Manual Taller Telescopica MF

TH.
6534 - S/N B41R11001 & Above

TH.6534X - S/N B41S11001 & Above EN
TH.7035 - S/N B3ZZ11001 & Above
TH.7035X - S/N B41111001 & Above
TH.7038 - S/N B41211001 & Above
TH.7038X - S/N B41311001 & Above
1857951M1
Service Manual
AGCO Ltd October 2016

Abbey Park Stoneleigh 1857951M1
Kenilworth Issue 1
England, CV8 2TQ TH.6534(X) / TH.7035(X) / TH.7038(X)
EU - English
MASSEY FERGUSON is a worldwide brand of AGCO. © AGCO Limited 2016
TH.6534(X) / TH.7035(X) / TH.7038(X)

Service Manual
Page left blank intentionally
1857951M1
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual and signs (decals) on machine.
WARNING Follow warnings and instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function after adjustments, repairs
or service. Untrained operators and failure to follow instructions can cause
injury or death. W-2975-xxxx
CORRECT
Safety Alert Symbol: This symbol with a warning statement,

means: “Warning, be alert! Your safety
is involved!” Carefully read the
message that follows.
P-90216
Never service the Massey Ferguson
telescopic handler without
instructions.
CORRECT WRONG WRONG
NA5428 NA5432 NA5433
Cleaning and maintenance are Disconnecting or loosening any Never work on telescopic
required daily. hydraulic tubeline, hose, fitting, handler with boom up unless
component or a part failure can boom is held by an approved
cause boom to drop. Do not go boom stop. Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Massey Ferguson.
WRONG WRONG WRONG
NA5434 NA5436 B-6589
Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator
without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be
performed ONLY BY QUALIFIED MASSEY FERGUSON SERVICE PERSONNEL. Always use genuine Massey Ferguson
replacement parts.
MSW43-EN-MF-0413
TH.6534(X) / TH.7035(X) / TH.7038(X)
1-1 Service Manual
TH.6534(X) / TH.7035(X) / TH.7038(X)
1-2 Service Manual
CONTENTS
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-3 Service Manual
TH.6534(X) / TH.7035(X) / TH.7038(X)
1-4 Service Manual
FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Dismantling And Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Telescopic Handler Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Telescopic Handler Statutory Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Other Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
MASSEY FERGUSON TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . 1-15
TH.6534(X) / TH.7035(X) / TH.7038(X)

10-05 Service Manual
TH.6534(X) / TH.7035(X) / TH.7038(X)
FOREWORD
This manual is for the Massey Ferguson telescopic handler mechanic. It provides necessary servicing and
adjustment procedures for the Massey Ferguson telescopic handler and its component parts and systems. Refer
to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the telescopic handler has had service or repair:
1. Check that ROPS/FOPS 9. Enclosure door latches must
(Including right side window) open and close freely.
is in good condition and is not
modified.
2. Check that ROPS mounting 10. Attachment locking pins must

hardware is tightened and is function correctly and be in
Massey Ferguson approved. good condition.
3. The seat belt must be 11. Safety treads must be in good

correctly installed, functional condition.
and in good condition.
4. Check boom support device, 12. Check for correct function of

replace if damaged. indicator lamps and gauges.
5. Machine signs must be 13. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.
6. Check tires for wear and 14. Inspect for fuel, oil or
pressure. Use only approved hydraulic fluid leaks.
tires.
7. Check for correct function of 15. Lubricate the telescopic

the work lights. handler.
8. The parking brake must 16. Check the condition of the

function correctly. battery and cables.
FW TLS EMEA-0411 SM
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-7 Service Manual
17. Inspect the air cleaner for 20. Operate the telescopic
damage or leaks. Check the handler and check all
condition of the element. functions.
18. Check the electrical charging 21. Check for any field
system. modification not completed.
19. Inspect for loose or broken 22. Recommend to the owner

parts or connections. that all necessary corrections
be made before the machine
is returned to service.
FW TLS EMEA-0411 SM
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-8 Service Manual
SAFETY INSTRUCTIONS Safe Operation Needs A Qualified Operator
For an operator to be qualified, he or she must not use
Safe Operation Is The Operator’s Responsibility
drugs or alcoholic drinks which impair alertness or co-
ordination while working. An operator who is taking
Safety Alert Symbol prescription drugs must get medical advice to determine
if he or she can safely operate a machine.
This symbol with a warning statement means: A Qualified Operator Must Do The Following:
“Warning, be alert! Your safety is involved!”
Understand the Written Instructions, Rules and
Carefully read the message that follows.
Regulations
• The written instructions from Massey Ferguson
Company include the Delivery Report, Operation &
Maintenance Manual and machine signs (decals).
WARNING • Check the rules and regulations at your location. The
rules may include an employer’s work safety
requirements. For driving on public roads, the
Operator must have instructions before operating the
machine must be equipped as stipulated by the local
machine. Untrained operators can cause injury or
regulations authorising operation on public roads in
death.
your specific country. Regulations may identify a
W-2001-0502
hazard such as a utility line.
• For operating the machine, some countries require an
operator license. Check the regulations at your
location.
IMPORTANT Have Training with Actual Operation
This notice identifies procedures which must be • Operator training must consist of a demonstration and
followed to avoid damage to the machine. verbal instruction. This training is given by your
I-2019-0284 Massey Ferguson dealer before the product is
delivered.
• The new operator must start in an area without
bystanders or structures and use all the controls until
he or she can operate the machine and attachment
DANGER safely under all conditions of the work area. Always
fasten seat belt before operating.
The signal word DANGER on the machine and in the Know the Work Conditions
manuals indicates a hazardous situation which, if not • Know the weight of the materials being handled.
avoided, will result in death or serious injury. Avoid exceeding the Rated Load Capacity of the
D-1002-1107 machine (as indicated on the Load Capacity Charts).
Material which is very dense will be heavier than the
same volume of less dense material. Reduce the size
of load if handling dense material.
WARNING • The operator must know any prohibited uses or work

areas, for example, he or she needs to know about
excessive slopes.
The signal word WARNING on the machine and in the • Know the location of any underground lines.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious • Wear tight fitting clothing. Always wear safety glasses
when doing maintenance or service. Safety glasses,
injury.
W-2044-1107
respiratory equipment, hearing protection or Front
Window Guard are required for some work. See your
Massey Ferguson dealer about Massey Ferguson
The Massey Ferguson telescopic handler and Safety Equipment.
attachment must be in good operating condition before
use.
Check all of the items on the Massey Ferguson Service
Schedule Decal under the 8-10 hour column or as shown SI TH MF EMEA-1015 SM
in the Operation & Maintenance Manual.
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-9 Service Manual
SAFETY INSTRUCTIONS (CONT’D) Dismantling And Disposal
Safe Operation Needs A Qualified Operator (Cont’d) On the completion of its useful life, the machine and its
parts shall be disposed of in an environmental friendly
Where overhead power lines are present in the operating manner. Please contact your local dealer. Parts of the
area, ensure sufficient clearance between the nearest of machine can be remanufactured like the engine
these lines and any part of the machine. depending on its age and condition, or recycled like
metals, plastics, rubbers and glasses. Respect the
VOLTAGE MINIMUM DISTANCE environment and dispose of waste properly. Worn or
damaged parts shall not be left in the environment. Oils,
up to 50 kV 3 m (10 ft) brake fluid, cooling refrigerants, batteries and cells shall
beyond 50 kV 5 m (16.5 ft) be disposed of in a proper manner through your local
dealer or recycling center.
The operator must survey his / her field of vision when
operating the telescopic handler. Adjust mirrors to obtain
the best visibility. Clean mirrors every day and more often
when necessary. Immediately replace any broken or
damaged mirrors. If a suspended load or the resulting
boom geometry blocks the vision of the operator
alternative carrying means must be considered.
The operator must know the wind speed. Do not use the
telescopic handler with wind speeds over 12,5 m/s (28
mph).
Avoid Silica Dust
Cutting or drilling concrete containing sand or rock

containing quartz may result in exposure to silica dust.
Use a respirator, water spray or other means to control
dust.
SI TH MF EMEA-1015 SM
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-10 Service Manual
FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use petrol or diesel fuel
for cleaning parts. Use commercial non-flammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs. These starting aids can cause explosion and
injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
Sl TH MF EMEA-1015 SM
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-11 Service Manual
FIRE PREVENTION (CONT’D)
Welding And Grinding
Always clean the machine and attachment, disconnect

the battery, and disconnect the wiring from the Massey
Ferguson controllers before welding. Cover rubber
hoses, battery and all other flammable parts. Keep a fire
extinguisher near the machine when welding.
Have good ventilation when grinding or welding painted

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing non-metallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
Sl TH MF EMEA-1015 SM
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-12 Service Manual
SERIAL NUMBER LOCATION Explanation of telescopic handler serial number:
XXXX XXXXX
Always use the serial number of the telescopic handler
when requesting service information or when ordering Module 2. - Production
parts. Sequence (Series)
If any serial number plate is damaged, contact your Module 1. - Model / Engine
Massey Ferguson dealer. Combination
Telescopic Handler Serial Number 1. The four digit Model / Engine Combination Module
number identifies the model number and engine
Figure 1 combination.
2. The five digit Production Sequence Number identifies

the order which the telescopic handler is produced.
Telescopic Handler Statutory Plate
Figure 2
S38967
S38967
7301644
The telescopic handler serial number plate is located on

the right side of the chassis in front [Figure 1].
S38981A_MF
The telescopic handler statutory plate (if equipped) is

located on the right side of the chassis in front [Figure 2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-13 Service Manual
SERIAL NUMBER LOCATION (CONT’D) DELIVERY REPORT
Engine Serial Number Figure 4
Figure 3
B-16315
P126245
The delivery report [Figure 4] contains a list of items that

must be explained or shown to the owner or operator by
2 the dealer when the Massey Ferguson telescopic handler
is delivered.
The delivery report must be reviewed and signed by the

owner or operator and the dealer.
P126244
The engine serial number can be found on the engine

cylinder block (Item 1) and on the engine rating plate
(Item 2) [Figure 3] near the flywheel in front of you when
opening the engine cover. Always use the full number
(type + number) when ordering replacement parts.
Other Serial Numbers
Other components can also have serial numbers and an

identification plate. Always use these serial numbers
when ordering parts.
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-14 Service Manual
MASSEY FERGUSON TELESCOPIC HANDLER IDENTIFICATION
13
3 18
4 14
2 17
1
5
6 12
10 11
9
19 15 16
8 EM9726
NA13062
ITEM DESCRIPTION ITEM DESCRIPTION

1 Operation & Maintenance Manual 10 Seat Belt
2 Mirrors 11 Boom Stop [A]
3 Work Lights 12 Operator Cab (ROPS and FOPS) [C]
4 Front Window Guard [A] 13 Rotating Beacon [A]
5 Front Lights 14 Rear Work Light
6 Telescoping Boom 15 Tail Lights and Direction Signals
7 Boom Head 16 Tyres [D]
8 Pallet Fork Attachment [B] 17 Engine Cover
9 Boom 18 Load Capacity Charts
19 Carrier Locking Bar Holder
[A] Optional or Field Accessory. (Not Standard Equipment).

[B] Attachments - Several different attachments are available for the Massey Ferguson telescopic handler.
[C] ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure
per ISO 3449, Level II.
[D] TYRES - Standard tyres are shown. Several different tyre styles and sizes are available for the Massey Ferguson
telescopic handler.
TH.6534(X) / TH.7035(X) / TH.7038(X)

1-15 Service Manual
TH.6534(X) / TH.7035(X) / TH.7038(X)
1-16 Service Manual
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Cab Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Rear Cab Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
Cab Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER . . . . . . . . . . . . . . . . 10-30-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
TOWING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Replacing Filter Elements (TH.7035(X)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Replacing Filter Elements (TH.6534(X) And TH.7038(X)) . . . . . . . . . . . . . . . . . . . . 10-60-3
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
Removing And Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-4
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Removing And Replacing Oil Separator Filter (TH.6534(X) And TH.7038(X) Only) . 10-90-3
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing And Replacing Hydraulic / Hydrostatic Filters . . . . . . . . . . . . . . . . . . . . 10-100-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-6
Fill / Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-6
Hydraulic Fluid Air Bleeding Procedure (Only For TH.6534(X) And TH.7038(X)) . . 10-100-7
Starter Procedure (Only For TH.6534(X) And TH.7038(X)) . . . . . . . . . . . . . . . . . 10-100-10
AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking And Adding Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking And Adding Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Removing And Replacing Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Checking And Adding Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Removing And Replacing Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Checking And Adding Oil (Gear Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
Removing And Replacing Oil (Gear Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
LUBRICATING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
ATTACHMENT CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2
APPROVED BOOM STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Installing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Removing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER . . . . . . . . . 10-170-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Right Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . 10-190-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
TL34.65(X)C / TL35.70(X) / TL38.70(X)

LIFTING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563 . . . . . . . . . . . . . . . . . . . . 10-210-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-3
REMOTE START TOOL (SERVICE TOOL) KIT - 3975015M1 . . . . . . . . . . . . . . . . . . . 10-220-1

Remote Start Tool (Service Tool) - 3975016M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1
Telescopic Handler Service Tool Harness - 3975017M1 . . . . . . . . . . . . . . . . . . . . 10-220-2
Computer Service Tool Harness - 3975018M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-4
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-4
TH.6534(X) / TH.7035(X) / TH.7038(X)

TL34.65(X)C / TL35.70(X) / TL38.70(X)
LIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2
HANDLER
Procedure
Always park the machine on a flat, solid and level

surface.
WARNING
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the S39237
machine before running engine for service.
W-2718-0208
Put the floor jack under the right side of the front axle. Lift
Figure 10-10-1 the telescopic handler and install the second jackstand
[Figure 10-10-2].
Figure 10-10-3
S39236
STOP the engine. Put the floor jack under the left side of S38065
the front axle. Lift the telescopic handler and install the
first jackstand [Figure 10-10-1].
Put the floor jack under the center of the rear axle. Lift the
telescopic handler and install jackstands [Figure 10-10-
3].
TH.6534(X) / TH.7035(X) / TH.7038(X)

10-10-1 Service Manual
TH.6534(X) / TH.7035(X) / TH.7038(X)
OPERATOR CAB Cab Door
Description Figure 10-20-1
The Massey Ferguson telescopic handler has an

operator cab (ROPS / FOPS) as standard equipment to
protect the operator. The seat belt must be worn for
ROPS / FOPS protection. 1
Check the ROPS / FOPS cab, mounting, and hardware

for damage. Never modify the ROPS / FOPS cab.
Replace the cab and hardware if damaged. See your 2
Massey Ferguson dealer for parts.
ROPS / FOPS - Roll Over Protective Structure per ISO

3471, Falling Object Protective Structure per ISO 3449
(FOPS Level II) and OECD code 4, code 9 and code 10.
S38156
Operator cab category 1 per EN 15695-1:2009.
The operator cab does not provide protection against Figure 10-20-2
hazardous substances. Do not use this machine under
conditions requiring protection against hazardous
substances.
WARNING 1
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Massey Ferguson. Do not
operate without right window. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in serious injury or P126565
death.
W-2906-MF-0211
The cab door can be opened from the outside of the cab
using the latch (Item 1) [Figure 10-20-1] and opened
from the inside of the cab when you push the lever (Item
1) [Figure 10-20-2] (as shown).
The cab door can be locked (Item 2) [Figure 10-20-1]

with the same key as the starter switch.
TH.6534(X) / TH.7035(X) / TH.7038(X)

OPERATOR CAB (CONT’D) Figure 10-20-5
Cab Door Window
Figure 10-20-3
1
S38163
Turn the handle (Item 1) [Figure 10-20-5] back into the

S38163 original position (as shown) to lock the window.
Figure 10-20-6
Turn the handle (Item 1) [Figure 10-20-3] (as shown) to
unlock the window. Push the window fully open until it
latches against the cab.
Figure 10-20-4
1 1
S38385
The handle (Item 1) [Figure 10-20-6] can also be used to

fixate the window in a partly open position.
S38164
Push the knob (Item 1) [Figure 10-20-4] inside the cab to

disengage the latch and close the window.
TH.6534(X) / TH.7035(X) / TH.7038(X)

OPERATOR CAB (CONT’D) Cab Light
Rear Cab Window Figure 10-20-9
Figure 10-20-7
1
2
1
1
S38912
S38910
The cab light [Figure 10-20-9] is located above the
operator’s right shoulder.
Turn the handle (Item 1) [Figure 10-20-7] (as shown) to
unlock the rear window. Move the lens to the left or the right (Item 1) to turn the
light ON. Move the lens to the centre position (Item 2)
Figure 10-20-8 [Figure 10-20-9] to turn the light OFF.
S38911
Push the rear window open until the handle lock (Item 1)
[Figure 10-20-8] is locked in the open position (as
shown).
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
TRANSPORTING THE TELESCOPIC HANDLER ON A Fastening
TRAILER
Figure 10-30-2
Loading And Unloading
Figure 10-30-1
3
2
4
1 1
EM7143
1 P126549 Fasten the telescopic handler to the transport vehicle to

prevent it from moving during sudden stops or when
going up or down slopes.
The telescopic handler must be loaded backward on the
trailer. • Block the wheels (Item 1) [Figure 10-30-2].
The rear of the trailer must be blocked or supported • Use chains to fasten the machine frame to the
(Item 1) [Figure 10-30-1] when loading or unloading the transport vehicle (Items 2 and 3) [Figure 10-30-2].
telescopic handler to prevent the front end of the trailer Use chain binders to tighten the chains.
from raising up.
• Attach the forks or bucket attachment to the transport
Be sure the transport and towing vehicles are of vehicle (Item 4) [Figure 10-30-2].
adequate size and capacity. For the weight of the
TH.6534(X) telescopic handler, (See Weights on Page
SPEC-10-2.), for the weight of the TH.7035(X) telescopic
handler, (See Weights on Page SPEC-10-11.) and for the
weight of the TH.7038(X) telescopic handler, (See
Weights on Page SPEC-10-20.)
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
TOWING THE TELESCOPIC HANDLER Figure 10-40-1
Procedure
The telescopic handler can be towed a short distance

such as removing it from mud or loading onto a transport
vehicle. 1
Tow the telescopic handler at a slow speed, not

exceeding 5 km/h (3 mph). Do not tow the machine for
more than 3 minutes.
WARNING S38174
UNEXPECTED MACHINE MOVEMENT CAN CAUSE

SERIOUS INJURY OR DEATH Remove the cap (Item 1) [Figure 10-40-1]. The cap can
• Block wheels to prevent roll away before be accessed from the underside of the machine, through
adjusting screws to bypass the park brake the oval hole (Item 1) [Figure 10-40-2].
system.
• Return adjustment screws to the operating
position before operating the machine.
W-2808-0909
Block the wheels to prevent the machine from rolling.
Disengaging The Parking Brake Pads
The parking brake is engaged by spring pressure and

released by hydraulic pressure. The parking brake must
be released manually before towing.
The following procedure describes how to disengage the

parking brake pads:
Release the parking brake. (See Operation &

Maintenance Manual.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TOWING THE TELESCOPIC HANDLER (CONT’D) Disengaging The Transmission
Procedure (Cont’d) Raise the engine cover.

Figure 10-40-4
Figure 10-40-2
1
1
P129294
S39411
Turn the tow valve (optional) counterclockwise 90° (Item

Figure 10-40-3 1) [Figure 10-40-4] to TOWING position.
This action will bypass the oil flow of the hydrostatic
transmission.
Tow the telescopic handler at a slow speed, not
exceeding 5 km/h (3 mph). Do not tow the machine for
more than three minutes.
1 Engaging The Transmission
S38175
WARNING
1
S38173 SERIOUS INJURY OR DEATH
• Block wheels to prevent roll away before
Turn the adjustment screw (Item 1) [Figure 10-40-3] adjusting screws to bypass the park brake
counterclockwise until the brake pads no longer make system.
contact with the brake disc. • Return adjustment screws to the operating
The parking brake is released manually now for towing W-2808-0909
the machine.
After towing is completed, block the wheels to prevent the
NOTE: The parking brake will not work until the machine from rolling.
adjustment screw is returned to the original
Raise the engine cover.
position.
Turn the tow valve (optional) (Item 1) [Figure 10-40-4]
clockwise 90° to the OPERATING POSITION.
Engage the parking brake pads. (See Engaging The
Parking Brake Pads on Page 10-40-3.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TOWING THE TELESCOPIC HANDLER (CONT’D) Towing Points
Procedure (Cont’d) Figure 10-40-6
Engaging The Parking Brake Pads
WARNING
SERIOUS INJURY OR DEATH 1
adjusting screws to bypass the park brake
system.
W-2808-0909 S41320MF
Block the wheels to prevent the machine from rolling. Figure 10-40-7
Figure 10-40-5
1
1
1 S41322
S38173
S38175 If the telescopic handler is equipped with a front hitch
(Item 1) [Figure 10-40-6], this must be used for towing.
NOTE: Before re-engaging the parking brake pads,
make sure the parking brake is released. (See Without the front hitch, use the two front lifting points
Operation & Maintenance Manual.) (Item 1) [Figure 10-40-7] for towing.
Turn the adjustment screw (Item 1) [Figure 10-40-5]

clockwise until the parking brake pads make contact with
the brake disc.
Turn the adjustment screw counterclockwise for 180°.
Engage the parking brake (See Operation &

Maintenance Manual.) and make sure it functions
correctly (the engagement between the parking brake
pads and the brake disc prevents the machine from
moving).
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
SERVICE SCHEDULE
Maintenance Intervals
Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early
failures.
WARNING
AVOID INJURY OR DEATH
The service schedule is a guide for correct maintenance Instructions are necessary before operating or
of the Massey Ferguson telescopic handler. servicing machine. Read and understand the
Operation & Maintenance Manual and signs (decals)
on machine. Follow warnings and instructions in the
manuals when making repairs, adjustments or
servicing. Check for correct function after
adjustments, repairs or service. Untrained operators
and failure to follow instructions can cause injury or
death.
W-2975-0413
Every 10 Hours (Before Starting The Telescopic Handler)
• Engine Oil - Check level and add as needed. Do not overfill. Check engine for oil leaks. (See Checking And Adding
Engine Oil on Page 10-90-1.)
• Engine Air Filters and Air System - Check condition indicator and empty dust cup as needed. Check for leaks. (See
AIR CLEANER SERVICE on Page 10-60-1.)
• Engine Cooling System - Check oil cooler, radiator and air conditioner condenser. Check coolant level cold in
reservoir. Add premixed coolant as necessary. Check cooling system for leaks. (See ENGINE COOLING SYSTEM
on Page 10-70-1.)
• Exhaust System - Check exhaust system and exhaust after-treatment components for leaks.
• Hydraulic Fluid - Check fluid level and add as needed. (See Checking And Adding Fluid on Page 10-100-1.)
• Fuel Filter - Check display panel. Remove the trapped water. (See Fuel Filter on Page 10-80-2.)
• Seat Belt - Check the condition of seat belt. Clean or replace seat belt retractors as needed. Clean dirt and debris
from moving parts. (See Operation & Maintenance Manual.)
• Back-up Alarm - Check for proper function. Service as necessary. (See Operation & Maintenance Manual.)
• Service Brakes - Check for function. Service as necessary. (See SERVICE BRAKE on Page 40-80-1.)
• Parking Brakes - Check for function. Adjust or service as necessary. (See PARKING BRAKE on Page 40-50-1.)
• Tires - Check for wear or damage. Inflate to correct pressure. Be sure all tires are inflated to the same pressure. Use
only approved tires. (See Pressure on Page 10-140-2.)
• Wheel Nuts - Perform every 8 hours or daily for the first week, then as scheduled. Check for loose wheel nuts and
tighten to correct torque. (See Wheel Nuts on Page 10-140-1.)
• Safety Signs and Safety Treads and Mirrors - Check for damaged signs (decals), safety treads and mirrors. Replace
any signs, safety treads or mirrors that are damaged or worn. (See Operation & Maintenance Manual.)
• Tilt Cylinder Rod End - Lubricate with multi-purpose lithium based grease. (See Lubrication Locations on Page 10-
120-1.)
• Attachment Carrier Pins - Lubricate with multi-purpose lithium based grease. (See Lubrication Locations on Page
10-120-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
Every 50 Hours
• Fuel Filter - Replace filter the first time, then as scheduled. (See Fuel Filter on Page 10-80-2.)
• Engine Cooling System - Clean debris from radiator, air cooler, hydraulic fluid cooler, air conditioning condenser (if
equipped), and grille. (See Cleaning on Page 10-70-1.)
• Engine Oil and Filter - Replace oil and filter the first time, then as scheduled. (See Removing And Replacing Oil And
Filter on Page 10-90-2.)
• Hydraulic / Hydrostatic Fluid Filters- Replace the three filter elements (TH.6534(X) and TH.7038(X)) or two filter
elements (TH.7035(X)) the first time, then as scheduled. Use a genuine Massey Ferguson filter. (See HYDRAULIC /
HYDROSTATIC SYSTEM on Page 10-100-1.)
• Air Conditioning Belt (if equipped) - Check condition. Replace as needed. (See Belt Replacement on Page 80-20-
2.)
• Articulation Pins, Axle Oscillation (Front/Rear), Boom Pivot, Lift Cylinder, Levelling Cylinder - Lubricate with
multi-purpose lithium based grease. (See Lubrication Locations on Page 10-120-1.)
• Telescopic Boom Wear Pads - Lubricate with multi-purpose lithium based grease. (See Lubrication Locations on
Page 10-120-1.)
• Hydraulic Hoses, Tubelines and Connections - Check for leaks. Repair or replace as needed.
• Harnesses - Check condition. Repair or replace as needed.
Every 100 Hours
• LLMC System - Test the LLMC calibration the first time, then as scheduled. (See LLMC Calibration Test on Page 60-
180-5.)
• Wheel Nuts - Check for loose wheel nuts and tighten to correct torque. (See Wheel Nuts on Page 10-140-1.)
• Planetary Carriers - Replace the fluid the first time, then as scheduled. (See AXLES (FRONT AND REAR) on Page
10-110-1.)
• Axle and Differential Fluid- Replace the fluid the first time, then as scheduled. (See AXLES (FRONT AND REAR)
on Page 10-110-1.)
• Gear Box Fluid - Check level. Replace the fluid the first time, then as scheduled. (See AXLES (FRONT AND REAR)
on Page 10-110-1.)
Every 250 Hours Or Every 12 Months
• LLMC System - Test the LLMC calibration. (See LLMC Calibration Test on Page 60-180-5.)
• Planetary Carriers - Check level. (See AXLES (FRONT AND REAR) on Page 10-110-1.)
• Axle and Differential Fluid - Check level. (See AXLES (FRONT AND REAR) on Page 10-110-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
• Fuel Filter - Clean and check filter. (See Fuel Filter on Page 10-80-2.)
• Engine Oil and Filter - Replace oil and filter. (See Removing And Replacing Oil And Filter on Page 10-90-2.)
• Engine Cooling System - Check coolant concentration (with a refractometer). Replace as needed. (See Removing
And Replacing The Coolant on Page 10-70-3.)
• Air Conditioning Belt (if equipped) - Check condition. Replace as needed. (See Belt Replacement on Page 80-20-
2.)
• Hydraulic / Hydrostatic Fluid Filters - Replace the three filter elements (TH.6534(X) and TH.7038(X)) or two filter
elements (TH.7035(X)). Use a genuine Massey Ferguson filter. (See HYDRAULIC / HYDROSTATIC SYSTEM on
Page 10-100-1.)
• Hydraulic Tank Breather - Replace the hydraulic tank breather. (See Fill / Breather Cap on Page 10-100-6.)
• Axle and Differential Fluid - Replace the fluid. Maximal service time is 800 hours. (See AXLES (FRONT AND REAR)
on Page 10-110-1.)
• Gear Box Fluid - Check level. (See Checking And Adding Oil (Gear Box) on Page 10-110-4.)
• Telescopic Boom Wear Pads - Check for wear. Replace as necessary. (See Removal And Installation on Page 50-
50-1.) and (See Removal And Installation on Page 50-51-1.)
• Service Brake Pedal Spring - Lubricate with multi-purpose lithium based grease.
• Cab Air Filter and Intake Pipes - Check filter condition. Replace as necessary. Check for damage. (See Filters on
Page 80-20-1.)
• Planetary Carriers - Replace the fluid. (See Removing And Replacing Oil (Planetary Carrier) on Page 10-110-1.)
• Axle and Differential Fluid - Replace the fluid. (See AXLES (FRONT AND REAR) on Page 10-110-1.)
• Battery and Cable Connectors - Check voltage. Check terminals for good contact and presence of protective grease.
(See Battery Maintenance on Page 60-20-1.)
• Engine Mounts - Tighten. Replace if damaged. (See Removal And Installation on Page 70-10-11.)
• Engine Air Filter - Replace the outer filter element. (See AIR CLEANER SERVICE on Page 10-60-1.)
• Charge Air Cooler - Check entry area.
• Alternator Belt - Check condition. Replace as needed. (See ALTERNATOR on Page 60-30-1.)
• Hydraulic Fluid - Replace the fluid. (See Removing And Replacing Hydraulic Fluid on Page 10-100-2.)
• Gear Box Fluid - Replace the fluid. (See Removing And Replacing Oil (Gear Box) on Page 10-110-4.)
• Fastenings, Hose Unions and Clips - Replace if damaged.
• Oil Separator Filter - Replace the oil separator filter. (See Removing And Replacing Oil Separator Filter (TH.6534(X)
And TH.7038(X) Only) on Page 10-90-3.)
Every 3000 Hours
• Alternator Belt - Replace the belt. (See Belt Replacement on Page 60-30-2.)
Every 3000 Hours Or Every 3 Years
• Diesel Exhaust Fluid (DEF) / AdBlue® Filter - Replace the diesel exhaust fluid (DEF) / AdBlue® filter. (See Supply
Module Filter Removal And Installation on Page 70-110-5.)
Every 24 Months
• Coolant - Replace the coolant. (See Removing And Replacing The Coolant on Page 10-70-3.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
AIR CLEANER SERVICE Install new outer filter. Push in until the filter contacts the
back of the housing.
Replacing Filter Elements (TH.7035(X))
Install the cover (Item 2) and secure the latches (Item 1)
Replace the inner filter every second time the outer filter [Figure 10-60-1].
is replaced or as indicated. (See SERVICE SCHEDULE
on Page 10-50-1.) NOTE: The rubber boot attached to the air cleaner
cover is an important part of the engine
Outer Filter cooling system and must remain correctly
installed on the air cleaner cover.
Stop the engine and open the engine cover. (See
Opening And Closing on Page 10-160-1.) Close the engine cover. (See Opening And Closing on
Page 10-160-1.)
Figure 10-60-1
P125324
Open the latches (Item 1) and remove the cover (Item 2)

[Figure 10-60-1].
Figure 10-60-2
P125325
Pull the outer filter element (Item 1) [Figure 10-60-2] out

and discard.
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
Clean the surfaces with a clean damp cloth.
Do NOT use compressed air.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AIR CLEANER SERVICE (CONT’D) Figure 10-60-4
Replacing Filter Elements (TH.7035(X)) (Cont’d)
Secondary Filter
1
Replace the inner filter element every second time the
outer filter is replaced.
2
Opening And Closing on Page 10-160-1.)
Remove the cover (Item 2) [Figure 10-60-1] and the

outer filter (Item 1) [Figure 10-60-2].
Figure 10-60-3 P125324

[Figure 10-60-4].
1 NOTE: The rubber boot attached to the air cleaner

cooling system and must remain correctly
Close the engine cover. (See Opening And Closing on

Page 10-160-1.)
P125323
Remove the inner filter (Item 1) [Figure 10-60-3].

