings and thrust rings on anticavitation and pressure relief valves (19). Torque cap (A) to 100 Nm
(73.7 pound feet).
STEP 3
1�
2�
1�
1�
2�
2
BS03C029

Install new O-rings and thrust rings on pressure relief valve (8).
8005-16
STEP 4 STEP 7
2� 1�
1�
1�
3
1� 1�
2�
BS03C025 BS03C028
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL

Install new O-rings and thrust rings on pilot pressure Install new O-rings, thrust ring, and spool seal on
reducing valve (20). anticavitation valve (22).
STEP 5 STEP 8
Install and torque regeneration check valve (14) to
2�
100 Nm (73.7 lb-ft).
STEP 9
Install and torque locking screw (15) to 100 Nm
2� (73.7 lb-ft).
1�
1� STEP 10
Install and tighten load sense chuttle check valve
(16).
BS03C026 STEP 11
1. O-RINGS 2. THRUST RINGS Install and torque locking screws (17) to 240 Nm
Install new O-rings and thrust rings on flow limit valve (177 lb-ft).
(9).
STEP 12
STEP 6 Install and torque pilot pressure reducing valve (20)
to 60 Nm (44 lb-ft).
1 STEP 13
Install new O-rings on housing (1). Install plate (2),
2� bolts (3) and washers (4), onto housing (1). Torque
bolts to 70 Nm (51.5 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 (51.5 lb-ft).
STEP 14
BS03C027 Install anticavitation valves (21, and 22) and torque
1. O-RINGS 2. THRUST RING to 100 Nm (73.7 lb-ft).
Install new O-rings and thrust ring on locking screw NOTE: Repeat step for a 3 and 4 spool anticavitation
(15). valves (35).
8005-17
STEP 15 Circuit Relief Pressure Test
Install anticavitation valves (19) and torque to 200
Nm (147.5 lb-ft). STEP 1
Connect the hand pump to the port for anticavitation
STEP 16 and circuit relief valves (21).
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 17 STEP 2
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 18
Lubricate spools with hydraulic oil and push spools STEP 3
(33) into housing (1).
Operate the handle of the hand pump and read the
IMPORTANT: Do not force spools into housing. highest pressure. Repeat this step several times to
be sure of the reading.
STEP 19
Install spring retainers (31), springs (32), covers (29), STEP 4
and bolts (28). Torque bolts to 10.4 Nm (92 lb-ft). Compare the reading to the specifications on Page 3.
NOTE: Repeat step 17 for a 3 and 4 spool valve
configuration. STEP 5
If the pressure is not correct, adjust the circuit relief
STEP 20 valve.
Install spring retainers (31), spring (32), cover (23),
and bolts (24). Torque bolts to 6 Nm (53 lb-in). Circuit Relief Adjustment
NOTE: Prior to installation in the machine, circuit reliefs
STEP 1
can be tested.
Loosen the lock nut. Turn the adjustment screw
clo ckwise to incre ase th e p ressure or
STEP 21
counterclockwise to decrease the pressure.
Install valve in machine, see section 8001.
STEP 2
STEP 22
Check the pressure again. Repeat the adjustment as
Check loader limit pressure, see section 8002. necessary.
8005-18
NOTES
Section
8006
CYLINDERS

8006-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8006-3
SPECIAL TORQUES
Gland Cap Screws for Lift Cylinder .........................................................402 to 500 Nm (296.5 to 368.7 pound-feet)
Gland Cap Screws for Bucket Cylinders .................................................402 to 500 Nm (296.5 to 368.7 pound-feet)
LIFT CYLINDER
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (22) in an acceptable repair free cloths for cleaning.
stand or other holding equipment, refer to Figure
3. Check to be sure that the piston rod is straight. If
1. Do not damage the tube (22).
the piston rod is not straight, replace it with a
3. Loosen and remove the cap screws (1) and new piston rod.
hardened washers (2) from the gland (3) and the
4. Illuminate the inside of the tube for deep grooves
tube (22).
and other damage. If there is any damage to the
4. Pull the piston rod (19) straight out of the tube tube, replace it with a new tube.
(22) to prevent damage to the tube (22).
5. Remove any small scratches on the piston rod or
5. Fasten the piston rod eye or yoke in a vise and inside the tube with emery cloth of medium grit.
put a support under the piston rod (19) near the Use the emery cloth with a rotary motion.
piston (12). Put a shop cloth between the support
6. Inspect the bushings in the piston rod eye or
and the piston rod (19) to prevent damage to the
yoke and the tube. Replace as required.
piston rod (19).
7. Inspect the gland for rust and clean and remove
6. Remove the retaining ring (10) that fastens the
rust as necessary.
pin (11) in the piston (12) and piston rod (19).
8. Inspect the gland end of the tube for sharp edges
7. Remove the pin (11) from the piston (12) and the
that will cut the gland o-ring and remove as
piston rod (19).
necessary.
8. Turn the piston (12) off the piston rod (19) and
9. Inspect the piston for damage and wear. If the
remove the piston (12).
piston is damaged or worn, replace it with a new
9. Remove the gland (3) from the piston rod (19). piston.
10. Remove the seal (13) and the backup ring (14)
from the OD of the piston (12).
11. Remove the wear ring (15) from the OD of the
piston (12).
12. Remove the backup rings (16 and 18) and the
O-ring (17) from the ID of the piston (12).
13. Remove the O-ring (8), backup ring (9), wiper
(4), wide seal (5), narrow seal (6), and bushing
8006-4
4�
5�
6�
19� 3�
7�
9�
8�
1
16� 2�
11� 18�
17�
12�
14�
13�
15� 22�
10�
20�
21�
20�
W270-5R007
1. CAP SCREW 7. BUSHING 13. SEAL 19. PISTON ROD

2. HARDENED WASHER 8. O-RING 14. BACKUP RING 20. SEAL
3. GLAND 9. BACKUP RING 15. WEAR RING 21. BUSHING
4. WIPER 10. RETAINING RING 16. BACKUP RING 22. TUBE
5. WIDE SEAL 11. PIN 17. O-RING
6. NARROW SEAL 12. PISTON 18. BACKUP RING
FIGURE 1. LIFT CYLINDER
8006-5
Assembly 15. Start the piston (12) onto the piston rod (19).
Turn the piston (12) onto the piston rod (19) until
NOTE: If a new gland is being used, put the part the piston (12) is seated against the shoulder of
number of the cylinder on the new gland. the piston rod (19).
1. Install the bushing (7) in the gland (3), refer to 16. If none of the holes in the piston (12) align with
Figure 1. the holes in the piston rod (19), turn the piston
2. Install the wide seal (5) in the gland (3). The wide (12) counterclockwise until one of the holes in
seal (5) is to be installed so that the lips of the the piston (12) aligns with one of holes in the
wide seal (5) are toward the bushing (7). The piston rod (19). Do not turn the piston (12) more
wide seal (5) can be difficult to install. than 90 de grees. Refer to Fig ure 2 fo r p in
placement and hole alignment.
3. Install a new wiper (4) in the gland (3). The lips of
the wiper (4) must be toward the outside end of
the gland (3). 11�
4. Install the narrow seal (6) in the gland (3). The
side of the narrow seal (6) with the groove must
be toward the bushing (7).
12�
5. Install a new backup ring (9) in the groove on the
outside of the gland (3). If both sides of the
backup ring (9) are not flat, the side that is not
flat must be toward the small end of the gland 10�
(3).
6. Install the O-ring (8) next to the backup ring (9) in
the groove on the outside of the gland (3). The
O-ring (8) must be toward the small end of the
gland (3).
7. Remove any marks and sharp edges on the 19
chamfer at the end of the piston rod (19). Make
sure that the piston rod (19) is clean.
8. Lubricate the bore of the gland (3) and the piston
rod (19) with clean oil. GS98J804
FIGURE 2. PISTON AND PISTON ROD HOLE ALIGNMENT
necessary, use a soft hammer to drive the gland 17. Install the pin (11) in the piston (12) and the
(3) onto the piston rod (19). piston rod (19).
18. Install the retaining ring (10) in the pin (11).
10. Put a support below and near the end of the
piston rod (19). Use a shop cloth between the 19. Install a new wear ring (15) in the wide groove on
suppo rt and the pisto n ro d (1 9) to prevent the OD of the piston (12), refer to Figure 1.
damage to the piston rod (19). 20. Install a new seal (13) in the groove on the OD of
11. Install a new backup ring (18) in the groove in the the piston (12).
ID of the piston (12). If both sides of the backup 21. Install the backup ring (14) on top of the seal
ring (18) are not flat, the side that is not flat must (13).
be toward the O-ring (17). 22. Fasten the tube (22) in an acceptable repair
12. Install a new O-ring (17) in the groove in the ID of stand or other holding equipment. Be careful to
the piston (12) next to the backup ring (18). prevent damage to the tube (22).
13. Install the other new backup ring (16) in the 23. Lubricate the inside of the tube (22) and the
groove in the ID of the piston (12) next to the outside of the piston (12) with clean oil.
O-ring (17). If both sides of the backup ring (16) 24. Push the piston (12) straight into the tube (22).
are not flat, the side that is not flat must be 25. Lubricate the O-ring (8) on the gland (3) with
toward the O-ring (17). clean oil.
14. Lubricate the ID of the piston (12) with clean oil.
8006-6
26. Push the gland (3) into the tube (22) and align 29. If the hoses were removed with the cylinder,
the holes in the tube (22), refer to Figure 3. install new O-rings, if equipped, on the fittings.
Lubricate the O-rings with clean oil. Install the
27. Install the cap screws (1) and hardened washers
hoses.
(2).
28. Tighten the cap screws (1) in the sequence
shown for the cylinder being repaired. Torque to
402 to 500 Nm (296.5 to 368.7 pound-feet).
W270-5R009
FIGURE 3. TUBE AND GLAND HOLE ALIGNMENT
8006-7
BUCKET CYLINDER
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder. 2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (21) in an acceptable repair free cloths for cleaning and drying.
stand or other holding equipment, refer to Figure 3. Check to be sure that the piston rod is straight. If
4. Do not damage the tube (21). the piston rod is not straight, replace it with a
3. Loosen and remove the cap screws (1) and new piston rod.
hardened washers (2) from the gland (3) and the 4. Illuminate the inside of the tube for deep grooves
tube (21). and other damage. If there is any damage to the
4. Pull the piston rod (18) straight out of the tube tube, replace it with a new tube.
(21) to prevent damage to the tube (21). 5. Remove any small scratches on the piston rod or
5. Fasten the piston rod eye or yoke in a vise and inside the tube with emery cloth of medium grit.
put a support under the piston rod (18) near the Use the emery cloth with a rotary motion.
piston (12). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (18) to prevent damage to the yoke and the tube. Replace as required.
piston rod (18).
7. Inspect the gland for rust and clean and remove
6. Remove the retaining ring (10) that fastens the rust as necessary.
pin (11) in the piston (12) and piston rod (18).
8. Inspect the gland end of the tube for sharp edges
7. Remove the pin (11) from the piston (12) and the that will cut the gland O-ring and remove as
piston rod (18). necessary.
8. Turn the piston (12) off the piston rod (18) and 9. Inspect the piston for damage and wear. If the
remove the piston (12). piston is damaged or worn, replace it with a new
9. Remove the gland (3) from the piston rod (18). piston.
10. Remove the seal (13) from the OD of the piston
(12).
11. Remove the wear ring (14) from the OD of the
piston (12).
12. Remove the backup rings (15 and 17) and the
O-ring (16) from the ID of the piston (12).
13. Remove the O-ring (8), backup ring (9), wiper
(4), wide seal (5), narrow seal (6), and bushing
8006-8
19�
20
19�
18�
1�
2�
3�
7�
9�
4�
8� 5�
11� 6�
15�
17� 16�
12�
13�
14�
21�
10�
19�
20�
19�
W270-5R008
1. CAP SCREW 7. BUSHING 13. SEAL 19. SEAL

2. HARDENED WASHER 8. O-RING 14. WEAR RING 20. BUSHING
3. GLAND 9. BACKUP RING 15. BACKUP RING 21. TUBE
4. WIPER 10. RETAINING RING 16. O-RING
5. WIDE SEAL 11. PIN 17. BACKUP RING
6. NARROW SEAL 12. PISTON 18. PISTON ROD
FIGURE 4. BUCKET CYLINDER
8006-9
Assembly 15. Start the piston (12) onto the piston rod (18).
Turn the piston (12) onto the piston rod (18) until
NOTE: If a new gland is being used, put the part the piston (12) is seated against the shoulder of
number of the cylinder on the new gland. the piston rod (18).
1. Install the bushing (7) in the gland (3), refer to 16. If none of the holes in the piston (12) align with
Figure 4. the holes in the piston rod (18), turn the piston
2. Install the wide seal (5) in the gland (3). The wide (12) counterclockwise until one of the holes in
seal (5) is to be installed so that the lips of the the piston (12) aligns with one of holes in the
wide seal (5) are toward the bushing (7). The piston rod (18). Do not turn the piston (12) more
wide seal (5) can be difficult to install. than 90 de grees. Refer to Fig ure 5 fo r p in
placement and hole alignment.
3. Install a new wiper (4) in the gland (3). The lips of
the wiper (4) must be toward the outside end of
the gland (3). 11�
4. Install the narrow seal (6) in the gland (3). The
side of the narrow seal (6) with the groove must
be toward the bushing (7).
12�
5. Install a new backup ring (9) in the groove on the
outside of the gland (3). If both sides of the
backup ring (9) are not flat, the side that is not
flat must be toward the small end of the gland 10�
(3).
6. Install the O-ring (8) next to the backup ring (9) in
the groove on the outside of the gland (3). The
O-ring (8) must be toward the small end of the
gland (3).
7. Remove any marks and sharp edges on the 19
chamfer at the end of the piston rod (18). Make
sure that the piston rod (18) is clean.
8. Lubricate the bore of the gland (3) and the piston
rod (18) with clean oil. GS98J804
FIGURE 5. PISTON AND PISTON ROD HOLE ALIGNMENT

necessary, use a soft hammer to drive the gland 17. Install the pin (11) in the piston (12) and the
(3) onto the piston rod (18). piston rod (18).
10. Put a support below and near the end of the 18. Install the retaining ring (10) in the pin (11).
piston rod (18). Use a shop cloth between the 19. Install a new wear ring (14) in the wide groove on
suppo rt and the pisto n ro d (1 8) to prevent the OD of the piston (12), refer to Figure 4.
damage to the piston rod (18).
20. Install a new seal (13) in the groove on the OD of
11. Install a new backup ring (17) in the groove in the the piston (12).
ID of the piston (12). If both sides of the backup
21. Fasten the tube (21) in an acceptable repair
ring (17) are not flat, the side that is not flat must
stand or other holding equipment. Be careful to
be toward the O-ring (16).
prevent damage to the tube (21).
12. Install a new O-ring (16) in the groove in the ID of
22. Lubricate the inside of the tube (21) and the
the piston (12) next to the backup ring (17).
outside of the piston (12) with clean oil.
13. Install the other new backup ring (15) in the
23. Push the piston (12) straight into the tube (21).
groove in the ID of the piston (12) next to the
O-ring (16). If both sides of the backup ring (15) 24. Lubricate the O-ring (8) on the gland (3) with
are not flat, the side that is not flat must be clean oil.
toward the O-ring (16).
14. Lubricate the ID of the piston (12) with clean oil.
8006-10
25. Push the gland into the tube (21) and align the 28. If the hoses were removed with the cylinder,
holes in the tube (21), refer to Figure 6. install new O-rings, if equipped, on the fittings.
Lubricate the O-rings with clean oil. Install the
26. Install the cap screws (1) and hardened washers
hoses.
(2).
27. Tighten the cap screws (1) in the sequence
shown for the cylinder being repaired. Torque to
402 to 500 Nm (296.5 to 368.7 pound-feet).
W270-5R010
FIGURE 6. TUBE AND GLAND HOLE ALIGNMENT
8006-11
REPLACING BUSHINGS FOR THE BUCKET AND LIFT CYLINDERS

Disassembly
1. Put the piston rod eye (3) in a press, refer to
3�
Figure 7.
2�
2. Use an acceptable driver to press the seals (1)
1�
and bushing (2) out of the piston rod eye (3).
1�
3. Put the tube (4) in a press.
4. Use an acceptable driver to press the seals (1)
and bushing (2) out of the tube (4).
5. Clean the bore for the bushings (2) in the piston
rod eye (3) and the tube (4).
Assembly 1�
1. Use an acceptable driver to press a new bushing
(2) into the piston rod eye (3) until the bushing
(2) is centered in the piston rod eye (3), refer to
Figure 7.
2. Use an acceptable seal driver to install the seals
(1) in the piston rod eye (3). The lips of the seals
1
(1) must be toward the outside of the bore.
3. Use an acceptable driver to press a new bushing
(2) into the tube (4) until the bushing (2) is
centered in the tube (4). 4�
4. Use an acceptable seal driver to install the seals 2�
(1) in the tube (4). The lips of the seals (1) must
be toward the outside of the bore. W270-5R011
1. SEAL 3. PISTON ROD EYE

2. BUSHING 4. TUBE
FIGURE 7. BUSHING REMOVAL AND REPLACEMENT
8006-12
NOTES
Section
8013
RIDE CONTROL ACCUMULATOR

8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8
Ride Control Accumulator Fluid Capacity............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure ...........................................................248.4 bar (3600 psi)
ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap.................................................................................13.6 Nm (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)
SPECIAL TOOLS
94L95 B786441M
380001737 NITROGEN ACCUMULATOR CHARGING KIT 380001738 GLAND WRENCH
8013-4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
C� E
F�
D� B� A�
94L95
CAS10899 NITROGEN CHARGING KIT
1. Use the 380001737 Nitrogen Charging Kit to 7. Turn the T-handle inward on valve F to engage
dis charge the ac c umulator, refer t o t he the pin in the valve stem.
illustration above. The tool must be disconnected
8. Open valve D and check the charge pressure on
from the nitrogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open
3. Adjust the regulator A to the minimum pressure valve B. The accumulator charge will bleed down
setting by turning the knob counterclockwise. through the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
5. Remove the guard and valve assembly cap from
the accumulator. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the
accumulator.
8013-5
ACCUMULATOR
Disassembly Assembly
NOTE: Refer to Section 8001 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.
WARNING: DO NOT attempt to
disassemble any accum ulator until the 2. Install a new wear ring (5), O-ring (7) and backup
nitrogen charge is properly discharged. ring (6) on the piston (4).
SM386 3. Lubricate the bore of the body (1) and the piston
1. Fasten the body (1) in a vise. Be careful not to (4) with clean oil.
damage the body (1), refer to the illustration on 4. Start the piston (4) into the body (1), round
page 6. surface first. Then push the piston (4) farther into
2. Remove the screws (9) and guard (11) from the the body (1).
body (1).
NOTE: The piston (4) must be installed squarely and
3. Remove the pressure valve (12) from the slowly into the body (1). Once the piston (4) is started
body (1). straight into the bore of the body (1), use a hammer and
4. Remove and discard the O-ring (10) from the wood block to gently tap the piston into the polished area of
pressure valve (12). the bore. Keep force on the piston (4) while tapping into the
bore or damage may occur to the O-ring.
5. Loosen and remove the cap (8) from the body
(1). 5. Install and tighten the cap (8) into the body (1).
6. Loosen and remove the gland (3) from the body 6. Install new seals (2) on the gland (3).
(1).
7. Lubricate the seals (2) with clean oil and start the
7. Remove the piston (4) from the body (1). gland (3) into the body (1).
8. Remove and discard the wear ring (5), O-ring (7)
8. Tighten the gland (3).
and the backup ring (6) from the piston (4).
9. Remove the seals (2) from the gland (3). 9. Install a new O-ring (10) on the pressure valve
(12).
Inspection 10. Install the pressure valve (12) in the body (1).
1. Clean body (1), gland (3), cap (8) and piston (4) 11. Install the guard (11), screws (9) in the body (1).
in cleaning solvent, refer to the illustration on 12. Charge the accumulator with dry nitrogen
page 6. according to instructions on page 7.
2. Inspect the piston (4) for cracks, burrs or other
damage. WA RNING : Use only nitrogen when
charging the accumulator. DO NOT use air
3. Inspect the bore of the body (1) for scratches or or oxygen that will cause an explosion.
scoring using a light. SM115A
NOTE: Minor scratches or scoring in the bore of the body

(1) can be removed using crocus cloth.
4. Inspect the pressure valve (12) and replace as
needed.
8013-6
1� 2� 5� 6� 7� 9�
8
3� 4�
10� 11�
9� 12�
BS01B224
1. BODY 5. WEAR RING 9. SCREW