Install new inner filter. Push in until the filter contacts the
Install the outer filter (Item 1) [Figure 10-60-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

AIR CLEANER SERVICE (CONT’D) NOTE: Make sure the filter housing is free of dirt and
Replacing Filter Elements (TH.6534(X) And Clean the surfaces with a clean damp cloth.
TH.7038(X)) Do NOT use compressed air.
Replace the inner filter every second time the outer filter Install new outer filter. Push in until the filter contacts the
is replaced or as indicated. (See SERVICE SCHEDULE back of the housing.
on Page 10-50-1.)
Outer Filter [Figure 10-60-5].
Stop the engine and open the engine cover. (See NOTE: The rubber boot attached to the air cleaner
Opening And Closing on Page 10-160-1.) cover is an important part of the engine
Figure 10-60-5 installed on the air cleaner cover.

Page 10-160-1.)
1
1 P125321
Open the latches (Item 1) and remove the cover (Item 2)

[Figure 10-60-5].
Figure 10-60-6
P125322
Pull the outer filter element (Item 1) [Figure 10-60-6] out

and discard.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AIR CLEANER SERVICE (CONT’D) Figure 10-60-8
Replacing Filter Elements (TH.6534(X) And

TH.7038(X)) (Cont’d)
2
Secondary Filter
Replace the inner filter element every second time the

outer filter is replaced.
1
Remove the cover (Item 2) [Figure 10-60-5] and the

outer filter (Item 1) [Figure 10-60-6].
2 P125321
Figure 10-60-7

[Figure 10-60-4].
NOTE: The rubber boot attached to the air cleaner

1

Page 10-160-1.)
P125320
Remove the inner filter (Item 1) [Figure 10-60-7].

Install new inner filter. Push in until the filter contacts the
Install the outer filter (Item 1) [Figure 10-60-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM Figure 10-70-2
Check the cooling system every day to prevent over-
heating, loss of performance or engine damage.
Cleaning
Stop the engine and open the engine cover. (See 1

Remove the plug.

2
Figure 10-70-1
P123745
Raise the condenser (Item 1) (if equipped) and keep in

position by installing the rod (Item 2) [Figure 10-70-2] in
the condenser mount.
1 Use low air pressure or water pressure to clean the top of

the cooler. Be careful not to damage fins.
NOTE: The cooler is a combined radiator, intercooler

and hydraulic fluid cooler.
P123744
NOTE: When cleaning with water, Do NOT aim the

Loosen the bolt (Item 1) [Figure 10-70-1]. waterjet directly toward the battery.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM (CONT’D)
Checking Level
Stop the engine and allow the engine to cool. Open the
IMPORTANT
engine cover. (See Opening And Closing on Page 10-
160-1.) AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Figure 10-70-3
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
1 Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
P123759
Check coolant level using the level markers (Item 1)

[Figure 10-70-3] on the tank. Coolant must be between
MIN and MAX level markers when the engine is cold.
NOTE: Always check coolant level before operating

the machine. Lack of engine coolant will
result in engine damage.
NOTE: The cooling system is factory filled with

ethylene glycol (EG) coolant. DO NOT mix
ethylene glycol with propylene glycol.
Use a refractometer to check the condition of ethylene

glycol in your cooling system.
Add premixed coolant to the reservoir if the coolant level

is low. (See Operation & Maintenance Manual.)
Close the engine cover.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM (CONT’D) Figure 10-70-5
Removing And Replacing The Coolant

1
See the SERVICE SCHEDULE for correct service
intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
Stop the engine. Open the engine cover. (See Opening

And Closing on Page 10-160-1.)
2
Figure 10-70-4
P123772
Loosen the collar (Item 1) and remove the hose (Item 2)

[Figure 10-70-5] from the radiator. Drain all of the
coolant into a container. Recycle or dispose of used
coolant in an environmentally safe manner.
Installation: Tighten the collar (Item 1) [Figure 10-70-5]

to 3 - 4 N•m (25 - 35 in-lb) torque.
P123759
Add premixed coolant to the coolant tank until the coolant
level reaches the MIN marker on the tank. Install the
When the engine is cool, remove the coolant fill cap coolant fill cap (Item 1) [Figure 10-70-4].
(Item 1) [Figure 10-70-4].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM (CONT’D)
Removing And Replacing The Coolant (Cont’d)
Follow these steps when using concentrated coolant

WARNING
instead of a ready-to-use premix:
Wear safety glasses to prevent eye injury when any
• Use a separate container to mix the coolant.
of the following conditions exist:
• When fluids are under pressure.
• The correct mixture proportions of coolant to provide
• Flying debris or loose material is present.
a -37°C (-34°F) freeze protection are 50% water and
• Engine is running.
50% ethylene glycol. For instance, to get 8 L OR
• Tools are being used.
2 U.S. gal of mixture, mix 4 L ethylene glycol with 4 L W-2019-0907
of water OR 1 U.S. gal ethylene glycol with 1 U.S. gal
of water.
• Add premixed coolant to the coolant tank until the

coolant level reaches the lower marker on the tank
(Item 1) [Figure 10-70-3].
Install the coolant fill cap (Item 1) [Figure 10-70-4].
NOTE: The coolant fill cap must be tightened until the

cap clicks.
Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level when cool. Add
coolant as needed. (See Checking Level on Page 10-70-
2.)

Page 10-160-1.)
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
U.S. Standard (ASTM D975)
• Biodiesel blend fuel is an excellent medium for
Use only clean, high quality diesel fuel, Grade Number microbial growth and contamination which can cause
2-D or Grade Number 1-D. corrosion and plugging of fuel system components.
• Use of biodiesel blend fuel can result in premature
Ultra low sulphur diesel fuel must be used in this failure of fuel system components, such as plugged
machine. Ultra low sulphur is defined as 15 mg/kg (15 fuel filters and deteriorated fuel lines.
ppm) sulphur maximum.
• Shorter maintenance intervals can be required, such
The following is one suggested blending guideline that as cleaning the fuel system and replacing fuel filters
should prevent fuel gelling during cold temperatures: and fuel lines.
• Using biodiesel blend fuel not compliant with the fuel
TEMPERATURE GRADE 2-D GRADE 1-D specifications and standard for approved fuels
Above -9°C (+15°F) 100% 0% described in this manual can affect engine life and
cause deterioration of hoses, tubelines, injectors,
Down to -21°C (-5°F) 50% 50% injector pump and seals.
Below -21°C (-5°F) 0% 100%
Apply the following guidelines if biodiesel blend fuel is
used:
NOTE: Biodiesel blend fuel may also be used in this
machine. Biodiesel blend fuel must contain
• Ensure the fuel tank is as full as possible at all times
no more than five percent biodiesel mixed
to prevent moisture from collecting in the fuel tank.
with ultra low sulphur petroleum based diesel.
This biodiesel blend fuel is commonly • Ensure that the fuel tank cap is securely tightened.
marketed as B5 blended diesel fuel. B5
blended diesel fuel must meet ASTM • Biodiesel blend fuel can damage painted surfaces,
specifications. remove all spilled fuel from painted surfaces
immediately.
E.U. Standard (EN590) • Drain all water from the fuel filter daily before
operating the machine.
Use only clean, high quality diesel fuel that meets the
EN590 specifications listed below: • Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Ultra low sulphur diesel fuel defined as 10 mg/kg (10 • Before machine storage; drain the fuel tank, refill with
ppm) sulphur maximum 100% petroleum based diesel fuel, add fuel stabiliser
and run the engine for at least 30 minutes.
• Diesel fuel with cetane number of 51.0 and above.
NOTE: Biodiesel blend fuel does not have long term
NOTE: Biodiesel blend fuel may also be used in this stability and should not be stored for more
machine. Biodiesel blend fuel must contain than three months.
no more than seven percent biodiesel mixed
with ultra low sulphur petroleum based diesel.
This biodiesel blend fuel is commonly
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL SYSTEM (CONT’D) Fuel Filter
Filling The Fuel Tank See the SERVICE SCHEDULE for the service interval
when to replace the fuel filter. (See SERVICE
SCHEDULE on Page 10-50-1.)
Removing Water
WARNING
Presence of water in the fuel system is displayed on the
AVOID INJURY OR DEATH display screen with an error code. (See Operation &
Stop and cool the engine before adding fuel. NO Maintenance Manual.)
SMOKING! Failure to obey warnings can cause an
explosion or fire. Stop the engine and open the engine cover.
W-2063-0807
Place a suitable container under the water separator in
Figure 10-80-1 order to catch any fuel that might spill. Clean up any
spilled fuel.
Figure 10-80-2
1
S40655
Remove the fuel fill cap (Item 1) [Figure 10-80-1]. P125140
Use a clean, approved safety container to add fuel of the

Loosen the drain (Item 1) [Figure 10-80-2] at the bottom
correct specifications. Add fuel only in an area that has
of the filter to remove trapped water from the filter.
free movement of air and no open flames or sparks. NO
SMOKING!
When clean fuel drains from the water separator, hand
tighten the drain valve (Item 1) [Figure 10-80-2].
Install and tighten the fuel fill cap [Figure 10-80-1].
Dispose of drained fluid in an environmentally safe
manner.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
IMPORTANT
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause AVOID ENGINE DAMAGE
explosion or fire. Water in the fuel system can cause serious engine
W-2103-0508 damage. Remove water from the primary fuel filter
daily.
I-2354-0112
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL SYSTEM (CONT’D) Loosen the clamps (Item 4) [Figure 10-80-4].
Fuel Filter (Cont’d) Remove the fuel filter element (Item 1) from the fuel filter
head (Item 3) [Figure 10-80-4].
Replacing Element
NOTE: Do NOT fill the new fuel filter element with fuel
Stop the engine and open the engine cover. at this time.
Place a suitable container under the water separator in Put clean oil on the two new fuel filter element O-rings,
order to catch any fuel that might spill. Clean up any install the element, and tighten to 14 N•m (10 ft-lb)
spilled fuel. torque.
Clean the outside of the filter / water separator. Install the fuel filter assembly into the clamps and tighten.
Connect the electrical connector (Item 2) [Figure 10-80-
Figure 10-80-3 4].
Remove air from the fuel system. (See Removing Air

From The Fuel System on Page 10-80-4.)
WARNING
2 1 sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
P125140

Loosen the drain (Item 1) [Figure 10-80-3] and allow the
fluid to spill into the container.
Start the engine and allow to operate for one minute.
When fuel stops draining from the water separator,
disconnect the connector (Item 2) [Figure 10-80-3].
Figure 10-80-4 WARNING

3 AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
1 death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
4 from a physician familiar with this injury.
W-2072-0807
Stop the engine and check for leaks at the filter.

2
P126666
Loosen the fuel filter head (Item 3) from the fuel filter
element (Item 1) [Figure 10-80-4]. Do NOT remove the
hoses from the fuel filter head.
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL SYSTEM (CONT’D)
Removing Air From The Fuel System

WARNING
After replacing the filter element or if the fuel tank has run
out of fuel, the air must be removed from the fuel system AVOID INJURY OR DEATH
before starting the engine. Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
WARNING W-2103-0508

death. Fluid leaks under pressure may not be visible.
from a physician familiar with this injury.
W-2072-0807
Figure 10-80-5
P126667
Open the air vent plug (Item 1) [Figure 10-80-5] on the

fuel filter assembly three full turns.
Squeeze the hand pump (priming bulb) (Item 2) [Figure

10-80-5] until fuel flows from the air vent plug with no air
bubbles.
Close the air vent plug (Item 1) [Figure 10-80-5].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-90-2

ENGINE OIL
Check the engine oil level every day before starting the RECOMMENDED SAE VISCOSITY NUMBER
engine for the work shift. (LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
Stop the engine.
Figure 10-90-1
TEMPERATURE RANGE ANTICIPATED BEFORE

NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CJ-4 OR BETTER, OR ACEA
P123757 E9 OR BETTER)
S41307
Massey Ferguson engine oils are recommended for use

Open the engine cover and remove the dipstick (Item 1) in this machine. If Massey Ferguson engine oil is not
[Figure 10-90-1]. available, use a good quality engine oil that meets API
Service Classification of CJ-4 or better, or ACEA E9 or
Keep the oil level between the marks on the dipstick better [Figure 10-90-2]. (See Specifications on Page
(Inset) [Figure 10-90-1]. Do not overfill. SPEC-50-1.) for approved oils.
WARNING WARNING
AVOID INJURY OR DEATH AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any Always clean up spilled fuel or oil. Keep heat, flames,
of the following conditions exist: sparks or lighted tobacco away from fuel and oil.
• When fluids are under pressure. Failure to use care around combustibles can cause
• Flying debris or loose material is present. explosion or fire.
• Engine is running. W-2103-0508
W-2019-0907
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE LUBRICATION SYSTEM (CONT’D) Install and tighten the oil drain cap (Item 1) [Figure 10-
90-4].
Removing And Replacing Oil And Filter
Figure 10-90-5
See the SERVICE SCHEDULE for correct service
interval for replacing the engine oil and filter. (See
SERVICE SCHEDULE on Page 10-50-1.)
2
Run the engine until it is at operating temperature. Stop
the engine.
1
Open the engine cover. (See Opening And Closing on
Page 10-160-1.)
Figure 10-90-3
2
P123770
1
Install the cover (Item 1) at the bottom of the frame using

2 the four bolts (Item 2) [Figure 10-90-5].
1
WARNING
P123770
Remove the four bolts (Item 1) and the cover (Item 2) • When fluids are under pressure.
[Figure 10-90-3] at the bottom of the frame. • Flying debris or loose material is present.
Figure 10-90-4 • Tools are being used.
W-2019-0907
P123771
Remove the oil drain cap (Item 1) [Figure 10-90-4].
Drain the oil into a container and recycle or dispose of

used oil in an environmentally safe manner.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE LUBRICATION SYSTEM (CONT’D) Put oil in the engine. For capacity, (See Fluid Capacities
on Page SPEC-10-5.) for the TH.6534(X) telescopic
Removing And Replacing Oil And Filter (Cont’d) handler, (See Fluid Capacities on Page SPEC-10-14.) for
the TH.7035(X) telescopic handler and (See Fluid
Figure 10-90-6 Capacities on Page SPEC-10-23.) for the TH.7038(X)
telescopic handler. For type, (See Engine Oil Chart on
Page 10-90-1.).
Install oil fill cap, start the engine and let it run for several
minutes.
Stop the engine, and check for leaks at the oil filter.
Add oil as needed if it is not at the top mark on the

1
dipstick. (See Checking And Adding Engine Oil on Page
10-90-1.)
P123757
WARNING
Place a suitable container under the oil filter (Item 1)
[Figure 10-90-6] in order to catch any oil that might spill. AVOID INJURY OR DEATH
Clean up any spilled oil. Always clean up spilled fuel or oil. Keep heat, flames,
Clean the filter housing surface and remove the oil filter Failure to use care around combustibles can cause
(Item 1) [Figure 10-90-6]. explosion or fire.
W-2103-0508
Put clean oil on the new filter gasket, install the filter and
hand tighten until the gasket contacts the surface, then Removing And Replacing Oil Separator Filter
an additional 1/2 - 3/4 turn. (TH.6534(X) And TH.7038(X) Only)
Figure 10-90-7 Figure 10-90-8
1
1
P126190
P125368
Remove the oil fill cap (Item 1) [Figure 10-90-7]. Remove the cap (Item 1) [Figure 10-90-8] by turning it
counterclockwise.
Remove and replace the filter.
Install the cap (Item 1) [Figure 10-90-8] by turning it

clockwise.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
HYDRAULIC / HYDROSTATIC SYSTEM Figure 10-100-3
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system. 4

(See Operation & Maintenance Manual.) 1
3
Completely retract and lower the boom.
Stop the machine on a level surface.

2
Stop the engine.
Oil must be at ambient temperature for this procedure.
Figure 10-100-1 S40582
Remove the fill / breather cap (Item 1) [Figure 10-100-3].
Add fluid until it is at the center of the sight gauge (Item 1)

[Figure 10-100-1].
Install the fill / breather cap (Item 1) [Figure 10-100-3].

1
Lift the washer (Item 2) against the nut (Item 3),
reposition the cover (Item 4) and tighten the nut (Item 3)
[Figure 10-100-3].
S38034
Check the fluid level at the sight gauge (Item 1) [Figure

WARNING
10-100-1].
Figure 10-100-2
explosion or fire.
W-2103-0508
2
S40581
Loosen the nut (Item 1) [Figure 10-100-2].
Rotate the cover (Item 2) [Figure 10-100-2] clockwise.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-100-4
Removing And Replacing Hydraulic Fluid
See the SERVICE SCHEDULE for the correct service

NOTE: The TH.6534(X) and TH.7038(X) machines are

equipped with a variable displacement piston
pump which is sensitive to cavitation. In order
to prevent damage the hydraulic fluid must be
bled after replacing the hydraulic fluid and/or
the hydraulic / hydrostatics filters. Contact
your Massey Ferguson Dealer to perform the
hydraulic fluid air bleeding procedure. 1
S38036
Replace the fluid if it becomes contaminated or after
major repair.
Remove the reservoir drain plug (Item 1) [Figure 10-100-
Always replace the hydraulic / hydrostatic filter whenever 4] behind the right front wheel and drain the fluid into a
the hydraulic fluid is replaced. (See Removing And container. Recycle or dispose of the fluid in an
Replacing Hydraulic / Hydrostatic Filters on Page 10-100- environmentally safe manner.
4.)
Put a new seal on the drain plug. Install the drain plug
(Item 1) [Figure 10-100-4] and tighten.
WARNING Figure 10-100-5

penetrate skin or eyes, causing serious injury or 2
Use a piece of cardboard or wood to find leaks. Do 1
from a doctor familiar with this injury.
W-2072-EN-0909
WARNING S40581
AVOID INJURY OR DEATH Loosen the nut (Item 1) [Figure 10-100-5].

sparks or lighted tobacco away from fuel and oil. Rotate the cover (Item 2) [Figure 10-100-5] clockwise.
explosion or fire.
W-2103-0508
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Fluid (Cont’d)
Figure 10-100-6
4
1
3
S40582
Remove the fill / breather cap (Item 1) [Figure 10-100-6].
Add fluid until it is at the center of the sight gauge (Item 2)

[Figure 10-100-4].
Reinstall the fill / breather cap (Item 1) [Figure 10-100-6].

[Figure 10-100-6].
WARNING
explosion or fire.
W-2103-0508
TH.6534(X) / TH.7035(X) / TH.7038(X)

Removing And Replacing Hydraulic / Hydrostatic TH.7035(X)

Filters

NOTE: The TH.6534(X) and TH.7038(X) machines are

equipped with a variable displacement piston 1
pump which is sensitive to cavitation. In order
to prevent damage the hydraulic fluid must be
bled after replacing the hydraulic fluid and/or
the hydraulic / hydrostatics filters. Contact
your Massey Ferguson Dealer to perform the
hydraulic fluid air bleeding procedure. S38038
Figure 10-100-7
Figure 10-100-10
TH.7035(X)
TH.6534(X) / TH.7038(X)
1 1
S38037
S40640
Figure 10-100-8
Remove the filter housing(s) (Item 1) [Figure 10-100-9]
TH.6534(X) / TH.7038(X) or [Figure 10-100-10].
WARNING
1 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
S38037
Remove the cover (Item 1) [Figure 10-100-7] or [Figure

10-100-8] at the bottom of the frame.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Removing And Replacing Hydraulic / Hydrostatic

Filters (Cont’d) WARNING
Figure 10-100-11
explosion or fire.
W-2103-0508
S38295MF
For TH.7035(X)
Remove the filter element (Item 1) [Figure 10-100-11]

and discard.
Install a new filter element ensuring that the element is

fully seated in the filter base.
Install the filter housing and hand tighten.
For TH.6534(X) And TH.7038(X)
Remove the filter element (Item 1) [Figure 10-100-11]

from both filter bases and discard.
For both filter bases, install a new filter element ensuring

that the element is fully seated in the filter base.
Install the filter housings and hand tighten.
For All Machines
Start the engine and let the engine run for one minute
(low idle) before operating the boom hydraulics.
Stop the engine and check for leaks at the filters. Check
the fluid level in the reservoir and add as needed. (See
Checking And Adding Fluid on Page 10-100-1.)
Install the cover.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Stop the engine and check for leaks at the filter. Check
the fluid level in the reservoir and add as needed. (See
Removing And Replacing Hydraulic Charge Filter Checking And Adding Fluid on Page 10-100-1.)
See the SERVICE SCHEDULE for the correct service Fill / Breather Cap
See the SERVICE SCHEDULE for the correct
Figure 10-100-12 replacement interval. (See SERVICE SCHEDULE on
Page 10-50-1.)
Figure 10-100-14
P125366
Place a suitable container below the filter housing and S40581

remove the filter housing (Item 1) [Figure 10-100-12]
using a socket wrench.
Loosen the nut (Item 1) [Figure 10-100-14].
Figure 10-100-13
Rotate the cover (Item 2) [Figure 10-100-14] clockwise.
Figure 10-100-15
4
1
3
1
P128050
Remove the filter element (Item 1) [Figure 10-100-13] S40582

and discard.
Install new filter element ensuring that element is fully Remove the fill / breather cap (Item 1) [Figure 10-100-
seated in the filter base. 15] and discard.
Install the filter housing and hand tighten.
Install the new fill / breather cap (Item 1) [Figure 10-100-
Start the engine and let the engine run for one minute 15].
(low idle) before operating the boom hydraulics.
[Figure 10-100-15].
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Tools
Hydraulic Fluid Air Bleeding Procedure (Only For Figure 10-100-17

TH.6534(X) And TH.7038(X))
7 6
Figure 10-100-16
1
5
2
1 4
3
8
S41036
S40786 A specific “hydraulic oil air bleeding field kit” P/N 6987774
[Figure 10-100-17] is required and contains:
TH.6534(X) and TH.7038(X) machines are equipped with • Diagnostic hose:

a variable displacement piston pump (Item 1) [Figure 10-
100-16] which is sensitive to cavitation. In order to
ITEM NR. QTY. P/N DESCRIPTION
prevent damage to the piston pump due to this cavitation,
the hydraulic fluid must be bled after different hydraulic 1 1 7025215 Female Coupler 3/8”
maintenance operations. 2 1 17KB0606 Fitting
NOTE: This is a mandatory action after various 3 1 7159331 Hose
hydraulic maintenance operations. 4 1 17KB0808 Fitting
5 1 6667805 Female Coupler 3/8”
• Bleed hose:
ITEM NR. QTY. P/N DESCRIPTION

6 1 7025215 Female Coupler 3/8”
7 1 15KB0606 Fitting
8 1 7159966 Hose
TH.6534(X) / TH.7035(X) / TH.7038(X)

Hydraulic Fluid Air Bleeding Procedure (Only For

TH.6534(X) And TH.7038(X)) (Cont’d)
Maintenance Items
Five maintenance cases are covered through three

different procedures.
CASE
DESCRIPTION COMMENTS PROCEDURE
NR.
1 Hydraulic / hydrostatic oil filter Service schedule operation to be done every 500 hours A
replacement (see Operation and Maintenance Manual)
2 Hydraulic / hydrostatic oil filter + Service schedule operation to be done every 1000 hours B
hydraulic oil replacement (tank) (see Operation and Maintenance Manual)
3 LS pump inlet maintenance In case of disassembly or replacement of components on B
work pump inlet line (LS accumulator, LS pump, hoses)
4 Hydrostatic system maintenance In case of disassembly or replacement of components on B
hydrostatic system (pump, motor, hose)
5 Workgroup maintenance In case of disassembly or replacement of components C
located after the main control valve (cylinders, steering,
axles, hoses,...)
NOTE: If several maintenance items are done at the Procedure A

same time, combine the procedures or
execute the most critical one. Procedure B is Replace the hydraulic / hydrostatic oil filters (Case Nr 1).
the most complete one.
Figure 10-100-18
Procedure
Refer to the telescopic handler Operation and

Maintenance Manual or Service Manual as necessary
2
for details of procedures outlined below.
3
NOTE: Before disassembling any components, wait
for at least ten minutes after the engine has 1
stopped. This is the time needed to let the LS
accumulator to discharge itself. There is no
high pressure risk, but it will prevent a large
amount of hydraulic oil loss.
S41542
Connect the diagnostic hose (Item 1) to the LS inlet

coupler (Item 2) and the charge pressure test coupler
(Item 3) [Figure 10-100-18].
NOTE: The diagnostic hose allows to directly supply

the LS pump inlet with hydraulic oil coming
from the charge pump.
TH.6534(X) / TH.7035(X) / TH.7038(X)


TH.6534(X) And TH.7038(X)) (Cont’d)
Procedure (Cont’d) 1
Procedure A (Cont’d)
Figure 10-100-19
1
S41545
Disconnect the connector C164 (engine stop) (Item 1)

[Figure 10-100-20].
NOTE: This allows you to only crank the engine and

run slowly on the starter, without really
starting the engine.
3
S41544 S41543
To fill the hydrostatic system for a first time, turn the start
key to crank the engine by using the starter until the
Connect the bleed hose to the coupler (Item 1) on the charge pressure reaches 15 - 18 bar (218 - 261 psi).
main control valve and route the other end of the hose
(Item 2) inside the hydraulic oil tank (Item 3) [Figure 10- NOTE: • For Case Nr 2 and Nr 3, running slowly for
100-19]. Make sure to reach the bottom of the tank. four seconds on the starter is enough to reach
the requested charge pressure.
NOTE: The bleed hose allows to bleed air from the LS
pump inlet line. • For Case Nr 4, it depends on the
maintenance operation and the amount of
Start the engine and let it run at low idle for two minutes. hydraulic oil lost during disassembly.
With the engine running at low idle, slowly (as slow as Connect the diagnostic hose (Item 1) to the LS inlet
possible) move the boom for four minutes. coupler (Item 2) and the charge pressure test coupler
(Item 3) [Figure 10-100-18].
Stop the engine, disconnect and remove the diagnostic
and bleed hoses.
Connect the bleed hose to the coupler (Item 1) on the
Procedure B main control valve and route the other end of the hose
(Item 2) inside the hydraulic oil tank (Item 3) [Figure 10-
Follow this procedure for the following three maintenance 100-19]. Make sure to reach the bottom of the tank.
items described in “Maintenance Items” on page
10-100-7: Turn the start key to crank the engine by using the starter
for fifteen seconds.
• Case Nr 2 and Nr 4: Hydrostatic system can be
partially filled or be out of hydraulic oil.
Re-connect the connector C164 (engine stop) (Item 1)
• Case Nr 3: LS pump inlet does not contain any [Figure 10-100-20] to the engine.
hydraulic oil.
Start the engine and let it run at low idle for two minutes.
In case of these situations, the impacted hydraulic circuit
needs to be bled and filled slowly. With the engine running at low idle, slowly (as slow as
possible) move the boom for four minutes.
Perform the required maintenance operation.
Stop the engine, disconnect and remove the diagnostic
Connect the pressure gauge (0-50 bar [0-1000 psi] and bleed hoses and disconnect the pressure gauge.
minimum) to the charge pressure test coupler.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Starter Procedure (Only For TH.6534(X) And
TH.7038(X))
TH.6534(X) And TH.7038(X)) (Cont’d) It is possible to keep the starter active without activating
the engine on models equipped with a piston pump.
Procedure (Cont’d)
NOTE: A Service Tool (See REMOTE START TOOL
Procedure C (SERVICE TOOL) KIT - 3975015M1 on Page 10-
220-1.) must be connected to the machine in
Follow this procedure for each maintenance operation order to perform this procedure.
(disassembly or replacement) on all components located
Figure 10-100-21
after the main control valve (Case Nr 5):
• Lift cylinder
• Extension cylinder
• Tilt cylinder
• Auxiliary circuit
• Steering and directional cylinders of axles
These maintenance operations create air inside the

2
impacted circuit. Perform this procedure to properly bleed
the complete circuit.
Perform the required maintenance operation.