2. SEALS (2) 6. BACKUP RING 10. O-RING
3. GLAND 7. O-RING 11. GUARD
4. PISTON 8. CAP 12. PRESSURE VALVE
RIDE CONTROL ACCUMULATOR ILLUSTRATION
8013-7
CHARGING THE ACCUMULATOR WITH NITROGEN
2�
6� 5�
4� 3�
GS98N801
1. VALVE C 4. VALVE B
2. TO NITROGEN TANK 5. VALVE D
3. VALVE A 6. TO ACCUMULATOR
NITROGEN CHARGING KIT 380001737
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator
Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during high pressure
(10 bar/150 psi and above) applications.
8013-8
1. Close the shutoff valve A by turning it all the way 12. Open the shutoff valve A on the nitrogen supply
to th e left (cou nte rclo ckwise), re fe r to the tank. While observing the pressure on the gauge,
illustration on page 7. slightly ope n the ne edle va lve on th e
accumulator charge hose. By regulating the
2. Open valve B by turning it out all the way to the
needle valve, fill the accumulator to pressure
left (counterclockwise).
according to temperature chart below. Close the
3. Close valve C by turning it all the way to the right needle valve. Close the shutoff valve A on the
(clockwise). nitrogen supply tank.
4. Close the gauge valve D by turning it all the way TEMPERATURE CHARGE PRESSURE
to the right (clockwise). 10° C 50° F 1636 KPA 237 PSI
13° C 55° F 1655 KPA 240 PSI
5. Connect the charging hose to the nitrogen supply
16° C 60° F 1674 KPA 243 PSI
tank.
18° C 65° F 1687 KPA 245 PSI
6. SLOWLY turn valve A clockwise while watching 21° C 70° F 1706 KPA 248 PSI
the high pressure gauge. Stop turning valve A 24° C 75° F 1726 KPA 250 PSI
when the needle on the gauge reaches 31 bar 27° C 80° F 1745 KPA 253 PSI
(450 psi). 29° C 85° F 1758 KPA 255 PSI
32° C 90° F 1777 KPA 258 PSI
NOTE: If the needle goes over the needed pressure,
35° C 95° F 1796 KPA 261 PSI
quickly open and close valve D and check the pressure
38° C 100° F 1815 KPA 263 PSI
setting again.
The charging kit is now ready to be installed on the TEMPERATURE/CHARGE PRESSURE RIDE CONTROL
accumulator. ACCUMULATOR
13. Close valve B by turning to the right (clockwise).
7. Remove the two cap screws (9) and the
After a few minutes, check the accumulator for
protection bracket (11) from the body (1) on the
leakage.
accumulator, refer to the illustration on pages 6.
14. Back off the needle valve on the accumulator
8. Remove the valve cap from the pressure valve
end of the charging hose by turning it
(12) on the accumulator.
counterclockwise the maximum amount. This will
9. Back off the needle valve on the accumulator p r e v e n t n it r o g e n f r o m e sc a p in g fr o m t h e
en d of the ch arging h ose b y tu rnin g it accumulator as the hose is removed. Remove
counterclockwise to the maximum amount. This the charging hose from the accumulator
pr ev en ts n itrog e n fr om es cap ing fro m th e pressure valve (12).
accumulator when the charging hose is attached
15. Install the valve cap onto the pressure valve (12)
to the accumulator gas charging valve.
on the accumulator.
10. Install the charging hose fitting onto the
16. Install the protection bracket (11) over the
accumulator pressure valve (12).
pressu re valve (1 2) an d secure it with cap
11. Tighten the needle valve by turning it clockwise. screws (9).
Slowly open the gauge valve D and observe the
17. Remove the charging hose from the nitrogen
re ad in g o n th e g au ge . Th is re ad in g is th e
supply tank.
nitrogen pressure level inside the accumulator.
Section
8014
RIDE CONTROL VALVE

8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8014-3
RIDE CONTROL VALVE
BC06A224
1. PLUG 5. SPRING 9. SOLENOID

2. CAP SCREW 6. SPRING 10. ORFICE
3. BUSHING 7. SPOOL 11. POPPET
4. SPRING CARRIER 8. PLUG 12. ORFICE
8014-4
Dissasembly Assembly
STEP 1 STEP 1
Remove ride control valve, refer to section 8001. Install new O-rings.
STEP 2 STEP 2
Remove plugs (1 and 8). Install and torque pressure relief valve to 50 Nm
(37 lb-ft).
STEP 3
Remove the solenoid (9). STEP 3
Install and torque accumulator drain screw to 3.5 Nm
STEP 4 (31 lb-in). Install the plug for accumulator drain screw
Remove the spool (7) from the valve block. and torque to 7 Nm (62 lb-in).
STEP 5 STEP 4
Remove cap screw (2), bushing (3), spring carrier Install and torque orifice (12) to 15 Nm (11 lb-ft),
(4), springs (5 & 6) from spool (7). install poppet (11), install and torque orifice (10) to 15
Nm (11 lb-ft).
STEP 6
STEP 5
Remove orifice (10), poppet (11), and orifice (12).
Install and torque solenoid valve (9) to 12 Nm
(106 lb-in).
STEP 7
Remove accumulator drain screw.
STEP 6
Install springs (5 &6), spring carrier (4), bushing (3),
STEP 8
cap screw (2) onto spool (7) and torque cap screw
Remove the pressure relief valve. (2) to 5.5 Nm (48.5 lb-in).
Inspection STEP 7
1. Discard all O-rings. Install spool (7) into valve block.
2. Clean all parts in cleaning solvent.

STEP 8
3. Check the spools and the spool bores for Install and torque plug (1) to 270 Nm (199 lb-ft).
damage and wear.
4. Check the parts of the pressure relief valve. STEP 9
Install plug (8) and torque to 90 Nm (66 lb-ft).
If any of the parts are damaged, install new parts.
STEP 10
Install the ride control valve in the machine, see
section 8001.
STEP 11
Test the ride control system, see section 8002.
SECTION INDEX
MOUNTED EQUIPMENT
Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant. . . . . . . . . . . . . 9002
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND

SYSTEM CHECKS FOR SYSTEMS WITH
HFC-134A REFRIGERANT

9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified by an 3. Keep refrigerant containers in the correct upright
approved training and certification organization may service position. Always keep refrigerant containers
or repair motor vehicle or mobile air conditioning systems. away from heat and sunlight. The pressure in a
It is mandatory that all refrigerant must be RECOVERED and container will increase with heat.
RECYCLED when removed from a system during servicing.
4. Always reclaim refrigerant from the system, if
Refrigerant HFC-134a is the most stable, and easiest you are going to weld or steam clean near the air
to work with of the refrigerants now used in air conditioner system.
conditioner systems. Refrigerant HFC-134a does not
5. Always check the temperature and pressure of
contain any chlorofluorocarbons (CFC’s) which are
the air conditioner system before reclaiming
harmful to the earth’s ozone layer.
refrigerant and when you test the system.
Safety procedures must be followed when working
6. Dangerous gas can form when refrigerant comes
with Refrigerant HFC-134a to prevent possible
in contact with an open flame. Never permit
personal injury.
fumes to be inhaled.
1. Always wear safety goggles when doing any
7. Never leak test with compressed air or flame
service work near an air conditioner system.
testers. Tests have indicated that compressed
Liquid refrigerant getting into the eyes can cause
mixt ur es o f H FC -1 3 4 a an d a ir ca n fo rm a
se rio us in jur y. D o the fo llo win g if yo u g et
combustible gas.
refrigerant near or in your eyes:
8. Always reclaim refrigerant from the system
A. Flush your eyes with water for 15 minutes.
before removing any air conditioning component.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.
9002-4
299L7C A22094
BELT TENSION TOOL 380001325 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, 380001326
A22090 BS03H012
ELECTRONIC LEAK DETECTOR 380001327 SAFETY GOGGLES CAS10073-3
9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
contains five major compon ents: co mpressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. e v a p o ra to r me te r s r e fr ig e r a n t flo w b a se d o n
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and
pressure gas. The compressor then compresses the flowing through the evaporator fins. The combination
refrigerant and sends it in the form of a high pressure of increased heat and decreased pressure causes
gas to the condenser. The air flow through the the air flow through the evaporator fins to become
condens er then rem ov es the heat from the very cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
the co nde nser to the recei ve r-dri er. Th e consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A.C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER
9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
No Check Page 8
Compressor Runs
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem

See Pressure Testing, Page 13
9002-7
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
See Mechanical Compressor Check Page 8.

HEATER
Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.
Problem:
System Makes Noise
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.

ELECTRICAL
See Compressor Clutch Check Page 9.
INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13. INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13.

9002-8
SYSTEM CHECKS
Mechanical Compressor Check

1. Too much belt wear - replace a worn belt,
Compressor and Fan Belts because a worn belt will cause too much
slippage.
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
Compressor Mounting Brackets 2. Bracket has cracks or breaks - replace the
bracket.
1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Remove the comp re ssor fo r
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
Compressor Clutch b e t w e e n t h e f r o n t p l a t e a n d p u ll e y
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
c om p re ss o r clo c k w ise . C o mp re s so r
rotation should be smooth and not require
much effort.
1. The compressor pulley and the

compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Pulley and Belt Alignment U se a stra igh t ed ge to c he ck p ulle y
alig nment. Adjust the compressor
mounting bracket if needed.
9002-9
Blower and Compressor Clutch Check

NOTE: Check supply voltage with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch
1. If there is electrical system voltage to the
clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.
1. See Section 4002 and check the high and

Low and High Pressure Switches low pressure switches.
Blower Fuse (10 amp) 1. Check for damaged blower fuse.
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor 2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.
1. With key in ON position, turn switch to

maximum cold. Compressor clutch must
engage.
NOTE: Blower must be operating, since
electrical power to temperature control switch
is received from blower switch.
Temperature Control Switch 2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
sw itc h t ermin als. If co ntin uity is no t
present when switch is on maximum cold,
replace switch.
9002-10
Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers louvers must be closed.
2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning 1. Feel the air conditioning hoses. The high pressure hoses
(small line) must be warmer than the low pressure hose
(large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and

run th e co mpre sso r for five minu tes to ma ke
temperature stable. Refer to page 12.
2. Duct temperature must be below 25° C (72° F) if the
system is operating at maximum efficiency.
Duct Temperature NOTE: Ambient temperature must be 27 to 43° C (80 to
110° F).
3. If temperature is above 25° C (72° F), system is low on
r ef rig e ra n t, th e r e is a r e s tr ictio n in th e s ys te m,
compressor is not working correctly, or air ducts are not
sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
Temperature Sensing Probe Check 4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control switch
should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.
9002-11
Visual and Leak Check

1. Make sure that all hose connections are
tight.
Compressor Hoses 2. Check hoses for bends or cracks. Replace
all hoses that have damage.
1. Shut off the engine.

WARNING: When refrigerant comes in
contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. Use
instructions from manufacturer of leak
Leak Finding Check finding tool.
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion valve
for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.
1. Make sure the condenser is clean and the

seals are in place. Make sure condenser
Condenser fans run when temperature control switch
is ON.
9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core . All th e fins that ha ve ben ds or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r ic t i o n s . I f t h e c o r e i s d r y , u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
wa te r dra ins fre ely from the
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
1. See Section 9004 for access to the

2. Make sure seals are in place so blower
Evaporator/Heater Core Sealing will pull air only through the
evaporator/heater core and not around the
Filters 1. Make sure the filters are clean.

9002-13
PRESSURE TESTING
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 10 to 35 psi (0.7 to 2.4
NOTE: The gauge set is not accurate enough to optimize bar) after the system has run 10 to 15 minutes.
an existing charge of HFC-134a. The best use of the gauge
set is to determine whether undercharge or overcharge HIGH PRESSURE GAUGE - The high pressure
exists, and then evacuate, reclaim and recharge system gauge is used to indicate pressures in the high side
with the recommended quantity (charge) of HFC-134a. of the system. The gauge must indicate from 0 to 400
psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool
used to service the air conditioning system. The During normal operation, the high pressure gauge
manifold gauge set is used to measure the high and will normally indicate from 120 to 310 psi (8.3 to 21.4
low pressures of the system, as a tool to troubleshoot bar). See pressure-temperature chart on page 14.
for correct refrigerant charge quantity, system
diagnosis, and operating efficiency. The manifold Pressure Test Connection
gauge set can read both the high (discharge) and low
C o n n e c t t h e m a n if o ld g a u g e s e t i n t o th e a ir
(suction) sides at the same time, since pressure must
conditioning system as shown. Make sure that both
be compared in order to make a diagnosis of system
valves in the manifold gauge set are closed.
operation.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. It is best u sed to judge
e v a cu a t ion e ff e ct ive n e s s. A v a cu u m r e a din g
indicates a system malfunction. For this reason, it is
nec essary to use a compou nd ga uge th at will
indicate both pressure and vacuum.
9002-14
PRESSURE-TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH

AIR LOUVER (BEHIND
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)

(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction pressure.
The table shown represents readings taken in low relative 5. Measurements taken 15 minutes after startup.
humidity. Adjust the chart according to local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART
PROBLEM LOW PRESSURE HIGH PRESSURE SEE

GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 16
NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25
9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1 STEP 4
Clean the external surfaces of the compressor and Connect the hose from the high pressure gauge to
hoses. Remove the caps from the service ports on the port on the discharge hose.
the suction and pressure hoses.
W AR N IN G : A lways wear safe ty g ogg les
W A R N I N G : Do n o t st ea m cle an an y a ir when working with liquid refrigerant. Liquid
conditioning system parts while the system is refr igerant in your eyes could cause
charged. The heat will cause the refrigerant blindness. SM105A
to rise to a pressure that could cause the
system to explode. SM104A
STEP 5
STEP 2 Make sure the charging station manifold gauge
valves are in the closed position.
Connect the hoses from the test gauges to the
service ports by turning the knurled knobs on the
depressors. STEP 6
Start the engine and run at 1500 RPM maximum
STEP 3 sp ee d . O pe ra te the a ir co n dition er sys tem at
maximum cooling setting and blower speed for 15
Connect the hose from the low pressure gauge to the
minutes with the cab door open. Observe the test
port on the suction hose.
gauges and check the chart on page 13 against the
gauge readings.
9002-16
PROBLEM: NO COOLING
VERY LOW VERY LOW
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate and reclaim remaining

refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow

the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off 4. Check level of oil in compressor - possible
Yes
rapidly after start-up. (A/C warning light for compressor to have an oil loss.
in cab should illuminate).
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See

Section 9003.
7. Continue performance test for other

possible problems.
9002-17
HIGH HIGH
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm Yes 3. Remove air and moisture from the
Section 9003.
Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
recla im a nd re cha rge re frigerant until gaug e
pressure is normal. See Section 9003.
4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
condenser) is very hot. caused by oil or reduced heat transfer.
A. Remove refrigerant from the system. See
B. Discharge air from evaporator warm.
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible

problems.
9002-18
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at See Section 9004 and replace the expansion
compressor. valve.
C. Much condensation on evaporator
outlet.
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
Refrigerant Contamination
table represent the boiling point for HFC-134a.
C. Pressure readings below range given in chart indicate
contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart
Temperature F ( C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)
9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO
SLIGHTLY HIGH NORMAL
476L7
Air in the System - Indications:

1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand. 3. Repair system leak as necessary.
B. Discharge air from heater/evaporator 4. Replace receiver-drier.
only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.
9002-20
LOW LO W
476L7
Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator 3. Repair system leaks as needed.

cool or warm - not cold.
4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace

Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section

9003.
High Side Restriction - Indications:

A. Discharge air from heater/evaporator
1. Discharge refrigerant from system-restriction in
only a little cool.
receiver-drier or liquid line must be removed.
B. Condensation or frost on
2. Remove and replace part with restriction.
receiver-drier.
3. Remove air and moisture from the system. See
C. Liquid line to receiver-drier cool, with
Section 9003.
frost or condensation.
4. Charge system with new refrigerant. See Section
NOTE: The frost will form downstream from
9003.
or at the point of the restriction
9002-21
Expansion Valve Not Operating - Indications:

1. Expansion valve outlet with condensation or frost is
A. Discharge air from evaporator warm an indication of a restriction in the expansion valve.
or cool - not cold. Replace expansion valve. See Section 9004.
B. Condensation or frost on expansion 2. Inlet end of expansion valve is warm (not hot),
valve outlet. indicating expansion valve is not completely open.
C. Inlet end of expansion valve is If the valve is stuck closed, there will be little or no
warm. flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.
9002-22
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
Compressor Turning But Not Pumping Properly - Indications:

1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged. 4. Replace compressor.
B. Cool discharge air from evaporator. 5. Replace receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.
Expansion Valve Stuck Open

Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.
9002-23
HIGH HIGH
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
B. Add refrigerant until gauge pressures are
A. Liquid line very hot.
normal. See Section 9003.
B. Discharge air from evaporator warm.
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System - Indications:

1. Discharge refrigerant from system. See
Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the
Section 9003.
9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL NORMAL
476L7
Moisture in the System - Indications:

1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the freezing of this
moisture can stop refrigerant flow. See
Section 9003.
2. Replace receiver-drier. The moisture

removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day.
3. Remove air and moisture from the
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

Section 9003.
9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
HIGH
TO HIGH
476L7
Too Much Refrigerant in System - Indications:

1. Remove refrigerant from system until gauge
readings are below normal. See Section
A. Cool discharge air from heater/evaporator.
9003.
B. Compressor makes noise.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.
9002-26
TUBE CONNECTIONS TORQUE CHART
TUBING SIZE 3/8 inch 1/2 inch 5/8 inch

THREAD SIZE M10 -1.25 5/8-18 3/4-18 7/8-18 1-14
OR OR
3/4-16 7/8-14
STEEL TO STEEL 31-36 Nm 31-36 Nm 40-46 Nm 45-52 Nm 45-52 Nm
ALUMINUM TO BRASS 10-14 Nm 10-14 Nm 24-30 Nm 30-37 Nm 45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator since these
connections are easily distorted.
Section
9003
AIR CONDITIONER SYSTEM SERVICE

9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ........................................................................................ 1.6 kg (3.5 lbs)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION 380001326
9003-4
SAFETY PROCEDURES

ATTENTION: Only authorized technicians certified by an 3. Keep refrigerant containers in the correct upright
approved training and certification organization may service position. Always keep refrigerant containers
or repair motor vehicle or mobile air conditioning systems. away from heat and sunlight. The pressure in a
It is mandatory that all refrigerant must be RECOVERED and container will increase with heat.
RECYCLED when removed from a system during servicing.
4. Always reclaim refrigerant from the system, if
Refrigerant HFC-134a is the most stable and easiest you are going to weld or steam clean near the air
to work with of the refrigerants now used in air conditioner system.
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFC’s) which are
harmful to the Earth’s ozone layer.
with refrigerant HFC-134a to prevent possible
personal injury.
se rio us in jur y. D o th e fo llow in g if yo u g e t
combustible gas.
refrigerant near or in your eyes:
8. Always reclaim refrigerant from the system
9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

R e co v e re d re f rig e r a n t pa s s es th ro u g h a n o il STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD06N047
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
BD06N048
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the p ort on th e discha rge h ose. Turn in valve
depressor.
9003-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
comp res sor disch arg e p ressu re b ack into the
separator.
BD06N047
Remove the hoses from the service ports and install

the caps.
9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or more of Air and moisture are removed from the system by a
the following conditions occurs before you remove the air vacu um pump. A vacuu m pump i s the only
and moisture from the system. equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
A. The system has been opened for service
from the system.
before.
NOTE: Refer to the vacuum pump manufacturer’s user
B. Receiver-drier has operated two or more
manual for additional information.
years.
C. Disassembly of compressor shows small STEP 11
particles of moisture removing material (gold
or brown particles).
D. Large system leak (broken hose, break in
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
A22113
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 minutes and press the Enter key. The display
will flash once indicating the programmed data has
been accepted.
STEP 12
BD06N048
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
A22115
Removal of air and moisture from the system is
necessary after the refrigerant has been removed Press the Charge key. “Program” and “Charge” will
after the system has been opened for maintenance. appear on the display.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.
NOTE: The pump on the reclamation unit will not pull a
sufficient vacuum to remove air and moisture.
9003-8
STEP 13 STEP 16
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. “Automatic” will appear on
will flash once indicating the programmed data has the display. Vacuum will appear on the display and
been accepted. after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
W h e n th e pr o g ra m me d t ime ha s e la p se d , a n
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
l e a k - f r e e s y s t e m w i ll l e a c h r e f r ig e r a n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
Fully open the low and high pressure valves.

STEP 17
STEP 15
A22113
Press the charge key to begin refrigerant charging.