1
Connect the diagnostic hose (Item 1) to the LS inlet P126567
coupler (Item 2) and the charge pressure test coupler
(Item 3) [Figure 10-100-18].
The Starter Key (Item 1) [Figure 10-100-21] is in the
OFF position.
Connect the bleed hose to the coupler (Item 1) on the
main control valve and route the other end of the hose Press the Emergency Stop button (Item 2) [Figure 10-
(Item 2) inside the hydraulic oil tank (Item 3) [Figure 10- 100-21] on the Instrument Panel.
100-19]. Make sure to reach the bottom of the tank.
Figure 10-100-22
Start the engine and let it run at low idle for two minutes.
NOTE: All following operations must be done with

the engine running at low idle.
1
With the engine running at low idle, slowly (as slow as
possible) operate the component on which the
2
maintenance operation was done for four seconds. Stop
for eight seconds, slowly (as slow as possible) operate
again for four seconds, stop for eight seconds.
Repeat this operation until two complete cycles (one

cycle = cylinder complete extension + cylinder complete
retraction) are performed on the impacted circuit. P-76439
If several circuits have been impacted, perform this

procedure for each affected circuit. Press the Run button (Item 1) [Figure 10-100-22] on the
Service Tool to power up the machine. [STOP] is
Slowly (as slow as possible) move the boom for four displayed on the Display.
minutes.
Press the Start button (Item 2) [Figure 10-100-22] on the
Stop the engine, disconnect and remove the diagnostic Service Tool.
and bleed hoses. The Starter will be controlled as long as the Start button
is pressed but the engine will not crank.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLES (FRONT AND REAR) Removing And Replacing Oil (Planetary Carrier)
Checking And Adding Oil (Planetary Carrier) See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.)
interval. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-110-2
Figure 10-110-1
1
1
S38040
S38039
Put the machine on a level surface with the plug (Item 1)
[Figure 10-110-2] positioned as shown.
Put the machine on a level surface with the plug (Item 1)
[Figure 10-110-1] positioned as shown. Remove the plug (Item 1) [Figure 10-110-2] and drain oil
into a container. Recycle or dispose of the used lubricant
Remove the plug (Item 1) [Figure 10-110-1]. The oil level in an environmentally safe manner.
should be at the bottom edge of the plug hole.
Reposition the plug hole as shown in [Figure 10-110-1]
Add oil through the hole if the oil level is below the hole. and add gear lube until the lube level is at the bottom
edge of the plug hole (Item 1) [Figure 10-110-1].
For oil capacity, (See Fluid Capacities on Page SPEC-10-
5.) for the TH.6534(X) telescopic handler, (See Fluid For oil capacity, (See Fluid Capacities on Page SPEC-10-
Capacities on Page SPEC-10-14.) for the TH.7035(X) 5.) for the TH.6534(X) telescopic handler, (See Fluid
telescopic handler and (See Fluid Capacities on Page Capacities on Page SPEC-10-14.) for the TH.7035(X)
SPEC-10-23.) for the TH.7038(X) telescopic handler. For telescopic handler and (See Fluid Capacities on Page
oil type, (See Engine Oil Chart on Page 10-90-1.). SPEC-10-23.) for the TH.7038(X) telescopic handler. For
oil type, (See Engine Oil Chart on Page 10-90-1.).
Install and tighten the plug to 35 - 50 N•m (26 - 37 ft-lb)
torque. Install and tighten the plug to 35 - 50 N•m (26 - 37 ft-lb)
torque.
Repeat the procedure for the other three planetary
carriers. Repeat the procedure for the other planetary carriers.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLES (FRONT AND REAR) (CONT’D) Removing And Replacing Oil (Rear Differential)
Checking And Adding Oil (Rear Differential) See the SERVICE SCHEDULE for the correct service
Figure 10-110-3
1 1
1
S38062
S38041
With the machine on a level surface remove the three
plugs (Item 1) [Figure 10-110-4] and drain oil into a
Put the machine on a level surface. container. Recycle or dispose of the used lubricant in an
environmentally safe manner.
Remove the plug (Item 1) [Figure 10-110-3]. The oil level
should be at the bottom edge of the plug hole. Install and tighten the plugs (Item 1) [Figure 10-110-4] to
35 - 50 N•m (26 - 37 ft-lb) torque.
Add oil through the hole if the oil level is below the hole.
Figure 10-110-5
5.) for the TH.6534(X) telescopic handler, (See Fluid
Capacities on Page SPEC-10-14.) for the TH.7035(X)
telescopic handler and (See Fluid Capacities on Page
SPEC-10-23.) for the TH.7038(X) telescopic handler. For
1
torque.
S38042
Add oil through the hole (Item 1) [Figure 10-110-5].


torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLES (FRONT AND REAR) (CONT’D) Removing And Replacing Oil (Front Differential)
Checking And Adding Oil (Front Differential) See the SERVICE SCHEDULE for the correct service
Figure 10-110-6
1 1
S38048
S38043
With the machine on a level surface remove the plugs
(Item 1) [Figure 10-110-8] and drain oil into a container.
Figure 10-110-7 Recycle or dispose of the used lubricant in an
environmentally safe manner.
Install and tighten the plugs (Item 1) [Figure 10-110-8] to

35 - 50 N•m (26 - 37 ft-lb) torque.
Add oil through the hole (Item 2) [Figure 10-110-8].

1 Capacities on Page SPEC-10-14.) for the TH.7035(X)
S38044 Install and tighten the plug to 35 - 50 N•m (26 - 37 ft-lb)

torque.
Remove the plugs (Item 1) [Figure 10-110-6] and
[Figure 10-110-7]. The oil level should be at the bottom
edge of the plug hole.
Add oil through the hole if the oil level is below the hole.


torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLES (FRONT AND REAR) (CONT’D) Removing And Replacing Oil (Gear Box)
Checking And Adding Oil (Gear Box) See the SERVICE SCHEDULE for the correct service
Figure 10-110-9
2
1
2
S38045
S38097
S38098
With the machine on a level surface, remove the plug
(Item 2) [Figure 10-110-10] and drain oil into a container.
Remove the plug (Item 1) [Figure 10-110-9]. The oil level Recycle or dispose of the used lubricant in an
should be at the bottom edge of the plug hole. environmentally safe manner.
Add oil through the hole if the oil level is below the hole. Install and tighten the plug (Item 2) [Figure 10-110-10].
For oil capacity, (See Fluid Capacities on Page SPEC-10- Remove the plug (Item 1) [Figure 10-110-9] and [Figure
5.) for the TH.6534(X) telescopic handler, (See Fluid 10-110-10] and add oil through the hole.
telescopic handler and (See Fluid Capacities on Page For oil capacity, (See Fluid Capacities on Page SPEC-10-
SPEC-10-23.) for the TH.7038(X) telescopic handler. For 5.) for the TH.6534(X) telescopic handler, (See Fluid
oil type, (See Engine Oil Chart on Page 10-90-1.). Capacities on Page SPEC-10-14.) for the TH.7035(X)
Install and tighten the plug. SPEC-10-23.) for the TH.7038(X) telescopic handler. For
Install and tighten the plug (Item 1) [Figure 10-110-9]

and [Figure 10-110-10].
TH.6534(X) / TH.7035(X) / TH.7038(X)

LUBRICATING THE TELESCOPIC HANDLER Axle Oscillation - Rear Axle (Item 1) [Figure 10-120-2].
Lubrication Locations Figure 10-120-3
Lubricate as specified in the SERVICE SCHEDULE for

the best performance of the machine. (See SERVICE
SCHEDULE on Page 10-50-1.)
Record the operating hours each time you lubricate so

that it is performed at the correct interval.
1 1
Always use a good quality lithium based multi-purpose
grease. Apply lubricant until extra grease shows. 2
Remove the attachment from the telescopic handler

before lubricating. (See Operation & Maintenance
Manual.)
S38100
Lubricate the following locations on the telescopic
handler:
Attachment carrier pins - Left and right (Item 1) [Figure
Figure 10-120-1 10-120-3].
Tilt Cylinder Rod End (Item 2) [Figure 10-120-3].
S38049
Axle Pivots - Top and bottom (Item 1) [Figure 10-120-1]

all four wheels.
Figure 10-120-2
S38063
TH.6534(X) / TH.7035(X) / TH.7038(X)

LUBRICATING THE TELESCOPIC HANDLER Figure 10-120-6
(CONT’D)
Lubrication Locations (Cont’d)
Figure 10-120-4
2
1
1
S38052
Lift Cylinder Base End (Item 1), Self Leveling Cylinder

Rod End (Item 2) [Figure 10-120-6].
S38101
Figure 10-120-7
Remove the front cover from the boom end. 1
Tilt Cylinder Base End (Item 1) [Figure 10-120-4].
Figure 10-120-5
2
1
S38102
Boom Pivot (Item 1) [Figure 10-120-7] (One Place).
S38051
NOTE: Raise the boom and install the approved

Boom Stop before lubricating the Lift and Self
Leveling Cylinders. (See Installing The
Approved Boom Stop on Page 10-150-1.)
Lift Cylinder Rod End (Item 1) and Pivot (Item 2) [Figure

10-120-5].
TH.6534(X) / TH.7035(X) / TH.7038(X)

LUBRICATING THE TELESCOPIC HANDLER Put the Travel Direction Control in NEUTRAL. (See
(CONT’D) Operation & Maintenance Manual.) Make sure the
parking brake is engaged. (See Operation &
Lubrication Locations (Cont’d) Maintenance Manual.) Stop the engine and exit the
telescopic handler. (See STOPPING THE ENGINE AND
Figure 10-120-8 LEAVING THE TELESCOPIC HANDLER on Page 10-
170-1.)
Remove the two bolts (Item 1) (both sides) and remove

the cover (Item 2) [Figure 10-120-9] from the back of the
boom.
Figure 10-120-10
S39099
Fully extend and lower the boom.
Put the Travel Direction Control in NEUTRAL. (See

Operation & Maintenance Manual.) Make sure the
parking brake is engaged. (See Operation &
S38930
Maintenance Manual.) Stop the engine and exit the
telescopic handler. (See STOPPING THE ENGINE AND
LEAVING THE TELESCOPIC HANDLER on Page 10- Use a brush to lubricate the inside of the fixed boom
170-1.) [Figure 10-120-10].
Use a brush to lubricate the outside of the inner boom

[Figure 10-120-8].
Figure 10-120-9
1 1
S39070
Fully extend and lower the boom.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
ATTACHMENT CARRIER Figure 10-130-3
Inspection And Maintenance
Figure 10-130-1
S40622
The telescopic handler attachment hydraulic locking pins

S38053 (if equipped) (Item 1) [Figure 10-130-3] (both sides)
must move freely. The pins must not be bent or the ends
deformed.
The attachment carrier mounting hooks (Item 1) [Figure
10-130-1] must not be damaged or worn. Inspect Figure 10-130-4
attachment carrier condition. Replace as needed.
Figure 10-130-2
1
1
S40623
S40622 The pins (if equipped) (both sides) must extend through
the holes in the attachment mounting frame (Item 1)
[Figure 10-130-4].
The stop plate (Item 1) [Figure 10-130-2] (both sides)
must not be damaged or worn. Inspect stop plate Lubricate the attachment carrier. (See SERVICE
condition. Replace as needed. SCHEDULE on Page 10-50-1.) (See LUBRICATING THE
TELESCOPIC HANDLER on Page 10-120-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
TIRE MAINTENANCE Wheel Replacement
Wheel Nuts Always park the machine on a level surface. STOP the
engine.
See the SERVICE SCHEDULE for the service interval to
check the wheel nuts. (See SERVICE SCHEDULE on
Page 10-50-1.)
WARNING
Figure 10-140-1
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
Front Wheels
Figure 10-140-2
S38099
The correct wheel nut tightening torque is 360 N•m (266

ft-lb) [Figure 10-140-1].
Rotating
Check the tires regularly for wear, damage and pressure.

For the correct tire pressure, (See Traction on Page
S39236
SPEC-10-4.) for the TH.6534(X) telescopic handler, (See
Traction on Page SPEC-10-13.) for the TH.7035(X)
telescopic handler and (See Traction on Page SPEC-10- Put the floor jack under the left side of the front axle. Lift
22.) for the TH.7038(X) telescopic handler. the telescopic handler and install the first jackstand
[Figure 10-140-2].
Rear tires usually wear faster than front tires. To keep the
wear even, move the front wheels to the rear and rear
wheels to the front.
It is important to keep the same size tires on each side of

the telescopic handler. If different sizes are used, each
tire will be turning at a different rate and cause excessive
wear. The tread bars of all the tires must face the same
direction.
Recommended tire pressure must be maintained to avoid

excessive tire wear and loss of stability and handling
capacity. Check for the correct pressure before operating
the telescopic handler.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TIRE MAINTENANCE (CONT’D) Mounting
Wheel Replacement (Cont’d) To change the size of the tires, contact your Massey
Ferguson dealer.
Figure 10-140-3
Tires are to be repaired only by an authorized person
using the correct procedures and type of equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and

cause serious injury or death.
During inflation of the tire, check the tire pressure

frequently to avoid over inflation.
S39237
Pressure
Put the floor jack under the right side of the front axle. Lift
the telescopic handler and install the second jackstand For the correct tire pressure, (See Traction on Page
[Figure 10-140-3]. SPEC-10-4.) for the TH.6534(X) telescopic handler, (See
Traction on Page SPEC-10-13.) for the TH.7035(X)
Remove the eight wheel nuts and replace the wheel. telescopic handler and (See Traction on Page SPEC-10-
Install the wheel nuts and tighten using a crisscross 22.) for the TH.7038(X) telescopic handler.
pattern to 360 N•m (266 ft-lb) torque.
Rear Wheels

Do not inflate tyres above specified pressure. Failure
to use correct tyre mounting procedure can cause an
explosion which can result in injury or death.
W-2078-EN-0909
IMPORTANT
Inflate tyres to the MAXIMUM pressure shown on the
S38065 sidewall of the tyre. DO NOT mix brands of tyres
used on the same machine.
I-2057-EN-1010
Put the floor jack under the centre of the rear axle. Lift the
telescopic handler and install jackstands [Figure 10-140-
4].
Remove the eight wheel nuts and replace the wheel.

Install the wheel nuts and tighten using a crisscross
pattern to 360 N•m (266 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

APPROVED BOOM STOP Figure 10-150-2
If the boom is raised for service or maintenance, use the

following procedure to install and remove the approved
boom stop (if equipped).
Installing The Approved Boom Stop

1
• Put the telescopic handler on a flat, solid and level
surface.
1
• With the operator in the seat, the seat belt fastened, 2
travel direction switch / control lever (optional) in
neutral and the parking brake engaged, start the
engine, raise the boom and stop the engine.
S38006
Figure 10-150-1
• Install the pins (Item 1) and secure with lock pins

(Item 2) [Figure 10-150-2].
• Start the engine and lower the boom slowly [Figure

10-150-2] so that the boom stop is held securely.
1
Removing The Approved Boom Stop
• Start the engine and raise the boom. Stop the engine.
• Operating from the left back side of the machine,

remove the lock pins, pins and boom stop (Item 1)
[Figure 10-150-1].
S40674
• Reinstall the boom stop in the storage position

(Item 1) [Figure 10-150-1].
• Remove the boom stop (Item 1) [Figure 10-150-1]
from the storage position.
Figure 10-150-1
WARNING
Never work on a machine with the boom up unless
the boom is held by an approved boom stop. Failure
1 to use an approved boom stop can allow the boom to
drop and cause injury or death.
Service boom stop if damaged or if parts are
missing. Using a damaged boom stop or with
missing parts can cause boom to drop causing injury
or death.
W-2899-1210
S40664
• Install the boom stop (Item 1) [Figure 10-150-1]

operating from the left back side of the machine.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
ENGINE COVER
Opening And Closing
Figure 10-160-1
P123743
Push the button (Item 1) and pull the latch handle

(Item 2) [Figure 10-160-1] outward. Raise the engine
cover to provide access to the engine compartment for
maintenance.
NOTE: The engine cover can be locked.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
STOPPING THE ENGINE AND LEAVING THE
TELESCOPIC HANDLER
Procedure WARNING
• Stop the telescopic handler on solid, flat and level
ground. Before you exit the operator’s position:
• Put the Travel Direction Control and the Joystick
NOTE: Ensure the machine is parked safely, taking in neutral.
into consideration the surrounding traffic. • Engage the parking brake.
• Retract and lower the boom and attachment flat
• Put the Travel Direction Control in neutral. (See on the ground.
Operation & Maintenance Manual.) • Stop the engine.
W-2907-0211
• Ensure that the parking brake is engaged. (See

Operation & Maintenance Manual.)
Figure 10-170-1
S38907MF
• Retract and lower the boom and attachment flat on

the ground [Figure 10-170-1].
• Turn the key switch (if equipped) or start switch (if

equipped) to STOP and unfasten the seat belt.
• (Standard Key Panel) Remove the key from the

switch to prevent operation of the telescopic handler
by unauthorized personnel.
• Use grab handles, safety tread and steps when

getting off.
DO NOT JUMP.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
EMERGENCY EXIT Right Rear Window
Rear Window Tractor Homologated Telescopic Handlers are equipped

with a secondary emergency exit.
Open the rear window. (See Rear Cab Window on Page
10-20-3.) Figure 10-180-3
Figure 10-180-1
S38985
S38911
Remove the safety hammer (Item 1) [Figure 10-180-3]
from its holder behind the operator’s seat.
Pull the handle (Item 1) [Figure 10-180-1] inward (as
shown) and push the rear window fully open. Use the safety hammer to break the right rear window.
Figure 10-180-2 Exit through the right rear window opening.
Figure 10-180-4
S38169
7197819
Exit through the rear window opening [Figure 10-180-2].
NOTE: A decal illustrating this procedure is located

on the right rear window [Figure 10-180-4].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
TELESCOPIC HANDLER STORAGE AND RETURN TO Return To Service
SERVICE
After the Massey Ferguson telescopic handler has been
Storage in storage, it is necessary to follow a list of items to return
the telescopic handler to service.
Sometimes it can be necessary to store your Massey
Ferguson telescopic handler for an extend period of time. • Check the engine and hydraulic fluid levels; check
Below is a list of items to perform before storage. coolant level.
• Store the attachments in a dry protected shelter. • Install a fully charged battery.
• Thoroughly clean the telescopic handler including the • Remove grease from exposed cylinder rods.
engine compartment.
• Check all belt tensions.
• Lubricate the telescopic handler.
• Be sure all shields and guards are in place.
• Replace worn or damaged parts.
• Lubricate the telescopic handler.
• Park the telescopic handler in a dry protected shelter.
• Check tire inflation and remove blocks from under
• Lower the boom all the way and put the attachment (if frame.
equipped) flat on the ground.
• Remove cover from exhaust pipe opening.
• Check tire inflation and put blocks under the frame to
remove weight from the tires. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Put grease on any exposed cylinder rods. correct operation.
• Put fuel stabiliser in the fuel tank and run the engine • Operate machine, check for correct function.
a few minutes to circulate the stabiliser to the pump
and fuel injectors. • Stop the engine and check for leaks. Repair as
needed.
If biodiesel blend fuel has been used, perform the
following:
Drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabiliser and run the engine for at least
30 minutes.
• Drain and flush the cooling system. Refill with

premixed coolant.
• Replace all fluids and filters (engine, hydraulic /

hydrostatic).
• Replace air cleaner, heater and air conditioning filters.
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is

correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that it is in storage

condition.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
LIFTING THE TELESCOPIC HANDLER Take into account the position of the machine’s centre of
gravity:
Procedure
TH.6534(X):
Figure 10-200-3
WARNING 1637 mm 1651 mm
(64.5 in) (65.0 in)
• Before lifting, check fasteners on four point lift. 6561 DaN
• Never allow riders in the cab or bystanders within (14749 lbf)
5 m (15 ft) while lifting the machine.
W-2160-0910
3308 DaN 3253 DaN
(7436 lbf) (7313 lbf)
Before lifting: Remove all attachments, lower boom fully,

position wheels straight forward and stop the machine.
Attach the lift hooks to the following lifting points (Items 1)

[Figure 10-200-1] and [Figure 10-200-2]:
Figure 10-200-1 EM7129
TH.7035(X) And TH.7038(X):
Figure 10-200-4
1828 mm 1460 mm
(72.0 in) (57.5 in)
1
7433 DaN
(16711 lbf)
3362 DaN 4072 DaN
(7557 lbf) (9154 lbf)
S41322
Figure 10-200-2
EM7129
S38102
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-210-2
MEL1563
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps

are: 2
3
• MEL1563 - Remote Start Tool 1
• MEL1565 - Service Tool Harness Control
• MEL1566 - Service Tool Harness Communicator
(Computer Interface)
Figure 10-210-1
P16117
The Traction Lock switch (Item 1) [Figure 10-210-2] is

not used for this machine.
The Maximum Flow / Variable Flow switch (Item 2)

[Figure 10-210-2] is used to activate the auxiliary
hydraulics. Pressing the switch once will activate variable
flow. Pressing the switch again will activate maximum
flow. The switch will illuminate to indicate which flow rate
is active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
P16114 flow rate.
The Auxiliary Pressure Release switch (Item 3)

The remote start tool (Item 1) [Figure 10-210-1] is [Figure 10-210-2] is used to release hydraulic pressure
required when the service technician is checking the to the front and / or rear auxiliary couplers. To release
hydraulic / hydrostatic system. pressure: push and hold the switch for 3 seconds.
NOTE: With the engine running: pushing and holding

the Pressure Release switch will cause the
engine to stop in 3 seconds. To relieve the
pressure: continue to press the switch after
the engine has stopped.
TH.6534(X) / TH.7035(X) / TH.7038(X)

MEL1563 (CONT'D)
Service Tool Harness Control - MEL1565
Figure 10-210-3
1
1
S97029
Locate the ACD connector (Item 1) [Figure 10-210-5]

and remove the cap from the connector.
P16114
Connect the main connector of the Service Tool Harness
Control to the ACD connector (Item 1) [Figure 10-210-5].
The service tool harness control (Item 1) is used to
connect the Remote Start Tool (Item 2) [Figure 10-210- NOTE: To monitor, diagnose or load new software
3] to the electrical system on the telescopic handler. the Service PC must be connected to the
Remote Start Tool switch.
Connect the service tool harness control to the Remote
Start Tool.
Figure 10-210-4
S38026
Loosen the retainer screw (Item 1) and remove the fuse

box cover (Item 2) [Figure 10-210-4].
TH.6534(X) / TH.7035(X) / TH.7038(X)

REMOTE START TOOL (SERVICE TOOL) KIT -
MEL1563 (CONT'D)
Service Tool Harness Communicator - MEL1566
Figure 10-210-6
P16119
The service tool harness communicator (Item 1) is

required to connect the remote start tool to the Service
PC (Item 2) [Figure 10-210-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
3975015M1
2
Remote Start Tool (Service Tool) - 3975016M1

5 3
are:
Order from Massey Ferguson Parts P/N: 3975015M1 - 6 4

Remote Start Tool (Service Tool) Kit
Kit Includes:
1
• 3975016M1 - Remote Start Tool (Service Tool)
• 3975017M1 - Telescopic Handler Service Tool
Harness
P-76439
• 3975018M1 - Computer Service Tool Harness
• 3975019M1 - BOSS® Service Tool Harness
The Remote Start Tool (Service Tool) (Item 1)
Figure 10-220-1 [Figure 10-220-2] has five buttons.
The STOP button (Item 2) [Figure 10-220-2] is used to

stop the Remote Start Tool (Service Tool) from
communicating and stop the telescopic handler engine.
The RUN button (Item 3) [Figure 10-220-2] is used to

turn the Remote Start Tool (Service Tool) on and
activates the telescopic handler ignition power. The
button will illuminate to indicate the service tool is active.
1
The START button (Item 4) [Figure 10-220-2] is used to
start the telescopic handler engine.
The PARKING BRAKE button (Item 5) [Figure 10-220-2]

P-76678 is not used for this machine.
The auxiliary button (Item 6) [Figure 10-220-2] is used to

The remote start tool (Item 1) [Figure 10-220-1] is activate the auxiliary hydraulics. The button will illuminate
required when the service technician is checking the to indicate the auxiliary hydraulics are active. Pressing
hydraulic / hydrostatic system. the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.
TH.6534(X) / TH.7035(X) / TH.7038(X)

3975015M1 (CONT'D)
Telescopic Handler Service Tool Harness -

3975017M1
Figure 10-220-3
1
1
S97029
2
Locate the ACD connector (Item 1) [Figure 10-220-5]
and remove the cap from the connector.
P-76678
The telescopic handler service tool harness (Item 1) is

used to connect the remote start tool (service tool) (Item
2) [Figure 10-220-3] to the electrical system on the
telescopic handler.
Figure 10-220-4
S38026
Loosen the retainer screw (Item 1) and remove the fuse

box cover (Item 2) [Figure 10-220-4].
TH.6534(X) / TH.7035(X) / TH.7038(X)

3975015M1 (CONT'D)
Telescopic Handler Service Tool Harness -

3975017M1 (Cont’d)
Figure 10-220-6
2
S39238
Connect the main connector (Item 1) [Figure 10-220-6]

of the Service Tool Harness Control to the ACD
connector (Item 1) [Figure 10-220-5].
NOTE: The remote start tool connection harness has

two connectors (Item 1) and (Item 2). The
main connector (Item 1) [Figure 10-220-6] is
always used for connection to the engine
harness.
The second connector (Item 2) [Figure 10-220-

6] is used for ACD upgrades or attachment
operational diagnostics only. This connector
has a cap attached to it to prevent damage or
corrosion when not in use.
WARNING
• Lift and block the machine.
• Check that wheels are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2938-0612
TH.6534(X) / TH.7035(X) / TH.7038(X)

REMOTE START TOOL (SERVICE TOOL) KIT - Remote Start Procedure
3975015M1 (CONT'D)
Computer Service Tool Harness - 3975018M1

UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
1 With the 7-pin connector plugged into the machine
and Remote Start Tool RUN button not illuminated,
the engine can be started from the operator panel
inside the cab.
• Press the RUN button of the Remote Start Tool to
disconnect the operator panel from the start
circuit.
• Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
2 otherwise disable the starter before working in
the engine area.
P-76450
W-2661-1110
The computer service tool harness (Item 1) is required to The tool listed will be needed to do the following
connect remote start tool (service tool) to the Service PC procedure:
(Item 2) [Figure 10-220-7].
• 3975015M1 - Remote Start Tool (Service Tool) Kit
Figure 10-220-8
P-76450
The Remote Start Tool (Service Tool) (Item 1)

[Figure 10-220-8] is required when the service
technician needs to turn on the telescopic handler or
start the engine without entering the cab.
TH.6534(X) / TH.7035(X) / TH.7038(X)