A22107
“Automatic” and “Charge” will appear on the display.
Open the red (vapor) and blue (liquid) valves on the The display shows the programmed amount and
tank. counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.
9003-9
STEP 18 STEP 21
A22114 BD06N048
Completely close the high and low pressure manifold Stop the engine, close any open valves and carefully
valves. remove the manifold gauge hoses.
ATTENTION: Check the OEM equipment manual before
performing Step 19 to avoid damaging the recovery unit. STEP 22
The pressure reading should be obtainable with valves
closed. Damage may occur if the machine is started with
the valves accidently open or if either or both valves are
opened while the A/C system is operating.
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the system
pressure is too low or too high. The pressure indicator lamp
will illuminate when the relay is actuated by a low or high BD06N047
pressure and the compressor clutch will disengage. To Install the caps on the service ports on the suction
restart the compressor, the air conditioner control or and discharge hoses.
blower switch must be turned to the OFF position and then
to the ON position.
STEP 20
A22117
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
and pressure variations.
9003-10
PRESSURE - TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.5)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.1 to 14.5)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.5 to 15.8)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.6)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.9 to 19.3)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position and all
9. Measurements taken 15 minutes after start-up.
louvers open.
4. Cab temperature control set to maximum
cooling.
Section
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING

AND HEATER COMPONENTS

9004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXPANSION VALVE, EVAPORATOR/HEATER CORE,
HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9004-3
SAFETY PROCEDURES

ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system if you
when removed from a system during servicing.
are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFC’s) which are
harmful to the earth’s ozone layer.
with Refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.
se rio us in jur y. D o the fo llo win g if yo u g et
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
9004-4
SPECIAL TOOLS
A22094-01 BS03H012
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION 380001326
A22090-01
ELECTRONIC LEAK DETECTOR
380001327
9004-5
COMPRESSOR
Removal STEP 5
STEP 1
BD07A222
Disconnect the low pressure line from the suction

W270-1R007
port and the high pressure line from the discharge
Move the battery cut-off switch into OFF as indicated p o r t o n t h e c o m p r e s s o r . I mm e d ia t e ly in s t a l l
in the figure. protective caps on the open ports and lines.
STEP 2 STEP 6
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD07A220
Disconnect the compressor clutch wire from the

engine harness assembly.
BD07A222
Loosen the three bolts holding the compressor

tension adjusting bracket. Loosen tension on belt.
STEP 4
Remove the belt.
9004-6
STEP 7 Installation
STEP 1
Place the compressor into position on the machine.
STEP 2
BD07A222
Loosen and remove the three compressor mounting

bolts.
STEP 8
Remove the compressor from the machine. BD07A222
Install the three bolts to mount the compressor.
STEP 3
BD07A220
Connect the compressor clutch wire to the engine

harness assembly.
9004-7
STEP 4 STEP 5
Carefully remove the protective cap, install a new
O-ring, and connect the low pressure line to the
suction port on the compressor.
STEP 6
Install the belt.
STEP 7
Charge the air conditioning system according to the
instructions in Section 9003..
BD07A222
Slowly remove the protective cap, install a new

O-ring, and connect the high pressure line to the
discharge port on the compressor.
IMPORTANT: Use caution when removing cap as
new compressors have internal pressure when
shipped.
9004-8
EXPANSION VALVE, EVAPORATOR/HEATER CORE,

HEATER VALVE, BLOWERS
3� 6�
5�
7�
4�
2�
1�
8�
9�
18� 10�
17�
12� 11�
14�
13�
16
15�
BS06G118
1. EVAPORATOR 7. WASHER 13. LOWER BOX PPE

2. UPPER BOX PPE 8. GROMMET 14. EXPANSION VALVE
3. COVER PPE 9. HEATER CORE 15. BLOWER
4. SOLENOID DRIVER 10. HEATER VALVE 24V 16. RECIRCULATING VAIN
5. UPPER BOX 11. THERMOSTAT 17. RECIRCULATING MOTOR
6. BOLT 12. LOWER BOX 18. RESISTOR BLOWER MOTOR
9004-9
Removal STEP 5
Disconnect the wiring harness from the operator’s
STEP 1 seat (if equipped with air seat option).
bucket to the floor. STEP 6
STEP 2
If ch an ging an y a ir con dition in g co mpo ne nts,
discharge the air conditioning system according to
STEP 3
BD07A202
Remove the four bolts that fasten the operator’s seat

to the upper box, remove the seat from the machine.
BD07A217
1. ENGINE COOLING SYSTEM DRAIN VALVE
2. ENGINE COOLING SYSTEM DRAIN HOSE
3. FUEL TANK
If changing the heater core, put a 57 liter (15 gallon)

container below the engine cooling system drain
hose (2). Remove deaeration cap, open drain valve
and drain coolant into container. Close drain valve
after coolant has drained. Install deaeration cap.
STEP 4
W270-1R007
1. HOOD SWITCH
2. MASTER DISCONNECT
Move the battery cut-off switch into OFF as indicated

in the figure.
9004-10
STEP 7 STEP 10
Fold the rubber mat over to gain access to the upper Place the air selector on the control panel to outside
box mounting bolts. air.
NOTE: In step 11 and 14 the upper box is shown
STEP 8 removed for clarity only, these steps must be done
prior to removing the upper box.
STEP 11
BD06G215
Remove the six bolts securing the upper box.
STEP 9 BD06G217
G o in g t h r o u g h th e i n s id e fi lt e r a r e a f e e l t h e
recirculating vain to make sure it is in the outside air,
“closed”, position.
STEP 12
BD06G216
Remove two screws, one on each side of the upper

box, securing the upper box to the lower box.
BD06G218
The above photo shows that the recirculating vain is

not in the outside air “closed” position.
9004-11
STEP 13 STEP 17
BD06G240 BD06G203
Use a screw driver and disconnect the linkage. Disconnect the solenoid driver.
STEP 14 STEP 18
BD06G219 BD06G236
Close the vain so the upper cover can be removed. Remove the upper PPE from the heater and air
conditioning cores.
STEP 15 NOTE: If testing on the electrical components are
Remove the u ppe r b ox and re st it aga inst the required the solenoid driver can be reconnected
console. once the upper PPE is removed.
STEP 16
BD06G220
Pull the wiring harness loose from the upper PPE.

9004-12
NOTE: If replacing the heater control valve, heater STEP 21
core, air conditioning expansion valve, air
conditioning evaporator core do steps 19 through 28,
if replacing electrical components go to step 32.
STEP 19
BD06G206
Remove the thermostat probe and clamp from the

evaporator core.
STEP 22
W270-8R010
Remove the right side cab skirt.
STEP 20
1� 2
BD06G237
Disco nne ct the electrical co nne ctors from the

thermostat control.
1. AIR CONDITIONING HOSES

BD06G205 STEP 23
2. HEATER HOSES
Fasten identification tags on the hoses. Disconnect

the hoses for the heater core and evaporator core,
install plugs in the hoses and caps on the fittings.
BD06G236
Disconnect the electrical connectors from the heater

control valve.
9004-13
STEP 24 STEP 30
Pull the heater core and evaporator core from the
lower box PPE.
STEP 25
Remove the expansion valve from the evaporator
core.
STEP 26
Remove and discard the O-rings from the openings
in the expansion valve.
STEP 27 BD06G208
D is c o n n e c t t h e e le c t r i c a l c o n n e c t o r f o r t h e
Remove the screws from the heater core and remove
recirculating vain motor, disconnect the linkage from
the control valve.
the vain. Remove the mounting screws and remove
the motor.
STEP 28
Remove and discard the O-rings from the heater STEP 31
control valve.
STEP 29 1�
2�
3
1�
3�
2�
BD06G209
1. FAN SPEED AND A/C SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
3. THERMOSTAT
BD06G207
1. RESISTORS R e m o v e t h e s w i tc h p a n e l f r o m t h e c o n s o le .
2. RESISTOR CONNECTOR Disconnect the electrical connectors and remove
3. BLOWER MOTOR CONNECTOR switches as required.
Remove the fans from the lower PPE, disconnect the
electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.
9004-14
Installation STEP 3
STEP 1
1�
1�
2�
3�
3
2�
BD06G207
1. RESISTORS
2. RESISTOR CONNECTOR
BD06G209 3. BLOWER MOTOR CONNECTOR
1. FAN SPEED SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH Install the resistor, install the two mounting screws
3. THERMOSTAT and tighten. Install the fa ns in the lower PPE,
R e p la ce s w itc h e s a n d c o n n e c t t h e e le c tr ic a l connect the electrical connectors.
connectors as required. Install the switch panel in the
console. STEP 4
Install new O-rings on the heater control valve.
STEP 2
STEP 5
Install the control valve, install and tighten the screws
to the heater core.
STEP 6
Install new O-rings on the openings of the expansion
valve.
STEP 7
Install the heater core and evaporator core into the
lower box PPE.
BD06G208
Install the motor and install the mounting screws and STEP 8
tighten. Connect the electrical connector for the
recirculating vain motor, connect the linkage to the
vain.
BD06G236
Connect the electrical connectors to the heater

control valve.
9004-15
STEP 9 STEP 11
1� 2
BD06G237 BD06G205
Connect the electrical connectors to the thermostat
2. HEATER HOSES
control.
Remove the plugs from the hoses and the caps from
STEP 10 the fittings. Install new O-rings in the evaporator
fittings, connect the heater and evaporator hoses.
Remove and discard identification tags that were
used during disassembly.
STEP 12
BD06G206
Install the thermostat probe coil and clamp to the

evaporator core “cold” tube.
W270-8R010
Install the right side cab skirt.
STEP 13
BD06G238
I n s t a ll th e u p p e r P P E o n t h e h e a t e r a n d a ir
conditioning cores.
9004-16
STEP 14 STEP 17
BD06G203 BD06G210
Connect the solenoid driver. Make sure that the recirculating vain is in the closed
position.
STEP 15 IMPORTANT: This photo shows it in the open
position and the upper box will not go back into
position without damaging the recirculating vain.
STEP 18
BD06G239
Push the wiring harness into the preformed notches

in the upper PPE.
STEP 16 BD06G241
Place the air selector on the control panel to outside Set the upper box into position on the heater and
air. evaporator cores.
STEP 19
BD06G216
Install two screws, one on each side of the upper box

securing the upper box to the lower box.
9004-17
STEP 20 STEP 24
BD06G242 BD06G202
Install the PPE cover in the center of the upper box. Install and torque the four bolts to 73 to 87 Nm (55 to
65 pound-feet).
STEP 21
BD06G215
Install and tighten the six bolts securing the upper

box.
STEP 22
W270-8R011
Install the right rear floor mat into the cab, if machine
is equipped with air ride seat make sure to pull the
wiring up above the mat for the seat.
STEP 23
Install the remainder of the floor mat.
9004-18
STEP 25 STEP 27
Connect the wiring connector to the operator’s seat Charge the air conditioning system according to the
(if equipped with air seat option). instructions in Section 9003.
STEP 26
W270-1R086
W270-8R012
Fill dearation tank with a solution of 50% Ethylene

Glycol and 50% water. Fill until you see the coolant in
in the sight bubble on the side Install the deaeration
cap.
9004-19
CONDENSER AND RECIEVER DRIER

Removal STEP 6
STEP 1
bucket to the ground.
STEP 2
W270-8R015
Pull the pin so the condensor can be slid out on the

channel.
STEP 7
W270-1R007
Move the battery cut-off switch into OFF as indicated

in the figure.
STEP 3
Discharge the air conditioning system according to
STEP 4
W270-8R013
Pull the condensor out from the right side, sliding on

the channel and remove the two bolts from the top
side of the condensor, through the opening in the top
of the channel. Tilt condensor upward when the
bottom bolt is at the opening in the bottom channel
remove the condensor.
BD07A227
F a s t e n i d e n t if ic a ti o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the condensor.
STEP 5
Install plugs in the hoses and caps on the fittings.
9004-20
STEP 8 Installation
STEP 11
Position bolt on the bottom of the condensor and
position it in the hole of the bottom channel.
STEP 12
W270-8R014
F a s t e n i d e n t if ic a ti o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the receiver drier.
STEP 9
Install plugs in the hoses and caps on the fittings.
W270-8R013
STEP 10 Slide the condensor on the channel till the first bolt
Disconnect the trinary switch, remove the mounting hole in condensor is exposed in the hole of the top
bolt, remove the receiver drier and bracket. channel and install the bolt. Continue sliding the
condensor in the channel till the second bolt hole is
exposed in the channel and install the bolt. Slide to
the end of the channel.
STEP 13
BD07A227
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings and connect the
hoses to the fittings on the condensor. Remove and
discard identification tags that were used during
disassembly.
9004-21
STEP 14 STEP 17
Charge the air conditioning system according to the
instructions in Section 9003.
W270-8R015
Install the pin.
STEP 15
Mount the receiver drier and bracket, install and
tighten the mounting bolt.
STEP 16
W270-8R014
Remove plugs from the hoses and caps from the

fittings, install new O-rings and connect the hoses to
the fittings, connect the trinary switch. Remove and
discard identification tags that were used during
disassembly.
9004-22
NOTES
Section
9006
LOADER

9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth .......................................................................1315 to 1480 Nm (970 to 1090 pound-feet)
BUCKET TEETH
Replacement of the Tooth Points

1. Use a hammer and punch to drive the retaining 3� 5�
pin (1) for the tooth point (2) out of the tooth
4�
shank (3), refer to the illustration on this page. 2� 1�
2. Remove the tooth point (2).
3. Install a new tooth point (2) on the tooth shank
(3).
4. Install the retaining pin (1) into the tooth point (2)
7�
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
6�
8� 10
a hammer to hit the retaining pin (1) until the 3�
retaining pin (1) is even with the outside of the
tooth shank (3).
2� 1�
Replacement of the Bucket Teeth
1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth. 9�
NOTE: If wear of the bolt or nut makes removal difficult, 7�
the bolt or nut can be cut off.
2. Remove the tooth.
B0740A88J
3. Install the new tooth on the bucket cutting edge 1. RETAINING RING 6. BOLT
(7). 2. TOOTH POINT 7. CUTTING EDGE
3. TOOTH SHANK 8. PLOW BOLT
4. Use new nuts (4), hardened washers (5), and
4. NUT 9. NUT
bolts (6) for the tooth being installed.
5. HARDENED WASHER 10. CORNER TOOTH
5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to
1090 pound-feet). BUCKET TEETH ILLUSTRATION
Replacement of the Bucket Corner

Teeth
1. Loosen and remove the nuts (9) and bolts (8)
from the bucket corner teeth (10).
NOTE: If wear of the bolt or nut makes removal difficult,
the bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket
cutting edge (7).
4. Use new nuts (9) and bolts (8) for the corner
tooth being installed.
5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to
1090 pound-feet).
9006-4
RETURN TO DIG ADJUSTMENT
BC06A223
1. TARGET MOUNTING BRACKET 3. TARGET BAR 5. PROXIMITY SWITCH

2. BUCKET CYLINDER 4. PROXIMITY SWITCH MOUNTING BRACKET 6. PROXIMITY SWITCH GUARD
RETURN TO DIG ADJUSTMENT ILLUSTRATION
9006-5
IMPORTANT: Before adjusting the return-to-dig, make 7. Loosen the bolts holding the target bar (3) to the
sure that the target bar on the bucket linkage is not target mounting bracket (1). Slide the target bar
damaged. Slowly roll back and dump the bucket and make (3) towards the proximity switch (5) until the face
sure that the target bar stays the same distance from the of the proximity switch (5) is completely covered.
switch. The switch mounting bracket protects the switch. 8. Align the target bar (3) parallel to the tilt cylinder
Make sure the target bar cannot touch the switch when the (2) and tighten the bolts.
bucket is dumped.
9. Turn the ignition switch to the ON position. Do
1. Park the machine on a level surface. Raise the NOT start the engine.
lift arms until they are approximately horizontal
and dump the bucket. Lower the bucket until the 10. Place the bucket control lever in the ROLLBACK
bucket edge is on the ground. position.
2. Apply the parking brake and stop the engine. 11. Loosen the bolts holding the target bar (3) to the
target mounting bracket (1).
3. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target 12. Slide the target bar (3) slowly away from the
mounting bracket (1) parallel to the tilt cylinder proximity switch (5), until the control lever returns
(2). Tighten the bolts, refer to the illustration on to the center position. Tighten the bolts holding
this page. the target bar (3).
4. Loosen the bolts holding the proximity switch 13. Check to make sure that the 3.2 to 5.0 mm (1/8
mounting bracket (4) to the tilt cylinder (2). to 3/16 inch) gap is still maintained.
Position the proximity switch (5) parallel to the 14. Start the engine.
target bar (3) and tighten the bolts. 15. Place the detent switch in the ON position and
5. Adjust the proximity switch (5) out towards the place the return to travel/float detent switch to
target bar (3), until an air gap of 3.2 to 5.0 mm the TRAVEL position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 16. Raise the lift arms approximately horizontal, and
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). put the bucket in the fully dumped position.
NOTE: The proximity switch (5) must not protrude past 17. Place the loader control lever in the ROLLBACK
the proximity switch guard (6). position, and verify that the electromagnet holds
6. Start the engine, position the bucket to the it in that position until the end of the target bar (3)
correct digging angle and stop the engine. passes in front of the proximity switch (5).
18. Lower the lift arms and verify that the bucket is at
the correct digging angle.
9006-6
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
1
6
W270-5R012
1. TARGET MOUNTING PLATE 3. PROXIMITY SWITCH 5. RETURN TO TRAVEL TARGET

2. HEIGHT CONTROL TARGET 4. LIFT ARM 6. FRONT CHASSIS (TOP LEFT HAND SIDE)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
1. Park the machine on a level surface.

WARNING: Raised equipment on the machine
2. Start the engine and apply the parking brake. without an operator can cause injury or death.
3. Lower the lift arms and place the bucket flat on Before you leave the operators compartment,
the ground. always support or lower the equipm ent
(ba c kh oe , bla d e, b oo m, bu ck et, e tc .) to th e
4. Stop the engine. ground and stop the engine.
NOTE: To avoid damge to the proximity switchs (3), they CSM105
must be adjusted back to clear everything on the lift arm as 5. Position the return to travel target (5) opposite
it passes. Refer to the illustration on this page. the proximity switch (3) and tighten it to the target
mounting plate (1).
6. Adjust the proximity switch (3) out towards the
return to travel target (5) until an air gap of 3.2 to
5.0 mm (1/8 to 3/16 inch) is obtained.
7. Lock the proximity switch (3) in this position with
the jam nut. Torque the jam nut to 6 to 7.5 Nm
(4.5 to 5.5 pound-feet).
9006-7
A
2
3
B
1
W270-5R013
1. HEIGHT CONTROL TARGET 2. RETURN TO TRAVEL TARGET 3. TARGET MOUNTING PLATE
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
W270B 44 mm (1.73 inch) 380 mm (14.96 inches) 38 mm (1.50 inches) 3302 mm (130 inches)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
8. Refer to the table and the illustration on this 10. Position the return to travel target (2) using the
page. Position the height control target (1) on the table above.
target mounting plate (3) using the table above.
NOTE: The higher the return to travel target (2) is
NOTE: The higher the height control target (1) is positioned in its slot in the target mounting plate (3), the
positioned in its slot in the target mounting plate (3), the lower the lift arms will stop as they are lowered.
lower the lift arms will stop as they are raised.
11. Check to make sure the proximity switch (3) and
9. Tighten the height control target (1). all of the mounting bolts are tight. Refer to the
12. Start the engine.
9006-8
13. Place the detent switch in the ON position, and 15. With the lift arms still raised, place the loader
set the return to travel/float detent switch to the control lever in the lower position and verify that
return to travel position. the electromagnet holds it in that position until
the return to travel target (5) passes in front of
14. Place the loader control lever in the raise
the proximity switch (3). Refer to the illustration
position and verify that the electromagnet holds it
on page 6.
in that position until the height control target (2)
passes in front of the proximity switch (3). Refer 16. Repeat steps 8 through 15 until the desired
to the illustration on page 6. heights are reached.
17. Lower the bucket to the ground and stop the
engine.
9006-9
REMOVING THE LOADER FRAME