3975015M1 (CONT'D)
Remote Start Procedure (Cont'd) 1
Figure 10-220-9
2
2 S39238
Connect the main connector (Item 1) [Figure 10-220-11]

of the Service Tool Harness Control to the ACD
S38026 connector (Item 1) [Figure 10-220-10].
NOTE: The remote start tool connection harness has

Loosen the retainer screw (Item 1) and remove the fuse two connectors (Item 1) and (Item 2). The
box cover (Item 2) [Figure 10-220-9]. main connector (Item 1) [Figure 10-220-11] is
always used for connection to the engine
Figure 10-220-10 harness.
The second connector (Item 2) [Figure 10-220-

11] is used for ACD upgrades or operational
diagnostics only. This connector has a cap
attached to it to prevent damage or corrosion
when not in use.
1
WARNING
• Lift and block the machine.
S97029
• Check that wheels are clear.
• Cab ignition must be in the “STOP” position to
Locate the ACD connector (Item 1) [Figure 10-220-10] start the engine with the Service Tool (if
and remove the cap from the connector. applicable).
• See machine Service Manual for more
instructions.
W-2938-0612
TH.6534(X) / TH.7035(X) / TH.7038(X)

3975015M1 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-220-12
2
1 2
5 3
6 4
P-76441
1
The gear icon with the left facing arrows (Item 1)

[Figure 10-220-13] will illuminate and blink when the
P-76439 RUN key is pressed and the telescopic handler is
communicating with the service tool.
The Remote Start Tool (Service Tool) (Item 1) The computer icon with the right facing arrows (Item 2)
[Figure 10-220-12] has five buttons. [Figure 10-220-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
The STOP button (Item 2) [Figure 10-220-12] is used to and from the computer.
stop the Remote Start Tool (Service Tool) from
communicating and stop the telescopic handler engine. NOTE: To relieve the pressure at the rear or
secondary front auxiliary, (if equipped) press
The RUN button (Item 3) [Figure 10-220-12] is used to the RUN button on the remote start tool. Then
turn the Remote Start Tool (Service Tool) on and press the auxiliary (AUX) hydraulics button on
activates the telescopic handler ignition power. The the remote start tool and move the AUXILIARY
button will illuminate to indicate the service tool is active. Hydraulic switch on the telescopic handler to
the right and left several times.
The START button (Item 4) [Figure 10-220-12] is used to
start the telescopic handler engine.
The PARKING BRAKE button (Item 5) [Figure 10-220-

12] is not used for this machine.
The auxiliary button (Item 6) [Figure 10-220-12] is used

to activate the auxiliary hydraulics. The button will
illuminate to indicate the auxiliary hydraulics are active.
Pressing the button a second time will turn the flow OFF.
The button is used when checking pressures and flow
rate.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10
SELF LEVELING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-7
SELF LEVELING CYLINDER (LOCK VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Cylinder Group Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Upper Tubeline Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
Extension Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Tubeline Tray Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
STEERING CYLINDER (FRONT / REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
GEAR CONTROL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6
TH.6534(X) / TH.7035(X) / TH.7038(X)

MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-3
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

PISTON PUMP (FOR TH.6534(X) AND TH.7038(X)) . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
GEAR PUMP (FOR TH.7035(X)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-1

FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Parts Identification (Single Speed Version) (Standard) . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Disassembly And Assembly (Single Speed Version) (Standard) . . . . . . . . . . . . . . 20-110-4
Parts Identification (Variable Speed Version) (Optional) . . . . . . . . . . . . . . . . . . . . . 20-110-7
Disassembly And Assembly (Variable Speed Version) (Optional) . . . . . . . . . . . . . 20-110-8
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Troubleshooting Chart (Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-2
Troubleshooting Chart (Control Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-6
Main Relief Valve Testing And Adjustment (Only For TH.7035(X)) . . . . . . . . . . . . . 20-140-7
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-8
Piston Pump Testing (Only For TH.6534(X) And TH.7038(X)) . . . . . . . . . . . . . . . . 20-140-9
Troubleshooting Chart (Piston Pump Testing) (Only For TH.6534(X) And TH.7038(X))
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-14
Servo Piston Testing (Only For TH.6534(X) And TH.7038(X)) . . . . . . . . . . . . . . . 20-140-17
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-18
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-20
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-21
End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-22
Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 20-140-23
Telescoping Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-140-27
Tilting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-31
Lifting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-35
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 20-140-39
TH.6534(X) / TH.7035(X) / TH.7038(X)

PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-2
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
Brake Accumulator Removal And Installation (If Equipped) . . . . . . . . . . . . . . . . . . 20-160-1
Gear Pump Accumulator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-160-2
FAN PUMP (ONLY FOR TH.6534(X) AND TH.7038(X)) . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
HYDRAULIC/HYDROSTATIC SCHEMATIC
TH.6534 (S/N B41R11001 – B41R99999)
TH.6534X (S/N B41S11001 – B41S99999)
TH.7035 (S/N B3ZZ11001 – B3ZZ99999)
TH.7035X (S/N B41111001 – B41199999)
TH.7038 (S/N B41211001 – B41299999)
TH.7038X (S/N B41311001 – B41399999)
(Printed OCTOBER 2016)
V-1633legend
ANTICAVITATION/WORK PORT RELIEF CHECK VALVE - Optional:

1 RESERVOIR: 24 RELIEF VALVE – Charge: 46 67
VALVE – Telescopic Cylinder – Base End: 20,6 kPa (0,26 bar) (2.9 psi)
Reservoir Capacity 59 L (15.6 U.S. gal) 2400 kPa (24 bar) (348 psi)
28000 kPa (280 bar) (4061 psi) SOLENOID ACTIVATED DIRECTIONAL
System Capacity 105 L (27.7 U.S. gal) RELIEF/REPLENISHING VALVE - HIGH
25 ANTICAVITATION/WORK PORT RELIEF 68 CONTROL VALVE (Optional) –
2 SIGHT GAUGE PRESSURE (2): 42000 kPa (420 bar) (6092 psi) 47 VALVE – Telescopic Cylinder – Rod End: Trailer Accumulator
3 FILTER – Hydraulic Suction 26 VARIABLE CAPACITY DISPLACEMENT 28000 kPa (280 bar) (4061 psi) ACCUMULATOR – Trailer (Optional):
69
BIDIRECTIONAL HYDROSTATIC PUMP LOAD SENSE BLEED VALVE: 1,0 L (0.264 gal) 2000 kPa (20 bar) (290 psi)
4 FILL CAP: With Filterr 48
27 CHARGE PUMP 1,4 L/m (0.37 gpm) SOLENOID ACTIVATED DIRECTIONAL
5 TEMPERATURE SWITCH 40,5 L/m (10.7 U.S. gpm) @ High Engine Idle 70 CONTROL VALVE (Optional) –
49 BRAKE VALVE: 6500 kPa (65 bar) (942 psi)
28 SERVO PISTON - Swash Plate Tractor Safety Valve
6 FILTER - Hydraulic 50 PRESSURE SWITCH – Brake 71 RELIEF VALVE – Trailer Brake:
7 SPRING LOADED CHECK VALVE: 29 PRESSURE SWITCH 13000 kPa (130 bar) (1885 psi)
340 kPa (3,4 bar) (49 psi) 51 RELIEF VALVE (2): SOLENOID ACTIVATED DIRECTIONAL
30 FACTORY FILL PORT 23500 kPa (235 bar) (3408 psi) 72
8 PRESSURE SWITCH CONTROL VALVE – Fan Reversing (Optional)
52 RELIEF VALVE:
SOLENOID ACTIVATED DIRECTIONAL FILTER – Charge - With By-Pass Valve: 73 PILOT ACTIVATED DIRECTIONAL
9 31 17500 kPa (175 bar) (2538 psi)
CONTROL VALVE – Defeat Valve 700 kPa (7,0 bar) (102 psi) CONTROL VALVE
53 ORIFICE - 1,2 mm (0.047 in)
SOLENOID ACTIVATED DIRECTIONAL 32 RELIEF VALVE: 25000 - 26000 kPa RELIEF VALVE:
10 74
CONTROL VALVE – MOTOR (250 - 260 bar) (3626 - 3770 psi) 54 TELESCOPIC CYLINDER LOCK VALVE: 23000 kPa (230 bar) (3335 psi)
DISPLACEMENT CONTROL SPOOL: 33 PRESSURE REDUCING VALVE: 14000 kPa (140 bar) (2031 psi) 75 GEAR PUMP - Fan
29000 kPa (290 bar) (4206 psi) TILT CYLINDER LOCK VALVE:
34 SOLENOID ACTIVATED DIRECTIONAL 55 76 PRIORITY VALVE – Fan / Trailer Brake
11 SHUTTLE VALVE - Drain CONTROL VALVE – Unload Valve: 28000 kPa (280 bar) (4061 psi)
56 SELF LEVELING CYLINDER LOC VALVE: 77 ORIFICE - 1,3 mm (0.05 in)
12 RELIEF VALVE: 1600 kPa (16 bar) (232 psi) 35 PRIORITY VALVE - Steering 25000 kPa (250 bar) (3626 psi)
78 FILTER
13 SERVO PISTON - Swash Plate 36 ORIFICE - 1,0 mm (0.039 in) 57 ACCUMULATOR - Suspension:
1,0 L (0.264 gal) 2000 kPa (20 bar) (290 psi) 79 ORIFICE - 0,6 mm (0.02 in)
VARIABLE CAPACITY DISPLACEMENT 37 ORIFICE - 1,3 mm (0.051 in)
14 ACCUMULATOR - Suspension:
BIDIRECTIONAL HYDROSTATIC MOTOR 58 80 ORIFICE - 0,75 mm (0.03 in)
38 ORIFICE - 1,2 mm (0.047 in) 1,0 L (0.264 gal) 5500 kPa (55 bar) (798 psi)
HYDRAULIC PUMP - Piston type
15 81 ACCUMULATOR: 0.75 L (0.019 gal)
190 L/m (50.2 U.S. gpm) @ High Engine Idle 59 ACCUMULATOR – Tilt / Self Levelling:
39 CHECK VALVE
0,075 L (0.2 gal) 5000 kPa (50 bar) (725 psi) 5000 kPa (50 bar) (725 psi)
16 DESTROKE PISTON 82 CHECK VALVE: 300 kPa (3,0 bar) (43 psi)
40 COMPENSATOR 60 ORIFICE - 0,6 mm (0.02 in)
17 NOT USED FOR THIS MODEL 83 ACCUMULATOR – LS: 11 L (2.9 gal)
41 SHUTTLE VALVE SOLENOID ACTIVATED DIRECTIONAL
TORQUE LIMITER - Electronic 61 84 CHECK VALVE: 20 kPa (0,2 bar) (2.9 psi)
18 CONTROL VALVE – Gear Box
42 ANTICAVITATION/WORK PORT RELIEF
62 CHECK VALVE: 34,5 kPa (0,35 bar) (5 psi) 85 POWER LIFT VALVE:
PILOT ACTIVATED CONTROL VALVE – VALVE – Boom Cylinder – Base End:
19 12000 kPa (120 bar) (1740 psi)
LS Primary: 1850 kPa (18,5 bar) (268 psi) 28000 kPa (280 bar) (4061 psi) SOLENOID ACTIVATED DIRECTIONAL
63 86 ORIFICE - 1,0 mm (0.39 in)
43 ANTICAVITATION/WORK PORT RELIEF CONTROL VALVE – Park Brake
20 PILOT ACTIVATED CONTROL VALVE – LS SOLENOID ACTIVATED DIRECTIONAL
VALVE – Boom Cylinder – Rod End: 64 SOLENOID ACTIVATED DIRECTIONAL 87
Secondary: 28000 kPa (280 bar) (4061 psi) CONTROL VALVE – Rear Auxiliary (Optional)
28000 kPa (280 bar) (4061 psi) CONTROL VALVE – Steering
21 ORIFICE (Crab/FWS/4WS) 88 SOLEENOID / PILOT ACTIVATED
44 ANTICAVITATION/WORK PORT RELIEF DIRECTIONAL CONTROL VALVE –
22 SOLENOID - Reverse Drive VALVE – Tilt Cylinder – Base End: 65 RELIEF VALVE: Front / Rear Auxiliary (Optional)
28000 kPa (280 bar) (4061 psi) 12000 kPa (120 bar) (1740 psi)
23 SOLENOID - Forward Drive 89 SOLENOID ACTIVATED DIRECTIONAL
ANTICAVITATION/WORK PORT RELIEF 66 FILTER WITH ORIFICE: 0,5 mm (0.019 in) CONTROL VALVE – Power QuickTach
45 VALVE – Tilt Cylinder – Rod End: (Optional)
28000 kPa (280 bar) (4061 psi) NOTE: Unless otherwise specified springs
Printed in U.S.A. have NO significant pressure value. V-1632 (10-27-16)
8 7 6 5 4 3 2 1
SUSPENSION
ACCUMULATOR
BOOM CYLINDER + SUSPENSION VALVE
LS P MAINVALVE
H H
T
C2 C1 ACC
M3
INVERSION FAN
MOTOR
(OPTIONAL)
B
LSC SELF LEVELING
(COMPENSATION)
CYLINDER
IN CHARGE
FILTER
C
COUPLER
MACHINE A TILT CYLINDER
FILL T
OUT
BYPASS VALVE
TRANSMISSION / TOW
D
(OPTIONAL) V2 V1
A1
HYDROSTATIC PUMP M4 F E M3 MA
G B1
SELF
G
LEVELING
ENGINE A VALVE
FORWARD P LS
DRIVE
TRACTOR
SAFETY
VALVE 2
1
3
FAN PUMP A2
min disp
2 3 A°
U EXTENSION CYLINDER POWER LIFT
VALVE
B2
REAR AUXILIARY DRAINED COUPLERS
B (OPTIONAL)
EF
REVERSE
CF DRIVE
S FEMALE
IN D LS PUMP - ELECTRONIC TORQUE CONTROL REAR AUX
M5 IN L1 L2 MB HYD HOOK
DIVERTER
F
INLET
F
VALVE
N B PRESSURE (OPTIONAL)
TRAILER SENSOR
BRAKE P COLD START
VALVE U BYPASS
OIL COOLER
A3
Y FEMALE
B2
B3 B1
P T A2
A1
C2
C1
L2 M4 M3 MOTOR HYDROSTATIC
MAIN OIL FILTER REAR COUPLERS

DRAIN TANK
A4 (OPTIONAL)
B A
B4 FRONT AUX / REAR OPTIONS

L R DIVERTER VALVE (OPTIONAL)
E A B
F D E C
A
E
Vg min
B
B A L V
REAR HOOK CYLINDER
(OPTIONAL)
PARK GEARBOX L1
BRAKE A B
n
T2
L MALE
V
MAIN OIL FILTER
HYDRAULIC
RESERVOIR DRAIN
MALE
TEMP
FEMALE
D
T LS P STEERING
UNIT 2 4
FRONT AUXILIARY
D
QUICKTACH PWR DRAINED COUPLERS
LOCK / UNLOCK BLOCK
VALVE
(OPTIONAL)
3 1
POWER QUICKTACH CYLINDER TRAILER BRAKE

(OPTIONAL) COUPLER
(OPTIONAL)
COLLECTOR BLOCK
TRAILER
A4 L4
ACCUMULATOR
(OPTIONAL)
B4 R4
C P
U C
LS 5
SERVICE BRAKE
2
(OPTIONAL)
T2
4 1
P
VALVE
ACCU
U
T
HYDRAULIC / HYDROSTATIC SCHEMATIC

P2
F
3
P
2
GEAR 2 GEAR 1
AXLE FRONT AXLE REAR

MF
P0 A3 B3 T4 T0 1
TH.6534 (S/N B41R11001 - B41R99999)

B
B
P
U GERMAN
TH.6534X (S/N B41S11001 - B41S99999)
ACCUMULATOR
(OPTIONAL)
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)

TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
A A
(PRINTED OCTOBER 2016)
7305418 (B)
Printed In Belgium
8 7 6 5 4 3 2 1
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
mc-2340
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
mc-2340
2
TH.6534(X) / TH.7035(X) / TH.7038(X)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
mc-2340
3
TH.6534(X) / TH.7035(X) / TH.7038(X)

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Massey Ferguson Service adjustments can cause injury or death.
Personnel only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
The hydraulic fluid temperature warning light comes ON when hydraulics are 1, 2
operating.
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine rpm. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct
2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. (See Specifications on Page SPEC-50-1.)
6. Using the machine for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Tightening Procedures
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
To tighten the hydraulic fittings, tubelines etc. (See

HYDRAULIC CONNECTION SPECIFICATIONS on Page
SPEC-40-1.) for the correct procedure and torque.
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
LIFT CYLINDER Figure 20-20-3
Removal And Installation
Figure 20-20-1
S38852
Support the lift cylinder using a cinch strap (Item 1)

[Figure 20-20-3].
S39207
Remove the roll pin (Item 2) [Figure 20-20-3].

Raise the boom and install on adequate stands [Figure
20-20-1]. Figure 20-20-4
Figure 20-20-2
1 2
S38853
S38851
Install a puller (Item 1) and remove the upper pivot pin
(Item 2) [Figure 20-20-4].
Position a wooden block (Item 1) [Figure 20-20-2] under
the lift and self leveling cylinders. Slowly loosen the cinch strap (Item 1) [Figure 20-20-3]
and lower the lift cylinder onto a block.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LIFT CYLINDER (CONT’D) Figure 20-20-7
Removal And Installation (Cont’d)
Figure 20-20-5
S38857
Lift and support the base end of the cylinder [Figure 20-
20-7].
S38854
Figure 20-20-8
Remove the two hoses (Item 1) [Figure 20-20-5] from

the lift lock on the lift cylinder.
2
NOTE: Mark all hoses for correct installation.
Figure 20-20-6
1 1
S38856
Remove the two nuts (Item 1) and the retainer bolt (Item
2) [Figure 20-20-8] from the lower pivot pin.
S38855
IMPORTANT
Remove the bolt and nut (Item 1) [Figure 20-20-6] and
separate the lift cylinder and self leveling cylinder. When repairing hydrostatic and hydraulic systems,
Installation: Tighten the nut (Item 1) [Figure 20-20-6] parts clean. Always use caps and plugs on hoses,
until contact with silent-block. Do not apply torque. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

LIFT CYLINDER (CONT’D)
Figure 20-20-9
S38858
Remove the lower pivot pin (Item 1) [Figure 20-20-9].
Lift and remove the lift cylinder from the machine.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LIFT CYLINDER (CONT'D)
Parts Identification
1. Housing
2. Bushing
3. Grease Fitting
4. Rod
5. Wear Ring 2
6. Seal 1 3
7. Set Screw
8. Piston
9. O-ring
10. Back-up Ring
11. Head Gland
12. Wiper 2
10
6
10
5 8
9 7
2 4
9
11
12
5
6
EM9675
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly
Figure 20-20-10
WARNING
immediately.
W-2145-0290
Figure 20-20-12
S38827
Use the following tools to disassemble the cylinders:
MEL1354 - Spanner Wrench

MEL1076 - Cylinder Wrench
Put the cylinder in a vise [Figure 20-20-10].
Figure 20-20-11 S39387
1 Carefully peen the two pinches (Item 1) [Figure 20-20-

12] in the head gland lock ring until flush.
2
S38828
Remove the four bolts (Item 1) and remove the lift lock
(Item 2) [Figure 20-20-11].
NOTE: Oil can still be under pressure. Equally loosen

the four bolts (Item 1) [Figure 20-20-11] to
allow residual oil pressure to escape.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LIFT CYLINDER (CONT'D) Figure 20-20-15
Disassembly (Cont'd)
Figure 20-20-13
P-29909
Put the rod end of the cylinder in a vise [Figure 20-20-

P-29906 15].
Figure 20-20-16
Heat the head gland (Item 1) [Figure 20-20-13].
Use a spanner wrench to loosen the head gland [Figure

20-20-13].
NOTE: Heating the head gland can damage the seals.

Always replace the seals. Heating is meant to
melt the Loctite® for ease of removal.
Figure 20-20-14
S39081
Support the cylinder rod on a wood block [Figure 20-20-

16].
P-29907
Remove the rod assembly (Item 1) [Figure 20-20-14]

from the housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-20-17
S39087
Remove the O-ring (Item 1) [Figure 20-20-19] from the

S39082 inside of the piston.
Figure 20-20-20
Remove the set screw (Item 1) [Figure 20-20-17].
Figure 20-20-18
1
S39084
S39083 Remove the two wear rings (Item 1) [Figure 20-20-20]

from the piston.
Heat the piston (Item 1) [Figure 20-20-18].
Loosen and remove the piston (Item 1) [Figure 20-20-18]

from the rod.
NOTE: Heating the piston can damage the seals.

Always replace the seals. Heating is meant to
melt the Loctite® for ease of removal.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-20-21 1
1 1
P-29918
Remove the head gland (Item 1) [Figure 20-20-23] from

S39085 the rod.
Remove the two back-up rings (Item 1) [Figure 20-20-

21].
Figure 20-20-22
S39086
Remove the seal (Item 1) [Figure 20-20-22].
TH.6534(X) / TH.7035(X) / TH.7038(X)

2 3
Figure 20-20-24
1 1
P-29921
2
Remove seal (Item 1), wear ring (Item 2) and wiper
P-29919
(Item 3) [Figure 20-20-26] from the head gland.
Remove the two O-rings (Item 1) and the back-up ring

(Item 2) [Figure 20-20-24] from the head gland.
Figure 20-20-25
P-29920
Remove the wear ring (Item 1) [Figure 20-20-25].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly
Use the following tools to assemble the cylinders:
MEL1354 - Spanner Wrench 1

MEL1033 - Rod Seal Installation Tool
Wash the cylinder parts in solvent and dry with

compressed air.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
P-29885
Lubricate all O-rings and seals with hydraulic fluid during
installation. Always use new O-rings and seals.
Install the center seal (Item 1) [Figure 20-20-29].
Figure 20-20-27
NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-20-27].
1
Figure 20-20-30
2
2
P-29884
1
Install the wiper (Item 1) and wear ring (Item 2) [Figure
20-20-27] in the head gland. P-29919
Figure 20-20-28
Install the back-up ring (Item 1) and two O-rings (Item 2)
[Figure 20-20-30].
1
P-29883
Install the wear ring (Item 1) [Figure 20-20-28].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
1 1
Figure 20-20-31
S39085
Install the two back-up rings (Item 1) [Figure 20-20-33].

P-29918
Figure 20-20-34
Install the head gland (Item 1) [Figure 20-20-31] onto the

rod.
Figure 20-20-32
1
S39084
Install the two wear rings (Item 1) [Figure 20-20-34].
S39086
Install the seal (Item 1) [Figure 20-20-32].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 20-20-35
S39092
Install the piston (Item 1) [Figure 20-20-37] onto the rod.

P-32047
Tighten the piston to 720 - 1080 N•m (530 - 797 ft-lb)
torque.
Clean off any old residue, and apply Loctite® #243 or
equivalent to the threads on the rod [Figure 20-20-35]. Figure 20-20-38
Figure 20-20-36
P-29887
S39087
Apply Loctite® #243 or equivalent to the set screw (Item
1) [Figure 20-20-38].
Install the O-ring (Item 1) [Figure 20-20-36] into the
inside of the piston.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd) 2
Figure 20-20-39
P-29907
Install the rod assembly (Item 1) [Figure 20-20-41] into

S39082 the housing.
Clean off any old residue, and apply Loctite® #262 to the
Install the set screw (Item 1) [Figure 20-20-39]. threads of the head (Item 2) [Figure 20-20-41].
Tighten the set screw to 20 N•m (15 ft-lb) torque. Figure 20-20-42
Figure 20-20-40
P-29925
S39082
Use the spanner wrench to tighten the head gland
[Figure 20-20-42].
Lock the set screw with a punch (Item 1) [Figure 20-20-
40] on the edge of the hole.
Tighten the head to 400 - 500 N•m (295 - 370 ft-lb)
torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 20-20-43
S39387
Peen the lock ring on both locations (Item 1) [Figure 20-

20-43] in the head gland.
NOTE: Do not peen the lock ring for more than 1 -

1,5 mm (0.04 - 0.06 in).
Figure 20-20-44
S38828
Install the lift lock (Item 1) onto the cylinder and tighten
the four bolts (Item 2) [Figure 20-20-44].
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELF LEVELING CYLINDER Figure 20-30-3
Figure 20-30-1
S38852
Support the lift cylinder using a cinch strap (Item 1)

[Figure 20-30-3].
S39207

Raise the boom and install on adequate stands [Figure
20-30-1]. Figure 20-30-4
Figure 20-30-2
1
2
S38853
S38851
Install a puller (Item 1) and remove the upper pivot pin
(Item 2) [Figure 20-30-4].
Position a wooden block (Item 1) [Figure 20-30-2] under
the lift and self leveling cylinders. Slowly loosen the cinch strap (Item 1) [Figure 20-30-3]
and lower the lift cylinder onto a block.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELF LEVELING CYLINDER (CONT’D) Figure 20-30-7

2
Figure 20-30-5
1
S38856
Remove the two nuts (Item 1) and the retainer bolt (Item
2) [Figure 20-30-7] from the lower pivot pin.
S38859
Figure 20-30-8

the self leveling cylinder.
Figure 20-30-6
1
S38858
Remove the self leveling cylinder from the machine.
S38855
Remove the bolt and nut (Item 1) [Figure 20-30-6] and IMPORTANT
separate the lift cylinder and self leveling cylinder.
Installation: Tighten the nut (Item 1) [Figure 20-30-6] clean the work area before disassembly and keep all
until contact with silent-block. Do not apply torque. parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELF LEVELING CYLINDER (CONT’D)
1. Bushing
2. Housing 1
3. Back-up Ring
4. Seal
5. Piston
6. O-ring 1
7. Spacer
8. Head Gland
9. Wear Ring
10. Wiper
11. Rod
12. Grease Fitting
3
4
3
5
6
7
6
8
4
9
10
11
12
EM7528
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELF LEVELING CYLINDER (CONT'D) Figure 20-30-11
Disassembly
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook
Figure 20-30-9
S38833
Use a spanner wrench to remove the head gland [Figure

20-30-11].
Figure 20-30-12
S38831
Put the cylinder in a vise [Figure 20-30-9]. 1
Figure 20-30-10
S38834
Remove the rod assembly (Item 1) [Figure 20-30-12]

from the housing.
S38832
Heat and remove the set screw (Item 1) [Figure 20-30-

10].
TH.6534(X) / TH.7035(X) / TH.7038(X)

1
Figure 20-30-13
S39421

S38835 piston.
Figure 20-30-16
Put the rod end of the cylinder in a vise and support the
cylinder rod on a wood block [Figure 20-30-13]. 1
Figure 20-30-14
1
2
S39419
2 Remove the two wear rings (Item 1) and seal (Item 2)

S39418 [Figure 20-30-16] from the piston.
Remove the set screw (Item 1) [Figure 20-30-14].
Heat and remove the piston (Item 2) [Figure 20-30-14]

from the rod with a spanner wrench.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-30-17 3
2
1
S38842
Remove the seal (Item 1), wear ring (Item 2) and wiper
S39420 seal (Item 3) [Figure 20-30-19].
Figure 20-30-20
Remove the expander O-ring (Item 1) [Figure 20-30-17].
Figure 20-30-18 2
1
S38843
S38841 Remove the back-up ring (Item 1) and two O-rings (Item
2) [Figure 20-30-20].
Remove the spacer (Item 1) and the head gland (Item 2)

[Figure 20-30-18] from the rod.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly
1
2
Clean all parts in solvent and dry with compressed air.
Inspect all parts for nicks, scratches or other damage.
Replace any damaged parts.
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
Figure 20-30-21
S38841
2
Install the head gland (Item 1) and the spacer (Item 2)

[Figure 20-30-23] onto the rod.
1
S38843

[Figure 20-30-21] onto the head gland.
Figure 20-30-22
3
2
S38842
Install the seal (Item 1), wear ring (Item 2) and wiper seal
(Item 3) [Figure 20-30-22].

the wiper seal.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
1
Figure 20-30-24
S39421
Install the O-ring (Item 1) [Figure 20-30-26] in the piston.

S39420
Figure 20-30-27
Install the O-ring (Item 1) [Figure 20-30-24] onto the

piston.
Figure 20-30-25
S38844
Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for about
1 S39419 3 minutes [Figure 20-30-27].
Install the seal (Item 1) and two wear rings (Item 2)

[Figure 20-30-25].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 20-30-28
P-29887
Apply Loctite® #243 or equivalent to the set screw (Item

P-32047 1) [Figure 20-30-30].
Figure 20-30-31
equivalent to the threads on the rod [Figure 20-30-28].
Figure 20-30-29
1
1
S39418
Install and tighten the set screw (Item 1) [Figure 20-30-

S39422 31] to 4 - 5 N•m (3 - 4 ft-lb) torque.
Install the piston (Item 1) [Figure 20-30-29] onto the rod.
Tighten the piston to 250 - 300 N•m (184 - 221 ft-lb)

torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 20-30-32
1
S38832
2
Apply Loctite® #243 and install the set screw (Item 1)

S38834 [Figure 20-30-34].
Tighten the set screw to 20 N•m (15 ft-lb) torque.

the housing.
Clean off any old residue, and apply Loctite® #262 to the
threads of the head gland (Item 2) [Figure 20-30-32].
Figure 20-30-33
S38845
Use the spanner wrench to tighten the head gland

[Figure 20-30-33] to 200 - 250 N•m (148 - 184 ft-lb)
torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELF LEVELING CYLINDER (LOCK VALVE)
Figure 20-31-1
S38006
Raise the boom and install the boom stop (Item 1)

[Figure 20-31-1]. (See Installing The Approved Boom
Stop on Page 10-150-1.)
Stop the engine.
Relieve hydraulic pressure.
Remove the Starter switch key.
Figure 20-31-2
3
1
1
1
S39446
Remove the four hoses (Item 1) [Figure 20-31-2] from

the self leveling cylinder lock valve.
Remove the two nuts (Item 2) and bolts and remove the
lock valve (Item 3) [Figure 20-31-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
EXTENSION CYLINDER Figure 20-40-4
Cylinder Group Removal And Installation
Remove the two bolts (Item 1) from each metal covers

1
2 1
1
2
1
S39098
Disconnect the five fittings (Item 1) [Figure 20-40-4] in

the top opening of the boom head.
P123051
(Item 2) [] on the boom head and remove the covers. NOTE: Mark the hoses for correct installation.
Remove the inner boom. (See Removal And Installation

on Page 50-40-1.)
Figure 20-40-3 IMPORTANT

damage the system.
1 I-2003-0888
1
Figure 20-40-5
1
S39069

the tilt cylinder.
NOTE: Mark the hoses for correct installation.
S39099
Remove the two bolts (Item 1) [Figure 20-40-5] from the

top of the boom.
TH.6534(X) / TH.7035(X) / TH.7038(X)

EXTENSION CYLINDER (CONT’D) Figure 20-40-8
Cylinder Group Removal And Installation (Cont’d)
Figure 20-40-6
S39102
Remove the extension cylinder assembly from the boom

[Figure 20-40-8].
S39100
Figure 20-40-9
Remove the snap ring (Item 1) [Figure 20-40-6] and
washer.
Figure 20-40-7
S39103
Support the extension cylinder on a work surface [Figure

20-40-9].
S39101
Remove the extension cylinder rod end pivot (Item 1)

[Figure 20-40-7].
WARNING
• When fluids are under pressure.
• Flying debris or loose material is present.
W-2019-0907
TH.6534(X) / TH.7035(X) / TH.7038(X)

Upper Tubeline Removal And Installation

1
Figure 20-40-10
1
1
S39110
Remove the tie-straps (Item 1) [Figure 20-40-12].

S39107
Figure 20-40-13
Remove the bolt (Item 1) [Figure 20-40-10].
Move the upper tubeline assembly away from the cylinder 1

[Figure 20-40-10].
Figure 20-40-11
2
2 1
S39109
1
1 Disconnect the four fittings (Item 1) [Figure 20-40-13].
1
S39111 IMPORTANT
Remove the tie-straps / clamps (Item 1) [Figure 20-40- When repairing hydrostatic and hydraulic systems,
11] from the electrical harness (if equipped). clean the work area before disassembly and keep all
Remove the clamps (Item 2) [Figure 20-40-11] from the tubelines and ports to keep dirt out. Dirt can quickly
tubelines. damage the system.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

EXTENSION CYLINDER (CONT’D)
Upper Tubeline Removal And Installation (Cont’d)
Figure 20-40-14
2
1
2
3
S39112
Remove the three bolts and nuts (Item 1) [Figure 20-40-

14].
Remove the two plates (Item 2) [Figure 20-40-14].
Remove the harness and grommet (Item 3) [Figure 20-

40-14].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Extension Cylinder Removal And Installation
Figure 20-40-15
1
1
S39106
1
Remove the two bolts (Item 1) [Figure 20-40-17] and

nuts.
S39104
Figure 20-40-18
Disconnect the two fittings (Item 1) [Figure 20-40-15].
Figure 20-40-16
2
1
S39108
Install a hoist (Item 1) [Figure 20-40-18] to lift and

S39105
support the extension cylinder.
Remove the two bolts (Item 1) [Figure 20-40-16] and Slide the extension cylinder through the tubelines (Item
nuts. 2) [Figure 20-40-18] and remove the cylinder.
NOTE: It can be necessary to reposition the lifting

strap.
TH.6534(X) / TH.7035(X) / TH.7038(X)

EXTENSION CYLINDER (CONT'D) Figure 20-40-21
Tubeline Tray Disassembly
Figure 20-40-19 1 1
1 1
S39116
1
S39113
Figure 20-40-22

1
1
Figure 20-40-20
1
2 1
1
2
1
S39115
1 Remove the tie-straps (Item 1) [Figure 20-40-22].

S39114
nuts.
Disconnect the six fittings (Item 1) [Figure 20-40-20].
IMPORTANT
damage the system.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

EXTENSION CYLINDER (CONT'D)
Tubeline Tray Disassembly (Cont’d)
Figure 20-40-23
2
5
4 3
S39116
Remove the three bolts (Item 1) and remove the clamp

(Item 2) [Figure 20-40-23].
Remove the bolt and nut (Item 3) and remove the plate
(Item 4) [Figure 20-40-23].
Remove the electrical harness (Item 5) [Figure 20-40-

23] and grommet.
Remove the eight tubelines.
TH.6534(X) / TH.7035(X) / TH.7038(X)

1. Housing
2. Safety Valve
3. O-ring
4. Expander O-ring 2
5. Wear ring
6. Rod
7. Back-up Ring 2
8. Piston
9. Head Gland
10. Wiper
11. Set Screw
5
1 8
3
4
7 11
6
3
4
10 7
EM7534
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly
1
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook
Figure 20-40-24
S38918
1
Use the cylinder wrench to loosen the head gland

(Item 1) [Figure 20-40-26].
Figure 20-40-27
S38922
Clamp the base end of the housing (Item 1) [Figure 20-

40-24] in a vise. Support the other end of the cylinder
with a wooden block. 1
Figure 20-40-25
1
S38919
Place a drain pan below the housing and slowly move the
rod (Item 1) [Figure 20-40-27] in and out to remove the
fluid from the cylinder.
Remove the rod (Item 1) [Figure 20-40-27] from the

S38917 housing.
Carefully peen the lock ring (Item 1) [Figure 20-40-25]

up and out of the lock groove.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly (Cont’d)
Figure 20-40-28
1
1
S39425
Heat and remove the set screw (Item 1) [Figure 20-40-

S38919 30] from the piston.
Figure 20-40-31
Clamp the rod end (Item 1) [Figure 20-40-28] of the rod
assembly in a vise. Support the other end of the rod
assembly with a wooden block.
2
Figure 20-40-29
1
S38923
Heat the piston (Item 1) [Figure 20-40-31].
S38921 Use the cylinder wrench to remove the piston (Item 1)

from the rod (Item 2) [Figure 20-40-31].
Remove the wear ring (Item 1) [Figure 20-40-29] from

the piston.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-40-32 1
S38926
Remove the head gland (Item 1) [Figure 20-40-34] from

S39426 the rod.
Figure 20-40-35
Remove the wear ring (Item 1) [Figure 20-40-32] from
the piston.
Figure 20-40-33 1
3
1 2
2 S38927
Remove the wiper seal (Item 1), the two wear rings (Item
S38925 2) and the seal (Item 3) [Figure 20-40-35] from the head
gland.
Remove the seal (Item 1) and the two O-rings (Item 2)

[Figure 20-40-33] from the piston.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-40-36
2
1
S38928
Remove the two O-rings (Item 1) and back-up ring (Item

2) [Figure 20-40-36] from the head gland.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly
Use the following tools to assemble the cylinder: 1
MEL1076 - Cylinder Wrench 3

2
Wash the cylinder parts in solvent and dry with

compressed air.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
S38927
Install the wiper seal (Item 1) and two wear rings (Item 2)
Figure 20-40-37 [Figure 20-40-38] into the head gland.
2 Install the seal (Item 3) [Figure 20-40-38] using the seal

installation tool.
1
2 the wiper seal.
Figure 20-40-39
S38928

[Figure 20-40-37] on the head gland.
S38931
Install the head gland (Item 1) [Figure 20-40-39] on the

rod.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 20-40-40
2
2 S38923

S38925 equivalent to the threads on the piston (Item 1) [Figure
20-40-42].
Install the seal (Item 1) and the two O-rings (Item 2) Use the cylinder wrench to install the piston (Item 1) on
[Figure 20-40-40] on the piston. the cylinder rod (Item 2) [Figure 20-40-42].
Figure 20-40-41 Tighten the piston to 414 N•m (305 ft-lb) torque.
1 Figure 20-40-43
S39426
P-29887
Install the backside wear ring (Item 1) [Figure 20-40-41]
on the piston. The second wear ring will be installed at a
later stage. Apply Loctite® #243 or equivalent to the set screw (Item
1) [Figure 20-40-43].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 20-40-44
S38919
Clean off any old residue and apply Loctite® #262 to the
S38921 threads of the head gland (Item 1) [Figure 20-40-46].

Install the set screw (Item 1) [Figure 20-40-44] into the the housing.
piston.
Figure 20-40-47
Tighten the set screw to 20 N•m (15 ft-lb) torque.
Figure 20-40-45
1
S38918
S38921 Use the cylinder wrench to tighten the head gland

(Item 1) [Figure 20-40-47].
Install the second wear ring (Item 1) [Figure 20-40-45] Tighten the head to 250 N•m (184 ft-lb) torque.
on the piston.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 20-40-48
S38917
Carefully peen the lock ring into the groove in the head
gland (Item 1) [Figure 20-40-48].
NOTE: Do not peen the lock ring for more than

1 - 1,5 mm (0.04 - 0.06 in).
TH.6534(X) / TH.7035(X) / TH.7038(X)

TILT CYLINDER Figure 20-50-2
Figure 20-50-1
1
1
S39069

the tilt cylinder.
S39074

Fully lower the attachment carrier [Figure 20-50-1] to
rest on a flat surface. Figure 20-50-3
Remove the two bolts (Item 1) and remove the cover
2
1
S39068
P122536
Install a hoist and lifting strap (Item 1) [Figure 20-50-3] to
(Item 2) [] from the boom head. the tilt cylinder.
IMPORTANT
damage the system.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

TILT CYLINDER (CONT’D) Figure 20-50-6
Figure 20-50-4
2
S39389
1
Remove the snap ring (Item 1) and washer (Item 2)
[Figure 20-50-6] from the upper pivot pin.
S39146
Figure 20-50-7
[Figure 20-50-4] from the lower pivot pin.
Figure 20-50-5
1 S39388
Remove the upper pivot pin (Item 1) [Figure 20-50-7].

S39147
NOTE: Make sure the hoist and strap are tight to
prevent the cylinder from falling.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TILT CYLINDER (CONT’D)
Figure 20-50-8
S39075
Carefully lower and remove the tilt cylinder (Item 1)

[Figure 20-50-8].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TILT CYLINDER (CONT’D)
1. Housing
2. Bushing
3. Grease Fitting
4. Rod
5. Wear Ring
6. Seal
7. Set Screw 2
8. Piston 3
1
9. O-ring
10. Back-up Ring
11. Head Gland
13
12. Wiper
13. Valve
10
6
10
5
9 8
5 7
2 4
9
10
11
6
12
EM8704S
TH.6534(X) / TH.7035(X) / TH.7038(X)

TILT CYLINDER (CONT'D)
Disassembly
NOTE: The tilt cylinder is no longer serviceable due

to safety reasons. Please replace the entire
cylinder in case of malfunction or damage.
WARNING
Figure 20-50-9
immediately.
W-2145-0290
Figure 20-50-11
1 1
S39076
Put the cylinder in a vise [Figure 20-50-9].
Figure 20-50-10
S39091
1 Remove the three O-rings and back-up rings (Item 1)

[Figure 20-50-11].
S39077
Remove the relief cartridge (Item 1) [Figure 20-50-10].
NOTE: Oil can still be under pressure. Carefully

loosen the relief cartridge (Item 1) [Figure 20-
50-10] to allow residual oil pressure to
escape.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TILT CYLINDER (CONT'D)
Assembly
Inspect the cylinder parts for damage. Replace any

damaged parts.

Figure 20-50-12
S39077
Install the relief cartridge (Item 1) [Figure 20-50-12].
Tighten the relief cartridge to 45 - 50 N•m (33 - 37 ft-lb)

torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

STEERING CYLINDER (FRONT / REAR) Figure 20-60-3
Removal
Remove:
2
• the front axle. (See Removal And Installation on Page 1
40-30-1.)
or
• the rear axle. (See Removal And Installation on Page

40-90-1.)
Figure 20-60-1
S2515
Remove the bolt (Item 1) for access to remove the nut

(Item 2) [Figure 20-60-3].
2
3 Figure 20-60-4
1
1
S2513
Remove the two bolts (Item 1) and remove the centering

sensor (Item 2) from the steering cylinder
(Item 3) [Figure 20-60-1].
Figure 20-60-2 S2516
Remove the nut (Item 1) [Figure 20-60-4].
S2514
Remove the cotter pin (Item 1) [Figure 20-60-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

STEERING CYLINDER (FRONT / REAR) (CONT’D) Figure 20-60-7
Removal (Cont’d)
Figure 20-60-5 2
S2519
Remove the bolts (Item 1) from the steering cylinder

S2517 (Item 2) [Figure 20-60-7].
Figure 20-60-8
Remove the tie rod end (Item 1) [Figure 20-60-5] by
means of a puller.
Figure 20-60-6 1
2
1
S2520
Extract the cylinder (Item 1) [Figure 20-60-8] using a

S2518 plastic hammer.
NOTE: For cylinder disassembly (See Disassembly

Heat and disconnect the left and right steering bars on Page 20-60-5.).
(Item 1) from the cylinder rod (Item 2) [Figure 20-60-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Installation
Figure 20-60-9
S2523
Apply Loctite® #243 to the thread and install the two tie
S2521 rods [Figure 20-60-11]. Tighten the tie rods to 240 - 270
N•m (177 - 199 ft-Ib) torque.
Lubricate the seats of the seals and install the steering Figure 20-60-12
cylinder (Item 1) [Figure 20-60-9] into its seat.
Figure 20-60-10
2
1
1 4
S2524
S2522 Insert the tie rods (Item 1) in the steering case

(Item 2) [Figure 20-60-12]. Tighten the nuts to 260 - 290
N•m (192 - 214 ft-Ib) torque.
Tighten the bolts (Item 1) [Figure 20-60-10] to 116 - 128
N•m (85 - 95 ft-lb) torque. Tighten the nut (Item 3) [Figure 20-60-12] until the
cotter pin hole is visible.
NOTE: Check that the rubber boots (Item 4)

[Figure 20-60-12] are intact.
TH.6534(X) / TH.7035(X) / TH.7038(X)

STEERING CYLINDER (FRONT / REAR) (CONT’D)
Installation (Cont’d)
Figure 20-60-13
S2525
Insert the cotter pins (Item 1) [Figure 20-60-13] and

bend the ends.
NOTE: Use new cotter pins.
Figure 20-60-14
1
S2526
Install the centering sensor for checking piston centering.
Tighten the bolts (Item 1) [Figure 20-60-14] to 5 - 6 N•m

(44 - 53 in-Ib) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly
Figure 20-60-15 2
1
S1518
With the help of a drift, apply pressure to the stop ring

S1516
(Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-60-17] and extract the ring using a
screwdriver.
Remove the snap ring (Item 1) from the cylinder head
(Item 2) [Figure 20-60-15]. Figure 20-60-18
Figure 20-60-16
1
1
3
2
S1519
S1517
Hammer the opposite side of the cylinder head
(Item 1) [Figure 20-60-18] using a plastic hammer.
With the help of a plastic hammer, push the head
Continue hammering until the head (Item 2) is ejected
(Item 1) inside the cylinder (Item 2) [Figure 20-60-16].
from the cylinder (Item 3) [Figure 20-60-18].
NOTE: The head should line up with the edge of the
cylinder.
TH.6534(X) / TH.7035(X) / TH.7038(X)

STEERING CYLINDER (FRONT / REAR) (CONT’D)
Figure 20-60-19
A
S1520
Disassemble the cylinder unit (Item 1) by extracting first

the head, then the piston (Item 2) [Figure 20-60-19].
NOTE: Mark the assembly side of the piston. The

beveled part “A” of the piston is oriented
toward the cylinder head.
Remove all seals, anti-extrusion rings and scraper rings

from head, cylinder and piston.
NOTE: 1) All seals must be replaced every time the

unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly
1
Figure 20-60-20
1 2 3
S1523
Install the seal (Item 1) [Figure 20-60-22] onto the

S1521
outside of the head.
After applying grease, install the sealing ring (Item 1), the NOTE: In order to facilitate assembly, apply grease to
anti-extrusion ring (Item 2) and the scraper ring the outer surface of the piston.
(Item 3) [Figure 20-60-20] inside the cylinder. Do not roll the seal (Item 1) [Figure 20-60-22].
NOTE: Thoroughly check that positioning of the anti- Figure 20-60-23

extrusion ring (Item 2) [Figure 20-60-20] is
correct.
5 3 2
Figure 20-60-21
1
3 2 1 4
S1524
Prepare the piston (Item 1) by installing it with the guide

ring (Item 2), the magnetic ring (Item 3), the O-ring
S1522 (Item 4) and the seal (Item 5) [Figure 20-60-23].
NOTE: In order to facilitate assembly, apply grease.

After applying grease, install the sealing ring (Item 1), the
anti-extrusion ring (Item 2) and the scraper ring (Item 3)
[Figure 20-60-21] in the head.
NOTE: Thoroughly check that positioning of the anti-

extrusion ring (Item 2) [Figure 20-60-21] is
correct.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 20-60-24 1
T18
T18
2
1
S1527
Remove tool T18 and apply it to the opposite side of the

S1525 piston rod (Item 1) [Figure 20-60-26].
Figure 20-60-27
Apply tool T18 to the shaft on the opposite side of the
head and center it in the cylinder (Item 1) so that the
piston (Item 2) [Figure 20-60-24] fits into the cylinder.
1
NOTE: Apply a little grease to seals and cylinder.
T18
Figure 20-60-25
1 3
2
S1528
Apply grease to the head seals (Item 1), install the head
onto the piston rod (Item 2) and push it onto the cylinder
2
(Item 3) [Figure 20-60-27].
S1526
Push the piston (Item 1) into the cylinder (Item 2)

[Figure 20-60-25] for 100 mm (4 in). Using a plastic
hammer.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d) 2
Figure 20-60-28
S1531
2 install the snap ring (Item 1) on the head (Item 2)

S1529 [Figure 20-60-30].
NOTE: Make sure that the snap ring (Item 1)

Insert the stop ring (Item 1) ensuring that it fits into the [Figure 20-60-30] is securely fastened in its
seat of the cylinder (Item 2) [Figure 20-60-28]. seat.
If necessary, force it into its seat using a drift
Figure 20-60-29 and a hammer.
S1530
Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-60-29].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
GEAR CONTROL CYLINDER Figure 20-70-3
Removal
Remove the engine / hydrostat assembly. (See Removal

And Installation on Page 70-20-1.)
Figure 20-70-1
1
S38227
Remove the piston (Item 1) [Figure 20-70-3].

3
Figure 20-70-4
2
S40896
Remove the two hoses (Item 1) from the gear control

cylinder (Item 2) [Figure 20-70-1].
NOTE: Mark the hoses for installation.
Remove the two bolts (Item 3) from the gear control

Remove the gear control cylinder (Item 2) [Figure 20-70-

1]. 1
S38229
Figure 20-70-2
Remove the cover plate (Item 1) [Figure 20-70-4].
1
2
S38225
Remove the screw (Item 1) from inside the cylinder rod

(Item 2) [Figure 20-70-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR CONTROL CYLINDER (CONT’D)
Removal (Cont’d)
Figure 20-70-5
1
S38230
Remove the O-ring (Item 1) [Figure 20-70-5].
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR CONTROL CYLINDER (CONT’D)
1. O-ring
2. Seal
3. Cylinder
4. Rod
5. Piston
6. Cover Plate
7. Sealant
8. Screw
1
8
9
3 5
6
1
1 1
7
1
EM7541
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR CONTROL CYLINDER (CONT’D) Figure 20-70-8
Disassembly
Figure 20-70-6
2
1
2 S40898
1
Remove the O-ring (Item 1) from the cylinder housing

S38228 (Item 2) [Figure 20-70-8].
Inspect the cylinder rod (Item 2) [Figure 20-70-6] for

nicks and scratches.
Figure 20-70-7
S40897
Remove the seal (Item 1) from the cylinder housing (Item

2) [Figure 20-70-7].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly
Figure 20-70-9
2
1
S38228
Install the O-ring (Item 1) [Figure 20-70-11].

S40898
Figure 20-70-12
Install the O-ring (Item 1) on the cylinder housing (Item 2)

[Figure 20-70-9].
Figure 20-70-10
1
S38230
Install the O-ring (Item 1) [Figure 20-70-12].
S40897
Install the seal (Item 1) on the cylinder housing (Item 2)

[Figure 20-70-10].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Installation
Figure 20-70-13
1
2
S38225
Install the screw (Item 1) inside the cylinder rod (Item 2)

[Figure 20-70-15]. Apply Loctite® #243 to the threads
S36809 before installation. Torque to 25 - 26 N•m (18 - 19 ft-lb)
torque.
Apply Loctite® #510 and install the cover plate (Item 1) Figure 20-70-16
[Figure 20-70-13].
Figure 20-70-14 3
2
1 S40896
S38227 Apply some hydraulic fluid on the control rod and piston
before installing the gear control cylinder (Item 2) [Figure
20-70-16].
Install the piston (Item 1) [Figure 20-70-14].
Install the gear control cylinder (Item 2) with the two bolts
(Item 3) [Figure 20-70-16].
Tighten the bolts (Item 3) [Figure 20-70-16] to 49 - 51

N•m (36 - 38 ft-lb) torque.
Install the two hoses (Item 1) onto the gear control

TH.6534(X) / TH.7035(X) / TH.7038(X)

MANIFOLD Figure 20-80-1
Removal And Installation 2
WARNING
sufficient force to enter a person’s body by 2 3
immediately. 1
W-2145-0290
1 1 P125400
Disconnect the five electrical connectors (Item 1)

[Figure 20-80-1] on the bottom of the manifold. (one is
IMPORTANT hidden at the back of the left solenoid)
Remove the fifteen hydraulic connections from the

manifold (Item 2) [Figure 20-80-1].
Remove the bolt and bracket (Item 3) [Figure 20-80-1].
damage the system.
I-2003-0888 NOTE: For picture clarity some hydraulic
connectors, electrical connectors and
mounting bracket are removed in [Figure 20-
Relieve hydraulic pressure. 80-1]. Mark the hydraulic and electrical
connectors for correct installation.
Figure 20-80-2
BOTTOM VIEW
S39412
Remove the two bolts (Item 1) [Figure 20-80-2] located

outside of the frame, in front of the hydraulic tank.
Remove the manifold from the machine.
TH.6534(X) / TH.7035(X) / TH.7038(X)

MANIFOLD (CONT’D)
4
4
1. Solenoid Valve
2 2. Solenoid
4 2 3. Spacer
4. Nut
5. Coil
3 6. Relief Valve
3
5 7. Check Valve
8. Plug
2
9. Orifice Screen
2 10. Valve Block
11. Seal Kit
1 12. O-ring
1 11
11
11
12
11
11
6
10
9
NA12517S
TH.6534(X) / TH.7035(X) / TH.7038(X)

MANIFOLD (CONT’D) Remove the check valve (Item 5) [Figure 20-80-3] from
the manifold.
Disassembly And Assembly
Figure 20-80-5
Figure 20-80-3
1 1
1
2
2
5
4
S39858
P128064
Inspect the O-rings and back-up washer (Item 1)

Remove the three nuts (Item 1) [Figure 20-80-3] from [Figure 20-80-5] for damage.
the solenoid valve stems.
Assembly: Put oil on O-rings and back-up washer.
Remove the four solenoids (Item 2) [Figure 20-80-3] Tighten to 26 - 29 N•m (19 - 21 ft-lb) torque.
from the solenoid valve stems.
Remove the three solenoid valve stems from the valve
Remove the coil (Item 3) [Figure 20-80-3] from the block.
solenoid valve stems.
Figure 20-80-6
Remove the relief valve (Item 4) [Figure 20-80-3] from
the valve block.
Figure 20-80-4
1
S39859
Inspect the O-rings and back-up washers (Item 1)

S39857 [Figure 20-80-6] for damage.
Assembly: Put oil on O-rings and back-up washers.