1. Park the machine on a level surface and apply 18. Raise the loader frame slightly. Use an
the parking brake. Roll the bucket all the way acceptable driver and drive the pivot pin (9 or 10)
forward and lower the bucket to the floor. Stop out of the front frame. Do not lose the washers
the engine. (18) and wipers (22) between the front frame and
the loader frame (2).
2. Loosen the filler plug in the reservoir to release
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 10.
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
cylinder (4). Do not remove the driver.
6. Repeat Steps 4 and 5 for the left lift cylinder.
BD01G009
7. Start the engine. Roll the bucket back and lower 19. Remove the proximity switch cover. Left-hand
the bucket so that the bucket is flat on the floor side of the machine only.
and fasten the chain hoist to a lift cylinder.
8. Raise the lift cylinder slightly and remove the
driver.
9. Repeat steps 7 and 8 for the other lift cylinder.
10. Connect the chain hoist to the bucket cylinder
(8). 1�
(16), and spacer (17) that fasten the pivot pin (7)
for the piston rod eye of the bucket cylinder (8) to 2
the bellcrank (11).
12. Use an acceptable driver and drive the pivot pin
(7) out of the p iston rod e ye o f the bucke t BD01G010
cylinder (8). 1. ELECTRICAL CONNECTION 2. PROXIMITY SWITCH
13. Raise the bucket cylinder (8) and use a chain or 20. Disconnect the electrical connector (1), remove
other acceptable holding equipment to hold the the lock nut from the proximity switch (2) and
bucket cylinder (8) in place. r e mo v e th e p r o x imit y s w itc h ( 2 ) f ro m t h e
machine. Left-hand side of the machine only.
14. If the machine is equipped with auxiliary
hydraulics, disconnect the two hoses from the 21. Repeat Steps 17 and 18 for the other pivot pin (9
tubes at the bracket on the right side of the or 10).
loader frame (2). Install caps on the hoses and
22. Raise the loader frame (2) out of the front frame.
plugs in the tube fittings.
Carefully move the machine out of the loader
15. If the machine is equipped with front lamps, frame (2).
loosen and remove the cap screws and lock
washers that fasten the lamp brackets to the front
frame. Put the lamp brackets on the fenders.
16. Connect the chain hoist to the loader frame (2).
(20) and spacer (21) that fasten the pivot pin (9
or 10) to the front frame.
9006-10
W270-5R014
1. CROSSMEMBER 7. PIVOT PIN 13. WASHER 19. BOLT

2. LOADER FRAME 8. BUCKET CYLINDER 14. SPACER 20. WASHER
3. PIVOT PIN 9. PIVOT PIN 15. BOLT 21. SPACER
4. LIFT CYLINDER 10. PIVOT PIN 16. WASHER 22. WIPER
5. PIVOT PIN 11. BELLCRANK 17. SPACER 23. DUMP LINK
6. NOT USED 12. BOLT 18. WASHER
LOADER FRAME ILLUSTRATION

9006-11
INSTALLING THE LOADER FRAME

1. Apply antiseize compound to the inner bores and 17. Disconnect the chain hoist from the bucket
outer bores for the pivot pins of the front frame, cylinder (8).
refer to the illustration on page 10.
18. Fasten the chain hoist to one of the lift cylinders.
2. Move the machine into alignment with the loader
19. Raise the piston rod yoke of the lift cylinder so
frame (2).
the piston rod yoke is aligned with the loader
3. Lower the loader frame (2) into alignment with frame (2).
the front frame.
20. Install a driver in the piston rod yoke and the
4. Apply antiseize compound to the pivot pins (9 loader frame (2).
and 10) that fasten the loader frame (2) to the
21. Repeat Steps 18, 19, and 20 for the other lift
front frame.
cylinder.
5. Start the pivot pins (9 and 10) into the front
22. Disconnect the chain hoist from the lift cylinder.
frame. Install the washers (18) and new wipers
(22) between the loader frame (2) and the front 23. Start the engine. Raise the loader frame and roll
frame. the bucket all the way forward. Lower the bucket
to the floor. Stop the engine.
6. Install the pivot pins (9 and 10) all the way.
24. Fasten the chain hoist to the crossmember (1) of
7. Install the bolt (19), washer (20) and spacer (21)
the loader frame (2).
that fasten the pivot pins (9 and 10). Tighten the
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
rod yoke of one of the lift cylinders with the
9. Disconnect the chain hoist from the loader frame
loader frame (2).
(2).
10. If the machine is equipped with front lamps, hold IMPORTANT: D o n o t u s e y o u r f i n g e r s t o
the front lamps in place and install the cap check the alignment of the cylinder rod.
screws and lock washers that fasten the front Personal injury can be the result.
lamps to the front frame. Tighten the cap screws. 48-88
11. If the machine is equipped with auxiliary 27. Remove the driver and install the pivot pin (3).
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses. Connect the 28. Install the bolt (12), washer (13), and spacer(14)
hoses to the tubes. that fasten the pivot pin (3). Tighten the bolt.
12. Connect the chain hoist to the bucket cylinder (8) 29. Repeat Steps 26, 27, and 28 for the other lift
and lower the bucket cylinder (8). cylinder. Stop the engine.
13. Start the engine and run the engine at low idle. 30. Lubricate the pivot pins with molydisulfide
grease.
14. Have another person help you at this time. Move
the bucket control lever as required to align the 31. Disconnect the chain hoist from the
piston rod eye of the bucket cylinder (8) with the crossmember (1) of the loader frame (2).
bellcrank (11). Stop the engine. 32. Tighten the filler plug in the reservoir.
33. If the machine is equipped with auxiliary
IMPORTANT: D o n o t u s e y o u r f i n g e rs t o
hydraulics, start the engine and run the engine at
check the alignment of the cylinder rod.
low idle.
Personal injury can be the result.
48-88 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
the piston rod eye of the bucket cylinder (8). 35. Stop the engine, check the level of the oil in the
reservoir, and check for leaks. Add oil to the
16. Install the bolt (15), washer (16), and spacer (17)
reservoir as required.
that fasten the pivot pin (7). Tighten the bolt.
9006-12
NOTES
Section
9007
ROLLOVER PROTECTIVE STRUCTURE (ROPS)

CAB STRUCTURAL FRAME (CSF)

9007-2
TABLE OF CONTENTS
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3
CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9007-3

CAB STRUCTURAL FRAME (CSF)
After an accident, fire or rollover, the following MUST
be performed before returning the machine to field or
Attention
job site operation:
The ROPS or CSF structure MUST be replaced.
The Rollover Protective Structure (ROPS) or Cab The ROPS or CSF mounting or suspension,
S truc tural Frame (CSF ) is a s peci al saf et y operator seat and suspension, seat belts and
component of your machine. mounting components and wiring within the
DO NOT attach any device to the ROPS or CSF for operator’s protective system MUST be carefully
pulling purposes. inspected for damage.
The ROPS or CSF is a certified structural support All damaged parts MUST be replaced.
and any damage, fire, corrosion or modification will DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
weaken the structure and reduce your protection. If R EPA IR TH E R O PS O R C AB S TR UC TU RA L
this occurs, the ROPS or CSF MUST be replaced so FRAME.
that it will provide the same protection as a new
ROPS or CSF.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following: WARNING: Do not install attachments that
will make the total weight of the m achine
1. Check the torque on the CSF cab or ROPS more than the weight shown in the maximum
canopy mounting bolts; torque should be 773 to gross vehicle weight section of the ROPS
854 Nm (570 to 630 lb-ft). If necessary, tighten serial number plate. 47-26
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight WARNING: Do not change the ROPS in any
and seat belt is not cut or frayed. Check the way. Changes made to the ROPS which are
torque on operators seat mounting bolts; torque not authorized, such as welding, drilling or
sh o u ld b e 7 3 t o 8 7 N m (5 4 to 6 4 lb- ft ). If c u t t i n g w il l m ak e th e R OP S w e a k e r a n d
necessary, tighten the bolts to the correct torque. decrease your pr otection. Replace the
Replace parts that are worn or damaged. ROPS if it becom es dam aged in any way.
DO N OT T RY TO M A K E RE P A IRS T O T HE
WAR NING : Grade 8 hardware is used to ROPS. 47-25
mount and anchor the ROPS. Parts used for
r eplacem en t m ust b e t ho se sh ow n in th e
parts catalog. 47-27A
9007-4
CSF CAB AND ROPS CANOPY

Removal STEP 5
NOTE: Procedures and photos in following steps cover in
detail removal and installation of CSF structure. Removal
and installation of ROPS is similar to removal and
installation of CSF structure.
STEP 1
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position. W270-8R001
Remove skirting under each side and front of cab.

STEP 2
STEP 6
W270-1R006
Put articulation lock in LOCKED position. BD06G186
Remove the ducts from the machine.

STEP 3
Put battery disconnect switch in OFF position. STEP 7
STEP 4
W270-8R002
At RH rear, bottom of cab, disconnect ground strap

W270-1R010 from rear chassis.
If machine is equipped with a heater, put a 57 liters
(15 Gallons) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.
9007-5
STEP 8 STEP 10
BD06G194 W270-8R003
If machine is equipped with windshield washers, Identify, tag, and disconnect hoses from steering
i d e n t i f y , t a g , a n d d is c o n n e c t f r o n t a n d r e a r control valve. Plug hoses and cap steering control
windshield washer nozzle hoses from supply hoses. valve fittings to prevent entry of foreign matter into
hydraulic system.
STEP 9
STEP 11
2� 3�
1�
BD06G205
1. TRANSMISSION FILTER
W270-8R009
3. HEATER HOSES
Disconnect throttle connector and the air duct.
If machine is equipped with a heater disconnect STEP 12

heater hoses (3), if machine is equipped with air
conditioning discharge the air conditioning system,
see section 9003, and disconnect the air conditioning 2�
hoses (2), cap and plug lines and fittings.
W270-8R004
Unlatch and open the compartment door on the right

hand side (1).
Open and remove the access panel (2).
9007-6
STEP 13 STEP 17
BD06F210 BD06G187
Disconnect the electrical connectors for the remote Disconnect t he elect rical c onnectors, pus h
control valve. connectors out of the bottom of the cab with the
rubber gromment
STEP 14
Loosen the filler cap on the reservoir to release any STEP 18
air in the reservoir. Connect a vacuum pump to the
STEP 15
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.
STEP 16
Push the hoses out of the bottom of the cab with the
rubber gromment.
BD06G188
Raise floor mat up and away from brake pedal to

gain access to mounting hardware.
STEP 19
BD06G185
Remove hardware securing brake valve to cab floor.