Inspect the O-rings and back-up washer (Item 1) Tighten the long solenoid valve stem to 33 - 35 N•m (24 -
[Figure 20-80-4] for damage. 26 ft-lb) torque. Tighten the short solenoid valve stem to
26 - 29 N•m (19 - 21 ft-lb) torque.
Assembly: Put oil on O-rings and back-up washer.
Tighten to 26 - 29 N•m (19 - 21 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
BRAKE VALVE Figure 20-90-3
Remove the steering column cover. (See Removal And

Installation on Page 50-110-1.)
Figure 20-90-1
1
1 1
S39132
Remove the two bolts (Item 1) [Figure 20-90-3] from

inside the operator cab.
2
Remove the brake valve (Item 4) [Figure 20-90-2] from
S38084 the outer cab.
Remove all fittings (Item 5) from the brake valve (Item 4)

Remove the three bolts (Item 1) and remove the cover [Figure 20-90-2].
(Item 2) [Figure 20-90-1] from the front of the operator
cab.
Figure 20-90-2
IMPORTANT
3 When repairing hydrostatic and hydraulic systems,
4 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
1
2
5
1
P125412
Disconnect the two hoses (Item 1), the tubeline (Item 2)

and the pressure sensor (Item 3) from the brake valve
(Item 4) [Figure 20-90-2].
NOTE: Some additional hoses may need to be

disconnected from the steering valve in order
to disconnect the tubeline.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
PISTON PUMP (FOR TH.6534(X) AND TH.7038(X)) Figure 20-100-2
Stop the engine and open the engine cover.
Relieve the hydraulic pressure. Drain the hydraulic

reservoir. (See Removing And Replacing Hydraulic Fluid
on Page 10-100-2.)
WARNING 1

P125347
and possible death if proper medical treatment by a Disconnect the electrical connector (Item 1) [Figure 20-
physician familiar with this injury is not received 100-2].
immediately.
W-2145-0290
Figure 20-100-3
IMPORTANT
damage the system.
I-2003-0888
Figure 20-100-1 P125348
1 Disconnect the electrical connector (Item 1) [Figure 20-

100-3].
2
Remove the DEF tank. (See Removal And Installation on
Page 70-110-1.)
1
P125203
Loosen the two bolts (Item 1) and remove the cover

(Item 2) [Figure 20-100-1] from the front side of the
engine / hydrostat assembly.
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)
Removal And Installation (Cont'd)

1
Figure 20-100-4
1
1 1
1
P125351
2 Remove the four hoses (Item 1) [Figure 20-100-6].
P125349 Figure 20-100-7
Loosen the two fittings (Item 1) and remove the tubeline 1 2

(Item 2) [Figure 20-100-4].
Figure 20-100-5
1
P125352
2
Install a wooden block under the gear pump assembly.
Remove the two mounting bolts (Item 1) [Figure 20-100-

P125350 7] from the gear pump.
Remove the gear pump assembly (Item 2) [Figure 20-

Remove the four bolts (Item 1) and remove the fitting 100-7].
(Item 2) [Figure 20-100-5] from the gear pump.
NOTE: It can be necessary to reposition any hose or
Installation: Tighten the bolts to 29 - 30 N•m (21 - 22 ft- wires.
lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

PISTON PUMP (FOR TH.6534(X) AND TH.7038(X)) (CONT'D)
7 7 6
1. Seal 32
2. Compensator Valve 7
3. Torque Limiter 8
2
4. Cover
5. Bearing 7 7 1 7
6. Screw 32 7
2
7. O-ring
9 8
8. Nut 8 21
7 10
9. Plug 25 7
10 7
10. Washer 1
11. Seal 6 7
26 9
12. Retaining Ring 7
27 8
13. Snap Ring 13
20
14. Support 25 17 7
31
15. Drive Regulator 28
16. Splined Ring 6
22
17. Support 5
16
18. Cylinder Block 26 11
19. Piston Spring
20. Counterbalancing 29 23
6 7
Spring 15
29 17 7
21. Connector
22. Swash Plate 14 7
6 7
23. Piston Plate 12
24. Valve Plate 6
7
25. Piston 3 7 9
26. Shaft 9
27. Segment
28. Body
29. Dowel Pin
30. Dowel
7
31. Pin
32. Nut Cap 6
29 24
7
12
19
5
6 10 30
4 7 10
18
NA12421S
TH.6534(X) / TH.7035(X) / TH.7038(X)

PISTON PUMP (FOR TH.6534(X) AND TH.7038(X)) Remove the two bolts (Item 1) [Figure 20-100-9].
(CONT'D)
Assembly: Tighten the bolts to 18 N•m (13 ft-lb) torque.
Remove the flow divider (Item 2) [Figure 20-100-9] from
the housing.
IMPORTANT Figure 20-100-10

parts clean. Always use caps and plugs on hoses, 2
damage the system.
I-2003-0888 1
Figure 20-100-8
S40818
Remove the O-ring (Item 1) from the housing (Item 2)

[Figure 20-100-10].
1
S40798
Mark the pump housing for correct assembly and remove

all fittings [Figure 20-100-8].
Installation: Tighten the fitting (Item 1) [Figure 20-100-

8] to 30 N•m (22 ft-lb) torque.
Figure 20-100-9
1
1
S40799
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)
Disassembly And Assembly (Cont'd)
Figure 20-100-11
1
6
3
5 4
4
3
1
S40824
3
Remove the O-ring (Item 1) from the housing [Figure 20-
2 100-13].
S40817
Figure 20-100-14
Remove the plug (Item 1), O-ring (Item 2), springs (Item
3), spring seats (Item 4) and spool (Item 5) from the
housing (Item 6) [Figure 20-100-11].
Assembly: Tighten the plug to 50 N•m (37 ft-lb) torque. 2
NOTE: Always use new O-rings.
Figure 20-100-12
2 1
1
S40820
Remove two O-rings (Item 1) from the housing (Item 2)

[Figure 20-100-14].
1 2
S40819
Remove the four bolts (Item 1) and the two housings

(Item 2) [Figure 20-100-12].
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)

8 7
Figure 20-100-15
4 5 6
1 3
S40823
1
Remove the valve (Item 1), O-ring (Item 2), spacer (Item
3), springs (Item 4), spring seat (Item 5), spool (Item 6)
S40821 and plug (Item 7) from the housing (Item 8) [Figure 20-
100-17].
Remove three O-rings (Item 1) from the housing (Item 2) Assembly: Tighten the valve (Item 1) to 36 N•m (27 ft-lb)
[Figure 20-100-15]. torque. Tighten the plug (Item 7) [Figure 20-100-17] to
15 N•m (11 ft-lb) torque.
Remove two O-rings from the other side of the housing.
Figure 20-100-18
Figure 20-100-16
8 7
1
5 6
4
3
1
2
S40825
S40822

Remove the valve (Item 1), O-ring (Item 2), spacer (Item housing.
3), spring (Item 4), spring seat (Item 5), spool (Item 6)
and plug (Item 7) from the housing (Item 8) [Figure 20-
100-16].
Assembly: Tighten the valve (Item 1) to 36 N•m (27 ft-lb)

torque. Tighten the plug (Item 7) [Figure 20-100-16] to
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)
Figure 20-100-19 2
1
1 1
S40828
2
Remove the four bolts (Item 1) and the cover (Item 2)
[Figure 20-100-21].
S40826
Remove the bolt (Item 1) and link (Item 2) [Figure 20- Figure 20-100-22
100-19] from the housing.
Assembly: Tighten the bolt to 18 N•m (13 ft-lb) torque. 1
Figure 20-100-20
S40829

cover.
S40827
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)
Disassembly And Assembly (Cont'd) 1
Figure 20-100-23
1 1
S40832
Remove the two O-rings (Item 1) [Figure 20-100-25]

from the housing.
S40830
Figure 20-100-26
Remove the wear plate (Item 1) [Figure 20-100-23] from

the cover.
Figure 20-100-24 1
S40833
Remove the bearing (Item 1) [Figure 20-100-26].
S40831
Remove the pin (Item 1) [Figure 20-100-24] from the

cover.
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)
Figure 20-100-27
2 1
S40842
Remove the spring retainer (Item 1) and the spring (Item

2) [Figure 20-100-29].
S40877
Figure 20-100-30
Remove the spacer (Item 1) [Figure 20-100-27].
Figure 20-100-28
S40834
Lightly tap on the drive shaft (Item 1) [Figure 20-100-30]

S40841 to remove the shaft and piston assembly.
Remove the plug (Item 1) [Figure 20-100-28].
Assembly: Tighten the plug to 50 N•m (37 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)
Figure 20-100-31
1 1
2
S38649
Remove the pistons (Item 1) [Figure 20-100-33] from the

piston assembly.
S40838
Figure 20-100-34
Remove the drive shaft (Item 1) from the piston / retainer

assembly (Item 2) [Figure 20-100-31]. 1
Figure 20-100-32
S40880
Remove the ball guide retainer (Item 1) [Figure 20-100-

34] from the cylinder block.
S38648
Remove the piston assembly (Item 1) [Figure 20-100-32]

from the cylinder block.
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)
Figure 20-100-35 1
2
1 S40840
Remove the spring (Item 1) and washer (Item 2)

[Figure 20-100-37].
S40839
Figure 20-100-38
Remove the three pins (Item 1) [Figure 20-100-35].
Figure 20-100-36
2
1
S40843
Remove the screw (Item 1) and the plate (Item 2)

P-91160 [Figure 20-100-38] from the swash plate.
Assembly: Tighten the screw to 18 N•m (13 ft-lb) torque.

Using a press and an appropriate sized spacer (Item 1)
[Figure 20-100-36], compress the spring in the cylinder
block.
Remove the snap ring (Item 2) [Figure 20-100-36].
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT'D)

1
Figure 20-100-39
S40879
S40844 Figure 20-100-42
Remove the swash plate (Item 1) [Figure 20-100-39].
Figure 20-100-40
S40846
Remove the shaft seal (Item 1) [Figure 20-100-42].
S40845
Remove the roller bearing (Item 1) [Figure 20-100-40].
TH.6534(X) / TH.7035(X) / TH.7038(X)

PISTON PUMP (FOR TH.6534(X) AND TH.7038(X))
(CONT'D)
Figure 20-100-43
2
2
1
1
S40846
Remove the two screws (Item 1) and bearings (Item 2)

[Figure 20-100-43].
Assembly: Tighten the screws to 2 N•m (18 in-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
GEAR PUMP (FOR TH.7035(X)) Figure 20-101-2
Stop the engine and open the engine cover.
Relieve the hydraulic pressure. Drain the hydraulic

reservoir. (See Removing And Replacing Hydraulic Fluid 1
on Page 10-100-2.)
WARNING 2

P125293
and possible death if proper medical treatment by a Loosen the two fittings (Item 1) and remove the tubeline
physician familiar with this injury is not received (Item 2) [Figure 20-101-2].
immediately.
W-2145-0290
Remove the hydraulic hose (Item 3) [Figure 20-101-2].
Figure 20-101-3
IMPORTANT 3

damage the system. 1
I-2003-0888 1
Figure 20-101-1
2
P125294
1
Loosen / remove the four bolts (Item 1) and remove the
2
fitting (Item 2) [Figure 20-101-3] from the gear pump.
Installation: Tighten the bolts (Item 1) [Figure 20-101-3]

to 29 - 30 N•m (21 - 22 ft-lb) torque.
Remove the fitting (Item 3) [Figure 20-101-3] from the

gear pump.
1 Installation: Tighten the fitting (Item 3) [Figure 20-101-

P125203 3] to 59 - 60 N•m (43 - 44 ft-lb) torque.
Loosen the two bolts (Item 1) and remove the cover

(Item 2) [Figure 20-101-1] from the front side of the
engine /hydrostat assembly.
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR PUMP (FOR TH.7035(X)) (CONT'D)
Figure 20-101-4
P125204
Remove the four hoses (Item 1) [Figure 20-101-4] from

the gear pump assembly.
Figure 20-101-5
P125295
Install a wooden block under the gear pump assembly.
Remove the two mounting bolts (Item 1) (both sides)

[Figure 20-101-5] from the gear pump.
Installation: Tighten the mounting bolts to 50 - 80 N•m

(38 - 59 ft-lb) torque.
Remove the gear pump assembly (Item 2) [Figure 20-

101-5].
NOTE: It can be necessary to reposition any hose or

wires.
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR PUMP (FOR TH.7035(X)) (CONT'D)
19
22
23 17 16
20
15
24
25
14
17
18 16
9 10
2
4 3
2
1. Fitting
2. O-ring 5 1
6
3. Spring 10 2 7
4. Spring Seat
5. Spool
6. Screen
7. Orifice Spool 18 10
8. Bolt 19 2
18
9. Cover
17 16 7
10. Plug 6
11. Bolt
12. Washer 5
13. Front Cover 17 2
16
14. Seal Ring
15. Pump Housing 13
16. Back-up Ring
17. Seal Ring
18. Holder
19. Gear
20. Spline Shaft
21. Mount Plate
4
22. Thrust Plate
23. Mount Plate 2 3
24. Seal 2
15
25. Snap Ring
1
EM7530
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR PUMP (FOR TH.7035(X)) (CONT'D) Figure 20-101-7

1 1
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1 1
damage the system.
I-2003-0888
2
S39437
Figure 20-101-6
4 Remove the four bolts (Item 1) [Figure 20-101-7].

1
3
Remove the flow divider (Item 2) [Figure 20-101-7] from
the housing.
Figure 20-101-8
5 4 3 2 1
6
2
P120023
Mark the pump housing for correct assembly and remove

all fittings [Figure 20-101-6].
Assembly: Tighten the fitting (Item 1) [Figure 20-101-6]

to 44 - 45 N•m (32 - 33 ft-lb) torque.
Assembly: Tighten the fitting (Item 2) [Figure 20-101-6] S39248

to 59 - 60 N•m (43 - 44 ft-lb) torque.
Assembly: Tighten the fitting (Item 3) [Figure 20-101-6] Remove the plug (Item 1), O-ring (Item 2), spring (Item
to 69 - 70 N•m (51 - 52 ft-lb) torque. 3), spring seat (Item 4) and spool (Item 5) from the
Assembly: Tighten the fitting (Item 4) [Figure 20-101-6]
to 11 - 12 N•m (97 - 106 in-lb) torque. Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque.
NOTE: Always use new O-rings.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-101-9
2
1
P-25296
To remove the orifice assembly (Item 1) [Figure 20-101-

P-25294 11] from the spool, make a holding fixture from a 19 mm
thick x 38 mm wide x 50 mm long (0.750 in thick x 1.500
in wide x 2.0 in long) piece of hardwood. Drill a 14 mm
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20- (0.550 in) hole in the center of the hardwood block. Cut
101-9] from the housing. the block lengthwise [Figure 20-101-10].
Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque. Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-101-11].
Figure 20-101-10
Cut NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
damaged.
Figure 20-101-12
14 mm dia.
(0.550” dia.) 1 2
38 mm
(1.500’’) 19 mm
(0.750’’) B-14674
P-25295
Remove the screen (Item 1) from the orifice (Item 2)

[Figure 20-101-12] and clean.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-101-13 1
2
3
1 1
2 4
S39351
1 1 Remove the housing (Item 1) from the gear assembly

S39437 (Item 2) [Figure 20-101-15].
Assembly: The position of the small opening (Item 3) on

Remove the four bolts (Item 1) and cover (Item 2) the gear holders will point toward the cut-away (Item 4)
[Figure 20-101-13]. [Figure 20-101-15] on the housing.
Assembly: Tighten the bolts to 70 N•m (51 ft-lb) torque. Figure 20-101-16
Figure 20-101-14
1
1
S39252
S39350
Remove both O-rings (Item 1) [Figure 20-101-16] from
the housing.
Remove the housing / gear assembly (Item 1)
[Figure 20-101-14] from the main housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-101-17 1 1
1 1
2
P-25304
1
Remove the four bolts (Item 1) and drive shaft (Item 2)

P-56453 [Figure 20-101-19].
Assembly: Tighten the bolts to 140 N•m (103 ft-lb)

Remove the back-up ring (Item 1) and seal ring (Item 2) torque.
[Figure 20-101-17] from the gear holder.
Figure 20-101-20
Assembly: The seal ring (Item 2) [Figure 20-101-17] is
installed onto the gear holder first followed by the back-
up ring.
Figure 20-101-18
P-25305
Turn the housing over and remove the mount plate

[Figure 20-101-20].
P-25322
Remove and discard the O-ring (Item 1) [Figure 20-101-

18] from the flange.
TH.6534(X) / TH.7035(X) / TH.7038(X)


2
Figure 20-101-21
1
1
3
4
P-25310
Remove the O-ring (Item 1) and gear assembly (Item 2)

P-25306 [Figure 20-101-23] from the housing.
Assembly: The position of the V portion (Item 3) on the

Remove the snap ring (Item 1) [Figure 20-101-21]. thrust plate must point toward the larger port (Item 4)
[Figure 20-101-23] on the housing.
Figure 20-101-22
Figure 20-101-24
1 2 2
3 1 3
1
P-25307
P-25313
Remove both shaft seals (Item 1) [Figure 20-101-22].

Remove the two thrust plates (Item 1), seal ring (Item 2)
Assembly: The open part of the first seal goes into the and back-up ring (Item 3) [Figure 20-101-24] from the
mount plate first. For the second seal the closed side gears.
goes into the mount plate first (reversed orientation).
Assembly: The seal ring (Item 2) will be installed on the
thrust plate (Item 1) first followed by the back-up ring
(Item 3) [Figure 20-101-24].
TH.6534(X) / TH.7035(X) / TH.7038(X)

FAN MOTOR Figure 20-110-2
IMPORTANT
damage the system.
I-2003-0888
P125183
Drain the radiator. (See Removing And Replacing The
Coolant on Page 10-70-3.)
Install the fan assembly onto blocks as shown in [Figure
Remove the radiator. (See Oil Cooler / Intercooler / 20-110-2].
Radiator Removal And Installation on Page 70-80-1.)
Figure 20-110-3
Figure 20-110-1
1 1
2
1
1 P125182
1
P125181
Remove the nut and Lockwasher (Item 1) [Figure 20-

Remove the eight bolts and washers (Item 1) [Figure 20- 110-3].
110-1].
Installation: Apply Loctite® #242 to the thread and
Installation: Tighten the bolts to 15 - 22 N•m (11 - 16 ft- tighten the nut to 19 - 20 N•m (14 - 15 ft-lb) torque.
lb) torque.
Remove the fan bracket with fan motor (Item 2) [Figure

20-110-1].
TH.6534(X) / TH.7035(X) / TH.7038(X)

FAN MOTOR (CONT’D)
Figure 20-110-4
P125184
Tap on the shaft to release the fan motor from the blade
assembly [Figure 20-110-4].
Flip the fan assembly around.
Figure 20-110-5
1 1
P125185
Remove the four fan guard mount bolts and nuts (Item 1)
[Figure 20-110-5].
Installation: Apply Loctite® #242 to the threads of the

bolts.
Remove the fan motor.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Parts Identification (Single Speed Version) (Standard)
1. Seal
2. Check Valve
3. Motor Housing
4. Gear Assembly
5. Rear Cover
6. Front Cover
7. Back-up Ring
8. Holder
9. Gear
10. Pin
11. Snap Ring
2
7
3 1
8
1
5 9
8
10 7
1
1 6
10
11
EM7529
TH.6534(X) / TH.7035(X) / TH.7038(X)

FAN MOTOR (CONT’D) Figure 20-110-8
Disassembly And Assembly (Single Speed Version)

(Standard)
Figure 20-110-6
P-53277

plug. Replace as needed.
P-53275
Figure 20-110-9
Remove three fittings (Item 1) [Figure 20-110-6].
NOTE: Mark the housing for correct assembly.

1
Figure 20-110-7 1
1 1
P-53278
4
3
Remove the four bolts (Item 1) [Figure 20-110-9] from
2
the front cover.
1
P-53276 Assembly: Tighten bolts to 45 N•m (33 ft-lb) torque.
Remove the plug (Item 1), spring (Item 2) and check

valve (Item 3) from the front cover (Item 4) [Figure 20-
110-7].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly And Assembly (Single Speed Version) 2

(Standard) (Cont’d)
1
Figure 20-110-10
P-53282
Remove the gear assembly (Item 1) from the motor

P-53279
Figure 20-110-13
Remove the front cover (Item 1) from the motor housing

(Item 2) [Figure 20-110-10].
Figure 20-110-11
P-53283
Remove the back-up ring / seal (Item 1) [Figure 20-110-

13] from the gear holder.
P-53281
Remove the seal (Item 1) [Figure 20-110-11] from the

housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly And Assembly (Single Speed Version)

(Standard) (Cont’d)
Figure 20-110-14
P-53256
Remove the snap ring (Item 1) and remove the seal

(Item 2) [Figure 20-110-14].
Assembly: The open part of the seal goes into the rear
cover first.
Figure 20-110-15
P-53285
Inspect the gears (Item 1) [Figure 20-110-15] for

damage or wear.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Parts Identification (Variable Speed Version) (Optional)
20 2
17
6
21 24
17
19 22
19
18 19
17 23
19
11 17
6
18
19
14
15
14
11
4
6
1. Nut
2. Washer
4
4 16 3. Snap Ring
4. Seal
12 5. Rear Cover
13 6. Dowel Pin
7. Shaft
8 8. Key
12 9. Splined Shaft
4 10. Ball Bearing
3 6 11. Flange
12. Back-up Ring
10 13. Gear Assembly
4 14. Holder
9 15. Drive Gear
2 16. Housing
1 7 17. Valve
18. Spring
19. Plug
4 20. Front Cover
21. Coil
6 22. O-ring
23. Solenoid
4 24. Bolt
5
3
NA12101S
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly And Assembly (Variable Speed Version)

(Optional)
2
IMPORTANT 1

damage the system.
I-2003-0888
S40836
Figure 20-110-16
Remove the fitting (Item 1) from the “IN” port and the
fitting (Item 2) [Figure 20-110-18] from the “OUT” port.
Assembly: Tighten the fittings to 45 N•m (33 ft-lb)

torque.
2
1 Figure 20-110-19
S40835
Remove the nut (Item 1) and solenoid (Item 2) [Figure

20-110-16].
Mark the housing for correct assembly.
Figure 20-110-17
S40837

“IN” port fitting.
1
S38803
Remove the two O-rings (Item 1) and the washer (Item 2)

[Figure 20-110-17].
TH.6534(X) / TH.7035(X) / TH.7038(X)


(Optional) (Cont’d)
Figure 20-110-20 1
S38808

fitting.
S38806
Figure 20-110-23

“OUT” port fitting.
Figure 20-110-21
S38809
Remove the solenoid stem (Item 1) [Figure 20-110-23]

from the front cover.
1
S38807
Assembly: Tighten the stem to 30 N•m (22 ft-lb) torque.
Remove the fitting (Item 1) [Figure 20-110-21].
Assembly: Tighten the fitting to 12 N•m (9 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)


Figure 20-110-24
2
S38812
1 Remove six back-up rings (Item 1) and four O-rings (Item

2) [Figure 20-110-26].
S38810
Figure 20-110-27
Remove the back-up ring (Item 1) and two O-rings (Item

2) [Figure 20-110-24] from the solenoid stem.
1
Figure 20-110-25
1 1
1 S38813
Remove five plugs (Item 1) [Figure 20-110-27] from the

front cover.
S38811
Assembly: Tighten the plugs to 15 N•m (11 ft-lb) torque.
Remove the solenoid stem (Item 1) [Figure 20-110-25]

from the front cover.
Assembly: Tighten the solenoid stem to 30 N•m (22 ft-

lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)


Figure 20-110-28 1
S38817

plug.
S38814
Figure 20-110-31
Remove the O-rings (Item 1) [Figure 20-110-28] from the

plugs.
Figure 20-110-29
2
1 1
S38816
Remove the spring (Item 1) and piston (Item 2) [Figure

20-110-31] from the front cover.
S38815
Remove the plug (Item 1) [Figure 20-110-29] from the

front cover.
Assembly: Tighten the plug to 30 N•m (22 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly And Assembly (Variable Speed Version) 1

2
Figure 20-110-32
S38820
Remove the rear cover (Item 1) from the motor housing

(Item 2) [Figure 20-110-34].
1 S38818
Figure 20-110-35
Remove the four bolts and washers (Item 1) and remove

the front cover (Item 2) [Figure 20-110-32].
2
Figure 20-110-33 1
1
2
S38821
1
Remove the two pins (Item 1) and the seal (Item 2)

[Figure 20-110-35] from the motor housing.
S38819
Remove the two pins (Item 1) and the seal (Item 2)

[Figure 20-110-33] from the motor housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)


Figure 20-110-36
1
2 1
S38824

S38822
Figure 20-110-39
Remove the gear assembly (Item 1) from the motor

Figure 20-110-37 2
1
1
S38825
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-110-39].
S38823
Assembly: The open part of the seal goes into the cover
first.
TH.6534(X) / TH.7035(X) / TH.7038(X)


Figure 20-110-40
S38826
Inspect the gears (Item 1) [Figure 20-110-40] for

damage or wear.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC FLUID RESERVOIR Figure 20-120-2
Raise the boom and install the boom stop. (See Installing
1
The Approved Boom Stop on Page 10-150-1.)
Remove the fuel tank. (See Removal And Installation on

Page 50-70-1.)
Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-100-2.)
Figure 20-120-1
1
S40930
2
Remove the three hoses (Item 1) [Figure 20-120-2] from
the hydraulic tank.
1 Figure 20-120-3
1
3
4
S38105
Loosen the two bolts (Item 1) and remove the cover (Item
2) [Figure 20-120-1].
2
P125346
Loosen the hose clamps (Item 1) and remove the hose

(Item 2) [Figure 20-120-3] from the hydraulic tank.
Remove the hose (Item 3) [Figure 20-120-3] from the

hydraulic tank.
Disconnect the hydraulic fluid temperature sensor

connector (Item 4) [Figure 20-120-3] from the hydraulic
tank.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-120-6
Figure 20-120-4
S38292
2
S38798 6] from the hydraulic tank.
Figure 20-120-7
Loosen the hose clamp (Item 1) and remove the hose
(Item 2) [Figure 20-120-4].
Figure 20-120-5
1 1
S38293

S38800 7] from the hydraulic tank.
Remove the hydraulic tank.

hydraulic tank.
Support the hydraulic tank using a jack or forklift.
TH.6534(X) / TH.7035(X) / TH.7038(X)

STEERING VALVE

IMPORTANT
Installation on Page 50-110-1.) When repairing hydrostatic and hydraulic systems,
Figure 20-130-1 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
1 Figure 20-130-3
1
2 1
S38084
Remove the three bolts (Item 1) and remove the cover

cab.
S39130
Figure 20-130-2
Remove the four bolts (Item 1) [Figure 20-130-3] and
1 remove the steering valve.

1 to 44 - 45 N•m (32 - 33 ft-lb) torque.
1 NOTE: The steering valve is not serviceable. If the

steering valve is damaged, the entire valve
must be replaced.
S38111
Remove the five hoses (Item 1) [Figure 20-130-2] from

the steering valve.
NOTE: Mark hoses for correct installation.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
HYDRAULIC CONTROL VALVE
Troubleshooting Chart (Controllers)

WARNING
Personnel. W-2004-1285
PROBLEM CAUSE CORRECTION

None of the solenoid valves work Insufficient power supply Check battery voltage
Insufficient pilot pressure Check pilot / charge pressure
Plugged solenoid valve filter Clean filter
Only one solenoid valve works No actuation signal Check signal voltage
Unsuitable actuation signal Check signal voltage
Insufficient actuation power supply Check signal voltage
All solenoid valves not working or Plugged solenoid valve filter Clean filter
jerky
One solenoid valve not working or Faulty actuation signal Check signal
jerky Friction or jamming of the plunger Replace solenoid valve
One solenoid valve not working or Contamination of the proportional Replace solenoid valve
jerky in one direction valve in the solenoid valve
Solenoid valve creeps Neutral position incorrect Adjust neutral adjustment
Oil leakage between control valve Faulty seals Replace seal
and solenoid valve
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D)
Valve Section Troubleshooting CODE FUNCTION REF

W2305 Lift Down Output Short To Battery 1
Record the serial number of the machine, control valve
W2306 Lift Down Output Short To Ground 1
and control module.
W2307 Lift Down Output Open Circuit 1
The following procedure must be done with the control W2332 Lift Down Output Overcurrent 1
valve in the machine. The control valve is removed for
W2205 Lift Up Output Short To Battery 2
photo clarity.
W2206 Lift Up Output Short To Ground 2
Raise the boom and install the boom stop. (See Installing W2207 Lift Up Output Open Circuit 2
W2232 Lift Up Output Overcurrent 2
Figure 20-140-1 W2405 Tilt Out Output Short To Battery 3
W2406 Tilt Out Output Short To Ground 3
W2407 Tilt Out Output Open Circuit 3
W2432 Tilt Out Output Overcurrent 3
W2505 Tilt Back Output Short To Battery 4
W2506 Tilt Back Output Short To Ground 4
1 W2507 Tilt Back Output Open Circuit 4
W2532 Tilt Back Output Overcurrent 4
W2605 Extend Output Short To Battery 5
W2606 Extend Output Short To Ground 5
W2607 Extend Output Open Circuit 5
2 W2632 Extend Output Overcurrent 5
P122916
W2705 Retract Output Short To Battery 6
W2706 Retract Output Short To Ground 6
The joystick lockout function must be disabled (light (Item
W2707 Retract Output Open Circuit 6
1) [Figure 20-140-1] is OFF).
W2732 Retract Output Overcurrent 6
To disable, press the button (Item 2) [Figure 20-140-1] to D7705 Aux Male Output Short To Battery 7
turn OFF for all testing procedures.
D7706 Aux Male Output Short To Ground 7
1. Check for diagnostic service codes. (See Operation & D7707 Aux Male Output Open Circuit 7
Maintenance Manual for the correct procedure.) D7732 Aux Male Output Overcurrent 7
When no service code is read, go to step 9.
D7605 Aux Female Output Short To Battery 8
Figure 20-140-2 D7606 Aux Female Output Short To Ground 8
D7607 Aux Female Output Open Circuit 8
D7632 Aux Female Output Overcurrent 8
2. Locate the valve section and solenoid valve to which

8 6 4 the service code refers [Figure 20-140-2]:
2
7 5 3 1 S40859
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-140-4
Valve Section Troubleshooting (Cont’d)
3. Disconnect the solenoid valve of the valve which has

been diagnosed and plug back in. 2
4. With adequate room in front of the machine, start the

engine and run the engine at low idle (900 rpm). 1
Operate the function which has been diagnosed
[Figure 20-140-3]. Move forward and back to see if
the function works. Stop the engine.
Figure 20-140-3
1 S40904
7
5 5. Disconnect the solenoid valve connector (Item 1)
3 [Figure 20-140-4] which has been diagnosed (“Tilt
Back” solenoid valve shown in picture).
4 6. Remove the two screws (Item 2) [Figure 20-140-4]
8
6 and pull out the solenoid valve (“Tilt Back” solenoid
valve shown in picture).
NOTE: Install a cap on the valve opening to prevent

2 contamination.
P126569
Figure 20-140-5
REF FUNCTION
1 Lower Boom
2 Raise Boom 1
3 Tilt Down
4 Tilt Up
5 Extend Telescopic Boom
6 Retract Telescopic Boom
7 Front Auxiliary Hydraulics B4 (Male Coupler)
8 Front Auxiliary Hydraulics A4 (Female Coupler)
S40849
IMPORTANT 7. Use an ohmmeter to check the solenoid. The reading

between both electrical connector terminals must be
approximately 5 ohm (Item 1) [Figure 20-140-5].
clean the work area before disassembly and keep all If the solenoid measurement is correct, the error could be
parts clean. Always use caps and plugs on hoses, located in wiring / connectors to the solenoid.
damage the system. 8. Reinstall the solenoid valve.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) P-Standby Pressure Checking (Only For TH.7035(X))
Valve Section Troubleshooting (Cont’d) Figure 20-140-8
Pilot Pressure Checking
Figure 20-140-6
1
S40793
13. Locate the test fitting (Item 1) [Figure 20-140-8] and

S40906 remove the cap.
14. Install a 7,0 MPa (70 bar) (1000 psi) gauge on the test
9. Locate the test fitting (Item 1) [Figure 20-140-6] at
fitting (Item 1) [Figure 20-140-8] located on the P-
the control valve and remove the cap.
port of the control valve.
Figure 20-140-7
15. Start the engine and run the engine at low idle (900
rpm). Record the pressure. The pressure at the gauge
should be within the following range: 1,3 - 1,5 MPa
(13 - 15 bar) (189 - 218 psi).
16. Run the engine at high idle (2315 rpm) and record the
pressure. The pressure at the gauge should be within
the following range: 1,6 - 1,8 MPa (16 - 18 bar) (232 -
261 psi).
S40905
10. Install a 7,0 MPa (70 bar) (1000 psi) gauge on the test
fitting [Figure 20-140-7].
11. Start the engine and run the engine at 2315 rpm.
Record the pressure. The pressure at the gauge
should be within the following range: 2,5 - 3,5 MPa
(25 - 35 bar) (363 - 508 psi).
12. Remove the gauge.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Valve Section Troubleshooting (Cont’d)
For All Machines

1
17. With adequate room in front of the machine, start the
engine and run the engine at low idle (900 rpm).
Operate the function which has been diagnosed
[Figure 20-140-9]. Move forward and back to see if
the function works. Stop the engine.
Figure 20-140-9
1
S40904
7
5
3 18. Remove the two screws (Item 1) [Figure 20-140-10]
and pull out the solenoid valve.
4 NOTE: Install a cap on the valve opening to prevent
8
6 dust penetration.
Figure 20-140-11
2
P126569
REF FUNCTION
1 Lower Boom
2 Raise Boom
3 Tilt Down
4 Tilt Up
5 Extend Telescopic Boom
1
6 Retract Telescopic Boom
S7171
7 Front Auxiliary Hydraulics B4 (Male Coupler)
8 Front Auxiliary Hydraulics A4 (Female Coupler)
19. Turn the Ignition key switch ON, but DO NOT start the
engine. Check the function of each solenoid valve by
having another person move the joystick or switch
(Item 1) [Figure 20-140-9]. The solenoid valve
piston, which can be seen through the valve orifices
(Item 1) [Figure 20-140-11] must be moving
according to the switch movement.
20. If a solenoid valve does not function properly, it must

be replaced.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Troubleshooting Chart (Control Valve)

WARNING
Personnel. W-2004-1285
AFFECTED
PROBLEM CAUSE CORRECTION
MACHINE
Lack of strength at all All Load sense relief cartridge Replace relief cartridge
actuators defective
Load sense relief cartridge out Make necessary adjustments
of adjustment
Lack of force on one actuator All Secondary relief valve out of Reset to original pressure
only adjustment
Secondary relief valve blocked Replace relief valve
open
Lack of load hold All Load check valve failure Replace load check valve
Excessive clearance between Replace housing and spool
housing and spool
Simultaneous movement of All Blockage of individual Remove and clean orifice
controls compensator orifice
Individual pressure Replace housing and
compensator blocked compensator
Load sense line leakage Replace load sense regulator
Engine remains under load TH.7035(X) Flow regulator blocked Replace flow regulator
after spools are returned to Flow regulator filter clogged Replace filter
neutral
Detent malfunction All Controller defective Replace controller
Spool return difficult All Tie rod bolts too tight Re-torque tie rod bolts
Spool leaking oil All Defective spool seal Replace spool seal
Oil leakage between valve All Defective seals Replace seals
section
TH.6534(X) / TH.7035(X) / TH.7038(X)

Main Relief Valve Testing And Adjustment (Only For

TH.7035(X))
The following tool will be needed to do the following

procedure:
MEL10003 - Hydraulic Tester
Figure 20-140-1
2 1
4 P122916
Start the engine and run at low idle rpm. Press the front
5
auxiliary hydraulics button (Item 1) [Figure 20-140-2].
3 Make sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
With the hoses connected correctly, increase the engine
speed to 2400 rpm.
1 S39186 Warm the fluid to 50°C (122°F) by turning the restrictor

control (Item 5) [Figure 20-140-1] on the tester to about
6,9 MPa (69 bar) (1000 psi). DO NOT exceed system
Connect the inlet hose (Item 1) from the tester (Item 5) to relief pressure. Open the restrictor control knob and
the front coupler (Item 2) [Figure 20-140-1]. record the free flow (U.S. gpm) at 2400 rpm.
Connect the outlet hose (Item 3) from the tester (Item 5) There should be 150 L/min (39.6 U.S. gpm) free flow.
to the rear coupler (Item 4) [Figure 20-140-1]. Turn the restrictor control (Item 5) [Figure 20-140-1] on
the tester until the main relief opens. The correct
pressure should be 25,5 MPa (255 bar) (3698 psi).
If adjustment is needed, see [Figure 20-140-3].