Let brake valve rest on the frame.
9007-7
STEP 20 STEP 23
W270-8R005 W270-8R008
Remove the four bolts securing the cab cover, install Slowly raise cab from rear chassis. Check that all tie
lifting eyes in threaded holes at top of the cab. straps and clamps have been removed and all
hoses, tubes, and wires are disconnected and free.
STEP 21 Check that brake valve with hoses attached are free
and clear of cab. Remove the ROPS or CSF from the
machine. Lower ROPS or CSF onto wooden blocks
to prevent damaging cab or canopy.
W270-8R006
Connect lifting equipment to cab at lifting eyes. Take

up all slack in lifting equipment.
STEP 22
W270-8R007
Remove nuts, bolts, and washers securing cab to

rear chassis.
9007-8
1�
2� 1�
2�
3�
3�
4�
4�
5�
5
6�
6�
BC06G031
1. NUT 4. RUBBER MOUNT

2. WASHER 5. WASHER
3. RUBBER MOUNT 6. BOLT
9007-9
STEP 24
Check rubber mounts (3 an 4) for deterioration, tears,
deforma tion, or othe r damage; rep lace rubber
mounts as necessary.
STEP 25
BD06G188
Position floor mat.
STEP 31
BD01D388
Position cab over rear chassis then put wood blocks

under brake valve. Slowly lower cab onto rear
chassis making sure that brake valve is positioned so
that brake pedal enters into cab. Remove wood
blocks as cab is lowered onto brake valve.
STEP 26
Install washers, bolts, and nuts to secure cab to rear W270-8R009
chassis. Tighten bolts to a torque of 773 to 854 Nm
Connect throttle connector and mount air duct.
(570 to 630 pound feet)
STEP 32
STEP 27
Disconnect lifting equipment from cab.
STEP 28
Remove lifting eyes.
STEP 29
W270-8R003
Remove plugs from hoses and caps from fittings.

Connect hoses to steering control valve following
tags installed during removal. Remove and discard
tags.
BD06G185
Align mounting holes in brake valve with associated

holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
9007-10
STEP 33 STEP 36
2� 3
1�
BD06G186 BD06G205
1. TRANSMISSION FILTER
Install the ducts on the machine.
3. HEATER HOSES
STEP 34
If machine is equipped with a heater, remove plugs
from hoses and caps from fittings, connect heater
hoses (3), if machine is equipped with air
conditioning, remove plugs from hoses and caps
from fittings, connect air conditioning hoses (2),
charge the air conditioning system, see section 9003.
STEP 37
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
shown on pages 11, 12, and 13.
W270-8R002
At RH rear, bottom of cab, connect ground strap to

rear chassis.
STEP 35
BD06G194
If machine is equipped with windshield washers,

connect front and rear windshield washer nozzle
hoses following tag s installed during remo val.
Remove and discard tags.
9007-11
3�
7�
4�
8�
6� 5�
1�
2�
7� 8
7� 5�
1� 2�
8� 3�
6� 4�
W270-6R008
1. PILOT TANK HOSE 4. ORANGE BLACK BLACK (ROLLBACK) 7. GREEN WHITE BLACK (4TH SPOOL)
2. PILOT PRESSURE HOSE 5. GREEN BLACK BLACK (DUMP) 8. RED WHITE BLACK (3RD SPOOL)
3. YELLOW BLACK BLACK (RAISE) 6. RED BLACK BLACK (LOWER)
9007-12
7�
1�
4� 6�
7� 5� 3�
4� 2�
1�
6� 3�
5�
3
7� 7� 7� 7�
2� 1� 2� 1�
3� 6� 3� 6�
4� 5� 4� 5�
W270-6R009 W270-6R010

7. RED WHITE BLACK (3RD SPOOL) 7. RED WHITE BLACK (3RD SPOOL)
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING
9007-13
5�
4� 1�
5� 6�
2� 4�
6� 1�
3�
3�
2
7� 7� 7� 7�
2� 1� 2� 1�
3� 6� 3� 6�
4� 5� 4� 5�
W270-6R011 W270-6R012

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING
9007-14
STEP 38 STEP 40
2�
1
BD06F210
Connect the electrical connectors for the remote W270-8R004
control valve. Close the right hand compartment door (1, 2).
STEP 39
STEP 41
BD06G187
Connect wiring harness connectors.

W270-8R001
Install skirting under each side and front of cab.

9007-15
STEP 42 STEP 45
Put articulation lock in OPERATING position.
If the machine is equipped with air conditioning,
charge the refrigerant making reference to the
procedure described in section 9003.
STEP 43
W270-1R086
Fill the engine cooling system through the filler neck

located on the engine hood with a 50% mixture of
water and ethylene glycol. For the specifications,
please refer to section 1002. Install the radiator cap.
STEP 44
W270-1R088
Move the main battery cut off switch onto ON. Start
the engine and run it at idle speed. Let the engine run
for about five minutes to completely mix the water
and ethylene glycol. Once the coolant reaches the
operational temperature, cut-off the engine. Once the
engine has cooled-off, check the coolant level in the
tank.
WARNING: hot coolant can be ejected when removing the
radiator cap. When removing the radiator cap, let the cooling
system cool-off, turn the cap very slowly and let the
pressure drain completely.
9007-16
NOTES
Section
9010
CAB GLASS INSTALLATION

9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9010-3
PREPARATION FOR GLASS REPLACEMENT

1. Remove all of the damaged glass section and 5. Clean the new glass section. Apply a 25 mm (1
the silicone sealant from the window frame inch) wide band of glass primer (349-110) to the
black ceramic painted edges of the window.
2. Remove all the adhesive from the window frame.
6. When replacing a front window section, a
3. The window frame recesses must be free of oil
silicone forming tool is needed, refer to Figure 2.
and dust. Clean the frame with rubbing alcohol
Use the template and instructions provided to
with a clean rag. Do not reuse the rag.
make the tool.
4. Apply a 25 mm (1 inch) wide band of metal
primer (349-108) to the window recesses.
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must be 3. For front glass installations install a glass spacer
installed within 5 minutes. If the glass is not installed within 12 mm (1/2 inch) from each corner on bottom
the 5 minute period, the adhesive must be removed and edge of each glass section, refer to Figure 3.
applied again.
4. Install the glass. The glass edges must not
1. Apply a 10 mm (3/8 inch) diameter bead of contact the metal frame at any point.
ad h esive (3 45 -13 5) to the prime d su rfa ce
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the front
glass apply extra adhesive in corners, refer to Figure 3.
SILICONE SEALANT APPLICATION - FRONT WINDOWS

1. Clean the edges of the front center and front side 6. Fill the joint with the clear silicone sealant
windows. Use glass cleaning primer. (114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
2. Apply masking tape to the inside edge of each
glass sections. The sealant must extend at least
glass section next to the gap.
1.5 mm (1/16 inch) above the outside surface of
3. Apply the polyester tape on top of the masking the glass section for the length of the gap. Be
tape across the inside side gap. Do not push the sure the sealant fills against the adhesive at
tape into the gap. each end of the joint.
4. Apply masking tape to the outside edge of each 7. Remove the polyester tape from the inside joint.
glass section. Align the edge of the tape with
8. Remove the extra silicone from the outside joint
edge of glass on both sections.
by carefully sliding the forming tool down the
5. The tape must be smooth to get the best result length of the joint. The tool must remain in
when using the silicone forming tool. contact with the g lass sections during this
process. Refer to Figure 2 for forming tool
template.
9010-4
9. Remove all the silicone from the forming tool
1� 2 immediately after use.
10. Remove the outside tape from the glass
sections.
11. Remove the extra silicone sealant from the
inside joint by carefully sliding the forming tool
down the length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.
3� 13. Remove the inside joint masking tape.
4 14. If two or more glass sections are being replaced,

498L93
use the procedure on the second joint.
1. FRONT RH SIDE GLASS 3. SILICONE BEFORE 15. Apply the gray silicone sealant above the front
SMOOTHING center, front side or rear windows for additional
2. FRONT CENTER GLASS 4. SILICONE AFTER leak protection.
SMOOTHING
FIGURE 1. SILICONE APPLICATION 16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
NOTE: Make the forming tool from 10 mm (3/8 inch)
each front side window replaced, refer to Figure
plexiglass, or wood. Sand all radius and edges smooth.
3.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.
6 MM 120°
(1/2 INCH) R
120°
4 MM
(3/16 INCH) R
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE
9010-5
5�
2�
1�
3�
4
6�
2�
1�
497L93
1. SIDE GLASS ADHESIVE 4. RIGHT HAND SIDE GLASS SPACER LOCATIONS

2. CENTER GLASS ADHESIVE 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS CENTER GLASS
FIGURE 3 SILICONE APPLICATION
NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break the seal on newly
installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and silicone to properly set.
9010-6
NOTES

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Use for Service Manual

Fuel System Tab 3

Copyright © 2007 CNH Italia S.p.A.

Power Train Tab 6

Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket

Copyright © 2007 CNH Italia S.p.A.

Section Title Section Number

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

GENERAL TORQUE SPECIFICATIONS

Copyright © 2007 CNH Italia S.p.A.

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Pound- Newton Pound- Newton

TORQUE SPECIFICATIONS - METRIC HARDWARE

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

Pound- Newton M24 780 to 940 1050 to 1275

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Split Flange Mounting Bolts

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

FLUIDS AND LUBRICANTS

Copyright © 2007 CNH Italia S.p.A.

CAPACITIES AND LUBRICANTS

ENGINE OIL RECOMMENDATIONS

HYDRAULIC OIL TEMPERATURE CHART

TRANSMISSION OIL TEMPERATURE CHART

ENGINE OIL TEMPERATURE CHART

DIESEL FUEL SYSTEM

The diesel fuel used in this machine must meet the

Specifications for Acceptable No. 2 Diesel Fuel

Every 5-16 Engine oil level 10

Every 5-23 Engine coolant filter 250

Every 5-27 Battery electrolyte level 500

Every 5-34 Change hydraulic oil 2000

METRIC CONVERSION CHART

Copyright © 2007 CNH Italia S.p.A.

Force: newton 3.596 942 ounce force

Section Title Section Number

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000

FOR THE REMOVAL, INSPECTION, OVERHAUL AND REINSTALLATION OF

ENGINE AND RADIATOR REMOVAL AND

Copyright © 2007 CNH Italia S.p.A.

O pen the e ngine hoo d upp er side pan els and

W270-1R007 Drain the hydraulic oil from the reservoir using a

Remove pipe (1) from th e turbo cha rger to the

Remove silencer (1) from the supports located on the

Remove hood (1) from the machine.

Remove the engine central upper hood by removing W270-1R028

Sling the hood in an appropriate manner, lift it and W270-1R029

If the machine is equipped with air conditioner,

If the machine is equipped with air conditioning,

Identify, tag and disconnect the electric connections W270-1R045

Identify, tag and disconnect all the pipes and hoses

Replicate the operation for the engine rear support. W270-1R055

From the right side of the engine-transmission group,

Using the adjustable chains previously installed,

Grease the mounting flanges of the transmission

Remove the outer screws (q.ty 12) securing the

U s in g t h e a dj u st a b le ch a in s in st a lle d o n t h e From the s ide right opening located on the

Insert, at first, two or three outer screws, without