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) Main Relief Valve Removal And Installation
Main Relief Valve Testing And Adjustment (Only For

Raise the boom and install the boom stop. (See Installing IMPORTANT
Figure 20-140-3 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
1
Figure 20-140-5
S40793
Locate the main relief valve (Item 1) on the front upper

side of the control valve [Figure 20-140-3].
Figure 20-140-4
S40793
Locate the main relief valve (Item 1) [Figure 20-140-5]

on the front upper side of the control valve.
2
Clean the area around the control valve.
1
Remove the main relief valve (Item 1) [Figure 20-140-5].
Installation: Tighten the main relief valve to 45 N•m

(33 ft-lb) torque.
S40794
Loosen the lock nut (Item 1) and turn the adjustment

screw (Item 2) [Figure 20-140-4] clockwise to increase
the pressure or counterclockwise to decrease the
pressure.
Retest the main relief valve after adjustment.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) Tool Installation to measure P pressure
Piston Pump Testing (Only For TH.6534(X) And Figure 20-140-1

TH.7038(X))
NOTE: In case of pump malfunction after piston

pump testing, do not adjust the pump
regulator valves but proceed to the full piston
pump replacement.
Test Tools Installation
WARNING
1
S40793
Put jackstands under the front and rear of the
machine before running engine for service. Locate the main pressure valve test fitting (Item 1)
W-2718-0208
[Figure 20-140-1] on the control valve and remove the
cap.
The tools listed will be needed to do the following
procedure: Figure 20-140-2
• MEL10003 - Hydraulic Tester

• 6670065 - Coupler
• 7025278 - LS Pump and Main Valve Troubleshooting
Test Kit 1
• 6671371 - Low Pressure Gauge 7 MPa (70 bar) (1000
psi)
• 6671380 - High Pressure Gauge 34,5 MPa (345 bar)
(5000 psi)
Lift and block the telescopic handler. (See Procedure on

Page 10-10-1.)
S40690
Install a gauge on the test port (Item 1) [Figure 20-140-

2] located on the P-port of the control valve to measure P
pressure on the main valve.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) NOTE: When testing the hydraulic flow of a machine,
hoses must be at least 19 mm (0.75 in) in
Piston Pump Testing (Only For TH.6534(X) And diameter and connected directly to the
TH.7038(X)) (Cont’d) hydraulic tester without using any type of
“quick coupler” on the connection to the
Tools Installation to measure LS pressure tester. Also make sure your hydraulic tester is
capable of at least 190 L/min (50 U.S. gpm).
Figure 20-140-3
Connect the inlet hose (Item 1) from the tester
(MEL10003) (Item 2) to the front coupler (Item 3)
1 [Figure 20-140-4].
2 Connect the outlet hose (Item 4) from the tester (Item 2)

to the rear coupler (Item 5) [Figure 20-140-4].
Hydraulic tester installed to measure hydraulic flow:

4
Figure 20-140-5
S40688
Install LS Pump and Main Valve Troubleshooting Test Kit

(7025278) (Item 1) between the LS port on main valve
(Item 2) and the hose (Item 3). Connect the coupler
(6670065) (Item 4) to the LS Pump and Main Valve
Troubleshooting Test Kit (Item 1) [Figure 20-140-3].
1
Install a gauge on the coupler (Item 4) [Figure 20-140-3]
to measure LS pressure on the main valve.
P-22253
Tools Installation to measure hydraulic flow

Open the restrictor valve fully (Item 1) [Figure 20-140-5].
Figure 20-140-4
Start the engine and run at low idle rpm. Activate on the
display the auxiliary hydraulic system and engage the
front auxiliary hydraulic. Make sure the hydraulic tester is
3 connected correctly. If no flow is indicated on the tester,
5 the hoses are connected wrong.
Shut the front auxiliary hydraulics and the engine off.

2
1 S39186
TH.6534(X) / TH.7035(X) / TH.7038(X)

Piston Pump Testing (Only For TH.6534(X) And 2. Auxiliary flow at 100% - Engine speed at 900 rpm:
Use the low pressure gauge 7 MPa (70 bar) (1000 psi).
Procedure
Activate the front auxiliary hydraulics at maximum flow.
With the front auxiliary hydraulics at maximum flow:

IMPORTANT • Record the P pressure.
The hydraulic tester must be in the fully open • Record the LS pressure.
position before you start the engine.
I-2024-0284 • The difference between P pressure and LS pressure
should be 1,5 - 2,1 MPa (15 - 21 bar) (218 - 305 psi).
This procedure will require one operator in the cab and
• Record the auxiliary hydraulic flow from the hydraulic
one operator running the tester.
tester. Hydraulic flow should be 30 - 40 L/min (7.9 -
10.6 U.S. gpm).
NOTE: If flow and pressure specifications are not
obtained, (See Troubleshooting Chart (Piston
3. Auxiliary flow at 100% combined with movement
Pump Testing) (Only For TH.6534(X) And
on end stroke - Engine speed at 900 rpm:
TH.7038(X)) on Page 20-140-14.)
Use the high pressure gauge 34,5 MPa (345 bar) (5000
Make sure the restrictor valve (Item 1) [Figure 20-140-5]
psi).
is fully open.
Start the engine at low idle. Activate on the display the
auxiliary hydraulic system and set the maximum available Figure 20-140-6
auxiliary flow setting to 100%. (See the Operation
Manual for the correct procedure.)
Warm the hydraulic fluid to 50°C (122°F).
After the temperature of the hydraulic fluid has reached 1

50°C (122°F), adjust the engine speed to 900 rpm.
1. Standby condition - Engine speed at 900 rpm:
Make sure that the front auxiliary hydraulics are

deactivated.
P123195
• Record the P pressure.
• P pressure should be 2,0 - 3,0 MPa (20 - 30 bar) (290 With the boom fully retracted, pull the left switch on the
- 435 psi). joystick (Item 1) [Figure 20-140-6] down as if to retract
the boom even further. This procedure allows for both
• Record the LS pressure. pressure and auxiliary flow to be at their maximum value
at the same time.
• The difference between P pressure and LS pressure
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) Increase the engine speed to 1600 rpm. The temperature
of the hydraulic fluid should still be at 50°C (122°F).
Piston Pump Testing (Only For TH.6534(X) And
TH.7038(X)) (Cont’d) 5. Auxiliary flow at 100% - Engine speed at 1600
rpm:
Procedure (Cont’d)
With the front auxiliary hydraulics at maximum flow and
while pulling the left switch on the joystick (Item 1) Activate the front auxiliary hydraulics at maximum flow.
[Figure 20-140-6] down:
• P pressure should be 25,0 - 26,0 MPa (250 - 260 bar)
(3626 - 3771 psi). • Record the LS pressure.
• Record the LS pressure. • The difference between P pressure and LS pressure
should be under 1,5 MPa (15 bar) (218 psi).
should be under 1,5 MPa (15 bar) (218 psi). • Record the auxiliary hydraulic flow from the hydraulic
tester. Hydraulic flow should be 125 - 135 L/min (33.0
- 35.7 U.S. gpm).
tester. Hydraulic flow should be 15 - 25 L/min (4.0 -
6.6 U.S. gpm).
4. Movement on end stroke - Engine speed at 900 on end stroke - Engine speed at 1600 rpm:
rpm:
Use the high pressure gauge 34,5 MPa (345 bar) (5000 psi).
psi).
Make sure that the front auxiliary hydraulics are
deactivated. With the boom fully retracted, pull the left switch on the
joystick (Item 1) [Figure 20-140-6] down as if to retract
With the boom fully retracted, pull the left switch on the the boom even further.
the boom even further. With the front auxiliary hydraulics at maximum flow and
while pulling the left switch on the joystick (Item 1)
While pulling the left switch on the joystick (Item 1) [Figure 20-140-6] down:
• P pressure should be 25,0 - 26,0 MPa (250 - 260 bar) (3626 - 3771 psi).
(3626 - 3771 psi).
• Record the LS pressure.
• The difference between P pressure and LS pressure should be under 1,5 MPa (15 bar) (218 psi).
should be under 1,5 - 2,1 MPa (15 - 21 bar) (218 - 305
psi). • Record the auxiliary hydraulic flow from the hydraulic
- 27.7 U.S. gpm).
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) 9. Cycle time without load - Engine speed at 2400
rpm:
Piston Pump Testing (Only For TH.6534(X) And
TH.7038(X)) (Cont’d) With the engine speed at 2400 rpm, measure the
duration of the different boom movement cycle times with
Procedure (Cont’d) a timer.
Increase the engine speed to 2400 rpm. The temperature Unload the telescopic handler for this procedure.
of the hydraulic fluid should still be at 50°C (122°F).
BOOM MOVEMENT CYCLE TIMES
7. Auxiliary flow at 100% - Engine speed at 2400
rpm: Raise boom 4,75 - 5,25 s
Lower boom 4,00 - 4,50 s
Extend telescopic boom 4,75 - 5,25 s
Activate the front auxiliary hydraulics at maximum flow. Retract telescopic boom 4,75 - 5,25 s
Tilting attachment carrier up 2,00 - 2,50 s
Tilting attachment carrier down 2,00 - 2,50 s
If the boom movement cycle times differ from the cycle
• Record the LS pressure. times in the table, the problem lies with the hydraulic
control valve. (See Valve Section Troubleshooting on
• The difference between P pressure and LS pressure Page 20-140-2.)

- 40.9 U.S. gpm).

on end stroke - Engine speed at 2400 rpm:
psi).
With the boom fully retracted, pull the left switch on the
the boom even further.
With the front auxiliary hydraulics at maximum flow and

while pulling the left switch on the joystick (Item 1)

(3626 - 3771 psi).


- 35.7 U.S. gpm).
TH.6534(X) / TH.7035(X) / TH.7038(X)

Troubleshooting Chart (Piston Pump Testing) (Only

For TH.6534(X) And TH.7038(X))
Tests At Minimum Speed 900 rpm, Oil Temperature @ 50°C
1. Standby Condition - Engine speed at 900 rpm:
MEASUREMENT POINT CORRECT VALUE MEASURED VALUE PROBLEM

P 2,0 - 3,0 MPa Too low - Too high Steering unit
(20 - 30 bar) Main valve bleed
(290 - 435 psi)
Priority valve
P - LS 1,5 - 2,1 MPa Too low - Too high LS regulator
(15 - 21 bar) Pump displacement system
(218 - 305 psi)
Flushing valve
2. Auxiliary flow at 100% - Engine speed at 900 rpm:

Auxiliary Flow (tester) 30 - 40 L/min Too low - Too high Pressure sensor
(7.9 - 10.6 U.S. gpm) Pump control current
Pump displacement system
Shut-off valve
Pilot pressure
Main valve electric control
Priority valve
Main valve
3. Auxiliary flow at 100% combined with movement on end stroke - Engine speed at 900 rpm:

P 25,0 - 26,0 MPa Too low Maximum pressure regulator
(250 - 260 bar) LS relief valve
(3626 - 3771 psi)
P - LS < 1,5 MPa >= 1,5 MPa Torque regulator
(15 bar) (15 bar) Pump displacement system
(218 psi) (218 psi)
(4.0 - 6.6 U.S. gpm) Pump control current
Shut-off valve
Pilot pressure
Priority valve
Main valve
TH.6534(X) / TH.7035(X) / TH.7038(X)

Troubleshooting Chart (Piston Pump Testing) (Only For TH.6534(X) And TH.7038(X)) (Cont'd)
4. Movement on end stroke - Engine speed at 900 rpm:

P 25,0 - 26,0 MPa Too low LS relief valve
(250 - 260 bar) Maximum pressure regulator
(3626 - 3771 psi)
Leakage on LS line
Too high but < 2,80 LS relief valve
MPa (280 bar) (4061
psi)
Too high and > 2,80 LS relief valve & maximum pressure
MPa (280 bar) (4061 regulator
psi)
P - LS 1,5 - 2,1 MPa Too low - Too high LS regulator
(15 - 21 bar) Pump displacement system
(218 - 305 psi)
Flushing valve
Tests At Medium Speed 1600 rpm, Oil Temperature @ 50°C

(33.0 - 35.7 U.S. Pump control current
gpm)
Shut-off valve
Pilot pressure
Priority valve
Main valve

(3626 - 3771 psi)
gpm)
Shut-off valve
Pilot pressure
Priority valve
Main valve
TH.6534(X) / TH.7035(X) / TH.7038(X)

Troubleshooting Chart (Piston Pump Testing) (Only For TH.6534(X) And TH.7038(X)) (Cont'd)
Tests At Maximum Speed 2400 rpm, Oil Temperature @ 50°C

gpm)
Shut-off valve
Pilot pressure
Priority valve
Main valve

(3626 - 3771 psi)
gpm)
Shut-off valve
Pilot pressure
Priority valve
Main valve
TH.6534(X) / TH.7035(X) / TH.7038(X)

Servo Piston Testing (Only For TH.6534(X) And

TH.7038(X))
Test the servo piston in case of any of these issues:
• Hydraulic fluid is overheated
• Engine is overloaded
• Noise coming from main valve inlet section 1
If any of these issues exist, follow the next procedure to

test the servo piston.
S40851
Servo Piston Testing Procedure
This procedure will require one operator in the cab and • Increase the setting of the flushing valve on the
one operator running the tester. hydraulic control valve (Item 1) [Figure 20-140-7] by
adding a 5 mm washer between the valve and the
The setup for this testing procedure is the same as for the spring. (See Disassembly And Assembly on Page 20-
piston pump testing procedure, without the Hydraulic 140-21.)
Tester (MEL10003). (See Test Tools Installation on Page
20-140-9.) • The P pressure should increase to approximately 3,5
MPa (35 bar) (507.6 psi).
Start the engine at low idle. Activate on the display the
auxiliary hydraulic system and set the maximum available • Record the LS pressure a second time.
auxiliary flow setting to 50%. (See the Operation Manual
for the correct procedure.) • Record the difference between the new P pressure
and LS pressure.
Warm the hydraulic fluid to 50°C (122°F).
Remove the washer and repeat the procedure, this time
After the temperature of the hydraulic fluid has reached without pulling down the left switch on the joystick.
50°C (122°F), adjust the engine speed to 900 rpm.
If in any of the procedures the difference between P
Use the low pressure gauge 7 MPa (70 bar) (1000 psi). pressure and LS pressure increases with more than 1,5 -
2,0 MPa (15 - 20 bar) (217.6 - 290.1 psi), the pump must
Activate the front auxiliary hydraulics at 50% flow. be replaced. (See Removal And Installation on Page 20-
140-18.)
With the boom fully retracted, pull the left switch on the
the boom even further.
With the front auxiliary hydraulics at 50% flow and while

pulling the left switch on the joystick (Item 1) [Figure 20-
140-6] down:
• P pressure should be approximately 2,5 MPa (25 bar)

(362.6 psi).

TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) NOTE: Mark all hoses and harnesses for correct
installation.
Figure 20-140-9
2 3
WARNING
Hydraulic fluid escaping under pressure can have 1
sufficient force to enter a person’s body by 4
and possible death if proper medical treatment by a 5
S38604
immediately.
W-2145-0290
Replace the bolt (Item 1) by a longer bolt (Item 2)

equipped with a nut (Item 3). Tighten the nut (Item 3)
[Figure 20-140-9].
IMPORTANT Repeat the above step for the bolt (Item 4) [Figure 20-
140-9].
damage the system.
I-2003-0888
Figure 20-140-8
S40850
Remove the seventeen hoses from the hydraulic control

valve [Figure 20-140-8].
Remove the nine electrical harnesses from the hydraulic

control valve [Figure 20-140-8].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 20-140-10
1
1
1
S38607
Remove the bolts (Item 1) [Figure 20-140-12].

S38607
Remove the hydraulic control valve.
Loosen the nuts (Item 1) [Figure 20-140-10] in order to Use care not to damage the tubelines or fittings.
create a gap between the frame and control valve.
Figure 20-140-11
S40851
Install a hoist and lifting strap (Item 1) [Figure 20-140-

11] on the control valve.
TH.6534(X) / TH.7035(X) / TH.7038(X)

1. End Housing
2. Auxiliary Valve Section
3. Telescoping Valve Section
4. Tilting Valve Section
5. Lifting Valve Section
6. Inlet-Outlet Valve Section
6
1
2 3 4 5
S40859
TH.6534(X) / TH.7035(X) / TH.7038(X)

IMPORTANT
damage the system.
I-2003-0888 1
S40860
Mark the valve sections for ease of assembly. (See Parts
Identification on Page 20-150-20.)
Remove the three nuts (Item 1) [Figure 20-140-14] from
Figure 20-140-13 the tie rod bolts.
Assembly: Tighten the nuts to 35 N•m (26 ft-lb) torque.
S40852
Remove all hydraulic fittings. Mark the valve sections for

proper assembly [Figure 20-140-13].
TH.6534(X) / TH.7035(X) / TH.7038(X)

End Housing Disassembly And Assembly
Figure 20-140-15 1
S38744

S40861 valve section.
Figure 20-140-18
Remove the end housing (Item 1) [Figure 20-140-15].
Figure 20-140-16
1
S38745
1
S40862 Remove the O-ring (Item 1) [Figure 20-140-18] from the

plug.
Remove the nine O-rings (Item 1) [Figure 20-140-16]

from the valve section.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONTROL VALVE (CONT’D) Auxiliary Valve Section Disassembly And Assembly
End Housing Disassembly And Assembly (Cont’d) Figure 20-140-21
Figure 20-140-19
S40864
S38747
Remove the auxiliary valve section (Item 1) [Figure 20-
140-21].
Remove the valve (Item 1) [Figure 20-140-19].
Figure 20-140-22
Figure 20-140-20
1
1
1
S40865
S38748
Remove the seven O-rings (Item 1) [Figure 20-140-22]

Remove the two O-rings (Item 1) [Figure 20-140-20]. from the valve section.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Auxiliary Valve Section Disassembly And Assembly

2
(Cont’d)
Figure 20-140-23
1
S38697
Remove the four screws (Item 1) [Figure 20-140-25]

1 from the controller.
S38695
Remove the two solenoids (Item 2) [Figure 20-140-25]
from the controller.
Remove the screws (Item 1) [Figure 20-140-23] from the
valve section. Figure 20-140-26
Figure 20-140-24
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-140-26]
Remove the three O-rings (Item 1) [Figure 20-140-24]

TH.6534(X) / TH.7035(X) / TH.7038(X)


(Cont’d)
Figure 20-140-27
S40868
Remove the O-ring (Item 1) (both sides) [Figure 20-140-

29].
S40866
Figure 20-140-30
Remove the spool (Item 1) [Figure 20-140-27].
Figure 20-140-28
1 1 S38702

S40867
Remove the three screws (Item 1) and remove the cover

(Item 2) [Figure 20-140-28].
TH.6534(X) / TH.7035(X) / TH.7038(X)


(Cont’d)
Figure 20-140-31
1 1
S38705
S38741 Figure 20-140-34
Remove the plug (Item 1) [Figure 20-140-31]. 1

2
Figure 20-140-32
3
4
1
1
2
S38719
Remove the spring (Item 1) and two shuttle spools (Items

2 and 3) [Figure 20-140-34] from the valve section.
S38740
Remove the O-rings (Item 4) [Figure 20-140-34] from
the plug.
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-140-32] from the plug.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Telescoping Valve Section Disassembly And

Assembly
Figure 20-140-35
1
1
1
S38695

valve section.
S40869
Figure 20-140-38
Remove the telescoping valve section (Item 1)

[Figure 20-140-35].
Figure 20-140-36
1
1
1
1
S38696
1 Remove the three O-rings (Item 1) [Figure 20-140-38]

S38694

TH.6534(X) / TH.7035(X) / TH.7038(X)


Assembly (Cont’d)
Figure 20-140-39
2
1
1
S38698
S38697 Figure 20-140-42


2
Figure 20-140-40
1 1
S38700

(Item 2) [Figure 20-140-42].
S38691
Clean the filter screen (Item 2) [Figure 20-140-40].
TH.6534(X) / TH.7035(X) / TH.7038(X)


Assembly (Cont’d)
1
Figure 20-140-43
S38703
S38701 Figure 20-140-46

43].
1
Figure 20-140-44 2
1
3
S38704
Remove the port relief spool assembly (Item 1) and

spring (Item 2) [Figure 20-140-46].

plug.
TH.6534(X) / TH.7035(X) / TH.7038(X)


2
Figure 20-140-47
3
S38719

S38705
the plug.
The relief pressure value (in bar) of the port relief valve is
indicated on the spool assembly (Item 1) [Figure 20-140-
47].
Repeat for the other side of the valve section.
Figure 20-140-48
S38705
TH.6534(X) / TH.7035(X) / TH.7038(X)

Tilting Valve Section Disassembly And Assembly
Figure 20-140-50
1
S38695

Figure 20-140-53
Remove the tilting valve section (Item 1) [Figure 20-140-
50].
Figure 20-140-51
1 1
1
S38696
1
S38694 from the controller.

TH.6534(X) / TH.7035(X) / TH.7038(X)


(Cont’d)
Figure 20-140-54
2
1
1
S38698
S38697 Figure 20-140-57


2
Figure 20-140-55
1 1
S38700

(Item 2) [Figure 20-140-57].
S38691
TH.6534(X) / TH.7035(X) / TH.7038(X)


(Cont’d)
1
Figure 20-140-58
S38703
S38701 Figure 20-140-61

58].
1
Figure 20-140-59 2
1
3
S38704


plug.
TH.6534(X) / TH.7035(X) / TH.7038(X)


(Cont’d) 1
2
Figure 20-140-62
3
S38719

S38705
the plug.
62].
Figure 20-140-63
S38705
TH.6534(X) / TH.7035(X) / TH.7038(X)

Lifting Valve Section Disassembly And Assembly
Figure 20-140-65
1
S38695

Figure 20-140-68
Remove the lifting valve section (Item 1) [Figure 20-140-
65].
Figure 20-140-66
1 1
1
S38696
1
S38694 from the controller.

TH.6534(X) / TH.7035(X) / TH.7038(X)


(Cont’d)
Figure 20-140-69
2
1
1
S38698
S38697 Figure 20-140-72


2
Figure 20-140-70
1 1
S38700

(Item 2) [Figure 20-140-72].
S38691
TH.6534(X) / TH.7035(X) / TH.7038(X)


(Cont’d)
1
Figure 20-140-73
S38703
S38701 Figure 20-140-76

73].
1
Figure 20-140-74 2
1
3
S38704


plug.
TH.6534(X) / TH.7035(X) / TH.7038(X)


(Cont’d) 1
2
Figure 20-140-77
3
S38719

S38705
the plug.
77].
Figure 20-140-78
S38705
TH.6534(X) / TH.7035(X) / TH.7038(X)

Inlet-Outlet Valve Section Disassembly And

Assembly 1
Figure 20-140-80
1
S38614
1
Remove the valve stem (Item 1) [Figure 20-140-82] from
the inlet-outlet valve section.
S40872
Remove the main relief valve (Item 2) [Figure 20-140-82]
from the inlet-outlet valve section.
Remove the tie rods (Item 1) from the inlet-outlet valve
section (Item 2) [Figure 20-140-80]. Figure 20-140-83
Figure 20-140-81
1
1
2
3
2
S38615
S40873
Remove the O-ring (Item 1), two back-up rings (Item 2)
and O-ring (Item 3) [Figure 20-140-83] from the valve
Remove the nut (Item 1) and valve stem solenoid (Item 2) stem.
[Figure 20-140-81] from the inlet-outlet valve section.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Inlet / Outlet Valve Section Disassembly And

Figure 20-140-84
3
2
1 6 5
1
5
S40876
2 Remove the spring retainer (Item 1), spring (Item 2),

spool (Item 3) and plug (Item 4) [Figure 20-140-86] from
S38616 the inlet-outlet valve section.
Remove the O-rings (Item 5) from the spring retainer and

Remove the O-ring (Item 1), back-up ring (Item 2) and O- the plug. Remove the seal (Item 6) [Figure 20-140-86]
ring (Item 3) [Figure 20-140-84] from the main relief from the plug.
valve.
Figure 20-140-85
3
2 4
1
S40875
Remove the spring retainer (Item 1), spring (Item 2),

spool (Item 3) and plug (Item 4) [Figure 20-140-85] from
the inlet-outlet valve section.

the spring retainer and the plug.
TH.6534(X) / TH.7035(X) / TH.7038(X)

PORT RELIEF VALVES Figure 20-150-2
Testing 6 4 2
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 5 3 1
damage the system.
I-2003-0888
S40859
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Massey NOTE: The valve is shown removed from the
Ferguson hydraulic fluid. machine for photo clarity.
Figure 20-150-1 Boom Port Relief set at:

Rod End (Item 1) [Figure 20-150-2] 27,5 - 30,0 MPa
[275 - 300 bar] [3988 - 4351 psi]
Base End (Item 2) [Figure 20-150-2] 27,5 - 30,0 MPa
[275 - 300 bar] [3988 - 4351 psi]
Tilt Port Relief set at:

[275 - 300 bar] [3988 - 4351 psi]
Base End (Item 4) [Figure 20-150-2] 27,5 - 30,0 MPa
[275 - 300 bar] [3988 - 4351 psi]
Telescopic Boom Port Relief set at:

[275 - 300 bar] [3988 - 4351 psi]
S40792 Base End (Item 6) [Figure 20-150-2] 27,5 - 30,0 MPa
[275 - 300 bar] [3988 - 4351 psi]
Install the hand pump, hose and a pressure gauge

(minimum of 34,4 MPa [344 bar] [5000 psi]) into the valve
section work port in which the port relief valve is located
[Figure 20-150-1]. Pressurize this section with the hand
pump until the port relief valve opens and record the
pressure reading.
If the port relief pressure setting is too high / low, release

the hand pump pressure valve and replace the port relief
valve.
TH.6534(X) / TH.7035(X) / TH.7038(X)

PORT RELIEF VALVES (CONT’D) Figure 20-150-5
Replacement Procedure
Figure 20-150-3
1
6 4 2
5 3 1 S38705
Replace the port relief valve spool (Item 1) [Figure 20-

S40859
150-5].
REF FUNCTION The relief pressure value (in bar) of the port relief valve is
indicated on the end of the assembly (Item 2) [Figure 20-
1 Lower Boom Port Relief Valve (Rod End) 150-5].
2 Raise Boom Port Relief Valve (Base End)
Figure 20-150-6
3 Tilt Out Port Relief Valve (Rod End)
4 Tilt Back Port Relief Valve (Base End)
5 Retract Telescopic Boom Port Relief Valve (Rod End)
6 Extend Telescopic Boom Port Relief Valve (Base End) 1
Remove the port relief valve plug [Figure 20-150-3]. 2

3
NOTE: The valve is shown removed from the
machine for photo clarity.
Figure 20-150-4
2 S38749
1
Install the port relief valve spool (Item 1), spring (Item 2)
and the plug (Item 3) [Figure 20-150-6].
Tighten the plug (Item 3) [Figure 20-150-6] to 24 N•m

(18 ft-lb) torque.
S38749
Remove the spring (Item 1) and port relief valve

assembly (Item 2) [Figure 20-150-4] from the hydraulic
control valve.
plug.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ACCUMULATORS Figure 20-160-2
Brake Accumulator Removal And Installation (If

Equipped)
WARNING 1

2
doctor familiar with this injury is not received
immediately. S38074
W-2145-EN-0210
Remove the cover plate (Item 1) to access the

accumulator which is mounted right below the frame
(Item 2) [Figure 20-160-6].
IMPORTANT For Italian Parking Brake:
When repairing hydrostatic and hydraulic systems, Figure 20-160-3

1
damage the system.
I-2003-0888
Figure 20-160-1
2
P125370
Remove the tubeline (Item 1) [Figure 20-160-3].
1 Loosen the clamp (Item 2) [Figure 20-160-3] and

remove the accumulator.
S38006

[Figure 20-160-1].
Stop the engine.
With engine off, subsequently engage and disengage the

service brake pedal for 30 times in order to release
remaining hydraulic pressure in the accumulator (if
equipped).
TH.6534(X) / TH.7035(X) / TH.7038(X)

ACCUMULATORS (CONT’D) Gear Pump Accumulator Removal And Installation
Brake Accumulator Removal And Installation (If Figure 20-160-5

Equipped) (Cont’d)
WARNING
doctor familiar with this injury is not received 1
immediately.
W-2145-EN-0210
S38006
IMPORTANT [Figure 20-160-5] (See Installing The Approved Boom

Stop on Page 10-150-1.).
When repairing hydrostatic and hydraulic systems, Stop the engine.

parts clean. Always use caps and plugs on hoses, Relieve hydraulic pressure.
damage the system.
I-2003-0888
For German Service Brake:
Figure 20-160-4
2
P125369
Remove the tubeline (Item 1) [Figure 20-160-4].
Loosen the clamp (Item 2) [Figure 20-160-4] and

remove the accumulator.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ACCUMULATOR (CONT’D) Figure 20-160-7
Gear Pump Accumulator Removal And Installation

3
(Cont’d)
2
WARNING
Hydraulic fluid escaping under pressure can have 1
immediately.
W-2145-0290 S40901
Loosen the clamp (Item 1) and remove the hose (Item 2)

from the accumulator (Item 3) [Figure 20-160-7].
WARNING Figure 20-160-8
Load, unload and turn on flat level ground. Do not 1

exceed Rated Operating Capacity (ROC) shown on
sign (decal) in cab. Failure to obey warnings can 2
cause the machine to tip or rollover and cause injury
or death.
W-2056-1112
4
Figure 20-160-6
3 1
S40902
2 Remove the four bolts (Item 1) and nuts (Item 2)

1 [Figure 20-160-8] from top and bottom (hidden).
Remove the clamps (Item 3) [Figure 20-160-8].
Remove the accumulator (Item 4) [Figure 20-160-8].
S38074

(Item 2) [Figure 20-160-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
FAN PUMP (ONLY FOR TH.6534(X) AND TH.7038(X)) Figure 20-170-3

Page 10-160-1.)
1
Figure 20-170-1
1
1
P125345

1
Remove the fan pump.
P125343
Remove the four hydraulic hoses (Item 1) [Figure 20-

170-1] from the fan pump.
Figure 20-170-2
P125344
TH.6534(X) / TH.7035(X) / TH.7038(X)

FAN PUMP (ONLY FOR TH.6534(X) AND TH.7038(X)) (CONT’D)
1. Rear End Cover 7

2. Front Cover
3. Thrust Plate
4. Drive Shaft 10
5. Gear
6. Bolt 8
7. Plug
8. Valve 15
9. Washer
10. O-Ring 11
11. Seal
12. Shaft Seal
13. Snap Ring 14
14. Spool
15. Filter 6
16. Spring 1 9
7
17. Pin
18. Housing
18 11 17
17
9
11
16
17
16
17
10
3 11
11
4
3
2
11 5
11
13 12
NA12440S
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT’D)
Figure 20-170-4
1 2
S40885
Remove the nut (Item 1) and washer (Item 2) [Figure 20-

170-6] from the fan pump.
1 S40884
Installation: Tighten the nut to 40 N•m (30 ft-lb) torque.
Remove the fittings (Item 1) [Figure 20-170-4] from the Figure 20-170-7
fan pump.
Figure 20-170-5
1
1 S40886
S40925 Remove the drive wheel (Item 1) [Figure 20-170-7] using

a puller.

fan pump.
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT’D)
Disassembly And Assembly (Cont’d) 1
Figure 20-170-8
S40889
1
Remove the housing (Item 1) [Figure 20-170-10].
S40887 Figure 20-170-11
Remove the key (Item 1) [Figure 20-170-8] from the 2

shaft. 1
Figure 20-170-9
S40787
Remove the seal (Item 1) from both sides of the housing

(Item 2) [Figure 20-170-11].
S40888
Remove the four bolts (Item 1) and the cover (Item 2)

[Figure 20-170-9] from the fan pump.
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT’D)
Disassembly And Assembly (Cont’d)
Figure 20-170-12
2
1 1
S40927
Remove the four bolts (Item 1) and the mount plate (Item
2) [Figure 20-170-14].
S40890
Remove the gear assembly (Item 1) [Figure 20-170-12]. Figure 20-170-15
Figure 20-170-13
1
1
S40891
S40892
Remove the two pins from the housing (Item 1)

[Figure 20-170-13].
TH.6534(X) / TH.7035(X) / TH.7038(X)

(CONT’D)
6 5
Disassembly And Assembly (Cont’d)
Figure 20-170-16
4 7
3
1 2
1
7
S40928
1
Remove adapter (Item 1), spring (Item 2), spring holder
(Item 3), spool (Item 4) and plug (Item 5) from the cover
S40926 (Item 6) [Figure 20-170-18].

Remove the O-rings (Item 1) [Figure 20-170-16]. the adapter and plug.
Figure 20-170-17 Figure 20-170-19
1 4
3
1
1
2
2
S40894 1 S40895
Remove the two pins (Item 1) [Figure 20-170-17] from Remove the back-up rings (Item 1), seals (Item 2) and
the cover. gear holders (Item 3) from the gears (Item 4) [Figure 20-
170-19].
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-16
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Swash Plate Calibration - Neutral Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
Swash Plate Calibration - Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-6
Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-14
Relief Valves Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-16
Charge Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-17
Piston Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-19
Solenoid Block Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-24
Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-26
Charge Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-30
Solenoid Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-32
Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-34
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
HYDROSTATIC SYSTEM INFORMATION
WARNING
Personnel only. W-2004-1285
PROBLEM CAUSE
The telescopic handler does not move 1, 2
The telescopic handler does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

1. The hydrostatic pump has damage.
2. The hydrostatic drive motor has damage.
3. The tires do not have the correct tire pressure.
4. The tires are not the same size.
5. The hydrostatic fluid is not at the correct level.
6. The oil cooler has a restriction.
7. The temperature sending switch is not operating correctly.
8. The telescopic handler is not being operated at the correct rpm.
9. The sender is defective.
10. Pump is defective or worn hydrostatics
11. Hydraulic filter is plugged.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC SYSTEM INFORMATION (CONT’D) 1. To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
Replenishing Valve Function because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1
Figure 30-10-1 [Figure 30-10-1].
2. To keep high pressure fluid out of the low pressure

side of the hydrostatic circuitry; Function 2
[Figure 30-10-1].
Valve Moves For

Function 1 Charge Oil
Replacement
Valve Stays on Seat

to Hold High
Pressure for
Drive
Function 2 B-2804
IMPORTANT
damage the system.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

OIL COOLER
Description
The oil cooler is a combined radiator / oil cooler. (See Oil

Cooler / Intercooler / Radiator Removal And Installation
on Page 70-80-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
HYDROSTATIC DRIVE MOTOR Figure 30-30-3
Remove the engine / hydrostat assembly. (See Removal 1

Figure 30-30-1
1
1
S38670
1
Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-3].
Remove the four mounting bolts (Item 1) [Figure 30-30-

S39861 3] from the drive motor.
Installation: Tighten the mounting bolts to 190 - 210

Remove the hose (Item 1) [Figure 30-30-1] from the N•m (140 - 155 ft-lb) torque.
hydrostatic drive motor.
Remove the hydrostatic drive motor from the gear box
Figure 30-30-2 housing.
1 Figure 30-30-4
1
S39860
S38247
the hydrostatic drive motor.
Installation: Replace the O-ring (Item 1) [Figure 30-30-
NOTE: Mark all hoses for correct installation. 4].
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC DRIVE MOTOR (CONT'D)
22
23
21
24
20
3 4
18
3
20 18
22 3
23
21
24 1 25
3 14
2
3 4
4 3
4
24 4 3
3 18
13 3 4
25
3 14 26 3
12 4 1
16 6
14
4 5
3
4 3 11
17 5 10
14 19
1. Housing
2. Adjuster 4 3
3. O-ring 3
4. Plug 4
5. Pin 4
6. Gasket 3
7. Shaft 18
8. Cylinder Block
9. Bearing Plate 3 26
3 4
10. Lip Seal 17
11. Retaining Ring 15 22
12. Piston Control
13. Servo Piston Seal
14. Spring 18
15. End Cap
16. Spool 7
17. Valve
18. Screw
19. Socket 27
20. Solenoid
21. Coil 7
22. Cap
23. Ring
24. Seal 8
25. Valve Spool
26. Nut 9
27. Piston Ring NA12516S
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-7
Disassembly
Clean the outside of the drive motor before disassembly.
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
P-22328
I-2003-0888
Figure 30-30-5 Remove the solenoid nut (Item 1) [Figure 30-30-7].
Figure 30-30-8
S39402
P-22329
Place the hydrostatic drive motor on a work surface, mark
the sections for correct assembly [Figure 30-30-5].
Remove the solenoid (Item 1) [Figure 30-30-8] from the
Figure 30-30-6 shaft.
1 1
S39403

remove the solenoid housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-9 3
P-22333
1 Remove the O-ring (Item 1) and pin (Item 2) from the

P-22330 solenoid shaft (Item 3) [Figure 30-30-11].
Figure 30-30-12
Remove and discard the O-ring (Item 1) [Figure 30-30-9]
from the solenoid.
Figure 30-30-10
2
P-22335
2
Loosen the large nut (Item 1) [Figure 30-30-12] on the

P-22331 compensator valve.
Do not loosen the small nut (Item 2) [Figure 30-30-12].

Remove the solenoid shaft (Item 1) and O-ring (Item 2)
[Figure 30-30-10] from the housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-13
3
2
1 1
P-22338

P-22336 housing.
Figure 30-30-16
Remove the adjusting screw (Item 1), valve spring (Item
2) and spool assembly (Item 3) [Figure 30-30-13] from
the housing.
Figure 30-30-14
1
1
P-22339

16] from the plug.
P-22337

14] from the adjustment screw.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-17
1
P-27537

P-27534
Remove the two fittings (Item 1) [Figure 30-30-17] from

the housing.
Figure 30-30-18
P-27536
Remove both spool limiters (Item 1) [Figure 30-30-18].
TH.6534(X) / TH.7035(X) / TH.7038(X)

1
Figure 30-30-20
P-22346
1
Lift and remove the end cap (Item 1) [Figure 30-30-22]
P-22344 from the housing.
Figure 30-30-23
Remove and discard the six O-rings (Item 1) [Figure 30-
Figure 30-30-21 1
1
1
P-22347
1
1
Remove the gasket (Item 1) [Figure 30-30-23] from the
S39404 end cap.
Remove the eight bolts (Item 1) [Figure 30-30-21] from

the end cap.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-24
S39406
1
Loosen the plug (Item 1) [Figure 30-30-26].

S39405
Figure 30-30-27
Remove the piston (Item 1) [Figure 30-30-24] from the

end cap.
Figure 30-30-25
3
1
2
1
S39407
Remove the plug (Item 1), spring (Item 2), spring seat
(Item 3) and spool (Item 4) [Figure 30-30-27] from the
P-22375 housing.
Remove the seal (Item 1) [Figure 30-30-25] from the

piston.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-28
1 3
1
S39408
Remove the plug (Item 1), spring (Item 2) and spring seat
P-22378 (Item 3) [Figure 30-30-30] from the housing.
Figure 30-30-31
28] from the plug.
Figure 30-30-29
1
P-22378

P-22379 31] from the plug.
Loosen the plug (Item 1) [Figure 30-30-29].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-32 1
P-22384
Remove the valve segment (Item 1) [Figure 30-30-34]

S39409 from the cylinder.
Figure 30-30-35
Loosen and remove the relief valve (Item 1) [Figure 30-
30-32] from the housing. 2
Figure 30-30-33 2 1
1 2 3 4 5 2
2
P-22386
Remove and discard the O-ring (Item 1). Remove eight

P-22501 mounting bolts (Item 2) [Figure 30-30-35] from the
mounting plate.
Remove the plug (Item 1), O-rings (Item 2), spring (Item
3) and poppet (Item 4) from the relief valve housing (Item
5) [Figure 30-30-33].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-36
1
2
P-22503
Remove the cylinder block (Item 1) and synchronizing

P-22504 shaft assembly (Item 2) [Figure 30-30-38] from the
housing.
Remove the mounting plate [Figure 30-30-36] using a NOTE: It is not important that the pistons are
suitable puller. installed in their original position.
Figure 30-30-37 Figure 30-30-39
P-22378 P-22459
Remove and discard the seal (Item 1) [Figure 30-30-37] Remove the bearing plate (Item 1) [Figure 30-30-39]
from the mounting plate. from the cylinder block.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-40
P-22390
Press the piston / shaft assembly from the housing

P-22458 [Figure 30-30-42].
DO NOT damage the pistons.

Remove the bearing from the cylinder block [Figure 30-
30-40]. Figure 30-30-43
DO NOT damage the bearing plate surface of the

cylinder block.
Figure 30-30-41
1 P-22505
Pry up the peened notch (Item 1) [Figure 30-30-43] in

the ring nut.
P-22388

housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-30-44
1
P-22446
Using a clamp, compress the spring seat and spring, and

P-22506 drive the pin (Item 1) [Figure 30-30-46] inward. Release
the clamp.
Remove the ring nut (Item 1) [Figure 30-30-44] from the Figure 30-30-47
shaft.
Figure 30-30-45
2
3
2
1
3
1
P-22447
P-22507 Remove the pin (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-47] from the shaft assembly.
Remove the large bearing and race (Item 1), small

bearing and race (Item 2) and spacer (Item 3)
[Figure 30-30-45] from the shaft.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC DRIVE MOTOR (CONT'D) Inspection
Disassembly (Cont'd) Clean all parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper as small pieces of
Figure 30-30-48 material can get into the system and cause damage.
Figure 30-30-49
1
2
1
P-22508 2
P-22461
Remove the piston rings (Item 1) [Figure 30-30-48] from
the pistons.
Inspect the running (bronze) surface of the bearing plate
NOTE: If any portion of the shaft assembly, bearings (Item 1) and locating pin holes (Item 2) [Figure 30-30-49]
or races must be replaced, the complete shaft for wear. Replace if damaged or worn.
/ bearing assembly must be replaced. The
only serviceable part is the piston rings Figure 30-30-50
(Item 1) [Figure 30-30-48].
P-22462
Inspect the cylinder block assembly for wear or damage.

The piston bores (Item 1) must be smooth. The races for
the synchronizing shaft rollers (Item 2) [Figure 30-30-50]
must not be worn.
If there is any defect in the cylinder block or pistons, the

complete rotating group must be replaced.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Inspection (Cont'd)
Figure 30-30-51
1
B-15936
Inspect the valve segment for damage or wear on the

P-22375 sealing surface (Item 1) [Figure 30-30-53].
Check that the spindle is located correctly in the valve

Inspect the piston (Item 1) [Figure 30-30-51] for wear or segment by measuring distance "A" [Figure 30-30-53]. If
damage. this dimension is not within 34,5 - 34,7 mm (1.36 - 1.37
in) the assembly must be replaced.
Figure 30-30-52
P-22349
Inspect the swash plate running surface (Item 1)

[Figure 30-30-52] in the end cap for wear or damage.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly
IMPORTANT
damage the system.
I-2003-0888
P-22446
Inspect all parts for wear or damage. Replace any worn Using a clamp, compress the spring and spring seat
or damaged parts. [Figure 30-30-55].
Always install new seals and O-rings. Lubricate all seals Figure 30-30-56
Figure 30-30-54
1 2 1
P-22441
P-22447
Install the pin (Item 1) [Figure 30-30-56] as shown.
NOTE: Clamp is removed for photo clarity.

Install the spring (Item 1) and spring seat (Item 2) into the
shaft assembly (Item 3) [Figure 30-30-54].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-57
2
P-22509
1
Using a punch seat the ring nut into the groove in the
P-22453 shaft. [Figure 30-30-59].
Figure 30-30-60
Support the shaft assembly in a press without causing
damage to the pistons, install the large bearing and race
(Item 1), spacer (Item 2) and small bearing and race
(Item 3) [Figure 30-30-57] into the shaft assembly.
NOTE: Be sure not to over press the bearings, they

should be able to roll freely.
Figure 30-30-58
P-22455
1 Press the piston / shaft assembly into the housing

[Figure 30-30-60].
DO NOT DAMAGE THE PISTONS.
P-22505
Install the ring nut (Item 1) [Figure 30-30-58] onto the

shaft.
NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-61 1
1
1
1
P-22387
Install the mounting plate onto the housing, install the

P-22450 eight mounting bolts (Item 1) [Figure 30-30-63] and
tighten to 63 N•m (46 ft-lb) torque.
Install a new seal (Item 1) [Figure 30-30-61] into the Figure 30-30-64
mounting plate until it is fully seated.
Figure 30-30-62
1
P-22386
P-22388 Install a new O-ring (Item 1) [Figure 30-30-64] onto the

mounting plate.
Install a new O-ring (Item 1) [Figure 30-30-62] onto the

housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd) 2
Figure 30-30-65
1
13,5 - 14,0 mm
(0.53 - 0.55 in)
P-22440
Figure 30-30-67
B-15933
Piston End
Press a new bearing into the cylinder block until it is

located 13,5 - 14,0 mm (0.53 - 0.55 in) below the bearing 2
plate surface [Figure 30-30-65].
B-15935
Install new piston rings (Item 1) [Figure 30-30-66] onto

the pistons, make sure the spherical surface (Item 1)
[Figure 30-30-67] conforms to the shape of the piston.
An identification mark (Item 2) [Figure 30-30-66] and

[Figure 30-30-67] is on the "outer" side of the piston ring.
The ends of the piston rings must NOT overlap each

other.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-68
1 1
P-22511
Install the synchronizing shaft support pin (Item 1)

P-22459 [Figure 30-30-70] into the cylinder block and retain with
grease.
Install the bearing plate (Item 1) [Figure 30-30-68] with Figure 30-30-71
the bronze surface facing up onto the cylinder block.
Figure 30-30-69
1
P-22499
P-22464 Install the six synchronizing shaft rollers (Item 1)

[Figure 30-30-71] onto the synchronizing shaft and
retain with grease.
Position the housing on end, tip the three pistons (Item 1)
[Figure 30-30-69] closest to the minimum angle stop out
toward the housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-72 1
2 2
1
P-22513
Install the synchronizing shaft and rollers (Item 1)

B-15934 [Figure 30-30-74] into the motor shaft races. When
properly installed the synchronizing shaft should move
freely in all directions.
NOTE: The recess (Item 1) [Figure 30-30-72] on each
roller MUST face the synchronizing shaft. NOTE: The motor shaft end of the synchronizing
shaft is smaller than the cylinder end.
Figure 30-30-73
Figure 30-30-75
2
1
3 1
1
P-22512
P-22511
Install the synchronizing shaft support pin (Item 1)

[Figure 30-30-73] into the motor shaft assembly and When installing the cylinder block, the races (Item 1)
retain with grease. [Figure 30-30-75] in the cylinder block must be
positioned so the synchronizing shaft rollers (Item 2)
[Figure 30-30-74] and pistons (Item 3) [Figure 30-30-
74] and their bores (Item 2) [Figure 30-30-75] are
aligned.
Install the six pistons (Item 3) [Figure 30-30-74] into the

cylinder bores, tilt the block so the synchronizing shaft
rollers enter their races in the block and the support pin
(Item 3) [Figure 30-30-75] enter the recess.
Lift the cylinder block slightly and guide the three

remaining pistons in position.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-76
1
1
P-22375
Install a new seal (Item 1) [Figure 30-30-78] onto the

P-22500
piston.
If the cylinder block (Item 1) [Figure 30-30-76] is properly Figure 30-30-79

installed, there should be very little rotational free-play
between the block and the motor shaft.
NOTE: A brass rod can be used to guide the pistons 1

into their bores.
Lubricate the pistons and cylinder block bores with

hydraulic fluid.
Figure 30-30-77
S39405
3
Lubricate and install the piston (Item 1) [Figure 30-30-

79] into the end cap.
2
4 P-22511
Install a new gasket (Item 1) [Figure 30-30-77] onto the

housing.
Install the valve segment (Item 2) [Figure 30-30-77] onto

the cylinder block and retain with heavy grease.
NOTE: The hole (Item 3) in the valve segment should

be opposite the minimum displacement
adjustment screw (Item 4) [Figure 30-30-77].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
1
Figure 30-30-80
S39409
Install the relief valve (Item 1) [Figure 30-30-82] into the

P-22349 housing and tighten to 52 N•m (38 ft-lb) torque.
Figure 30-30-83
NOTE: Note the position of the hole (Item 1)
[Figure 30-30-80] in the end cap.
Figure 30-30-81
1
3
5 1 4
4 2
P-22378

P-22501 plug.
Assemble the poppet (Item 1) and spring (Item 2) into the

relief valve housing (Item 3) install O-rings (Item 4) and
plug (Item 5) [Figure 30-30-81].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-84
1
2
2
3
3 S39408
4
Install the spring seat (Item 1), spring (Item 2) and plug
S39407 (Item 3) [Figure 30-30-86] into the housing and tighten to
Install the spool (Item 1), spring seat (Item 2), spring Figure 30-30-87
(Item 3) and plug (Item 4) [Figure 30-30-84] into the
housing and tighten to 41 N•m (30 ft-lb) torque.
Figure 30-30-85 2
1
1
P-22346
Align the hole in the piston (Item 1) and the valve

P-22378 segment (Item 2) [Figure 30-30-87].

plug.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-88
1
1
P-22339
1
1
S39404 plug.
Figure 30-30-91
Install the end cap housing and tighten the eight bolts
(Item 1) [Figure 30-30-88] to 115 N•m (85 ft-lb) torque.
Figure 30-30-89
P-22338
1
Install the plug (Item 1) [Figure 30-30-91] into the
P-22344 housing.
Install six new O-rings (Item 1) [Figure 30-30-89] onto

the housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-92
1
1
2
P-22333

P-22337 solenoid shaft.
Lightly lubricate the pin (Item 2) [Figure 30-30-94] and

Install a new O-ring (Item 1) [Figure 30-30-92] onto the install into the solenoid shaft.
adjusting screw.
Figure 30-30-95
Figure 30-30-93
1
2
3 1
P-22340
P-22336
Install a new O-ring (Item 1) and solenoid shaft assembly

Install the spool (Item 1), spring (Item 2) and adjusting (Item 2) [Figure 30-30-95] into the housing.
screw (Item 3) [Figure 30-30-93] into the housing and
tighten to 9 N•m (80 in-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont'd)
Figure 30-30-96
1 1
S39403
2
Install the solenoid housing assembly with four bolts
(Item 1) [Figure 30-30-98]. Tighten the bolts to 78 N•m
P-22342
(58 ft-lb) torque.
Install the solenoid (Item 1) onto the shaft and install a

new O-ring (Item 2) [Figure 30-30-96].
Figure 30-30-97
P-22343
Install the solenoid nut (Item 1) [Figure 30-30-97] and

hand tighten.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
HYDROSTATIC PUMP Figure 30-40-2
Calibration
This calibration is used to adjust the start of forward and

reverse movement of the telescopic handler.
NOTE: A Service Tool must be connected to the

telescopic handler and the engine must be
running and the travel mode must be in
NEUTRAL in order to perform this procedure.
Connect the service tool to the telescopic handler. (See

MEL1563 on Page 10-210-1.) (See REMOTE START
TOOL (SERVICE TOOL) KIT - 3975015M1 on Page 10- EM9672
220-1.)
Put the Travel Direction Switch or the Travel Direction Press the AUX button (Item 3) [Figure 30-40-1] for 3
Lever (if equipped) in the NEUTRAL position. seconds until the drive pump calibration mode
[Figure 30-40-2] appears on the display screen.
Figure 30-40-1
Travel Direction Switch
Figure 30-40-3
2
1 3
3
1 2
3
P122914
Press the information button (Item 1) to cycle the display P126569

screen (Item 2) [Figure 30-40-1] until the engine speed
menu is displayed. (See Operation & Maintenance
Manual for the correct procedure.) Press the top of the switch (Item 1) [Figure 30-40-3] for
forward travel calibration (display is showing [DF])
[Figure 30-40-5].
Press the bottom of the switch (Item 2) [Figure 30-40-3]

for reverse travel calibration (display is showing [DR])
[Figure 30-40-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC PUMP (CONT’D) Figure 30-40-5
Calibration (Cont’d)
Travel Direction Lever (If Equipped)
Figure 30-40-4
P128115
Figure 30-40-6
P126555
Move the lever (if equipped) forward (Item 1) [Figure 30-

40-4] for forward travel calibration (display is showing
[DF]) [Figure 30-40-5].
Move the lever (if equipped) backward (Item 2)

[Figure 30-40-4] for reverse travel calibration (display is
showing [DR]) [Figure 30-40-6].
P128116
Press the “+” and “-” buttons (Item 3) [Figure 30-40-3] to

adjust the value.
The DF and DR values have to be set in the range 60 ± 5.
NOTE: With cold hydraulic oil temperature (20°C

[68°F]) the machine has to move forward or
backward between 1080 rpm and 1150 rpm.
With warm hydraulic oil temperature (50°C

[122°F]) the machine has to move forward or
backward between 1100 rpm and 1200 rpm.
Press the AUX button (Item 3) [Figure 30-40-1] once to

validate and finish the procedure.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC PUMP (CONT’D)
Figure 30-40-7
EM8037
If calibration is successful, [STORE] [Figure 30-40-7]

appears on the display screen. The three calibration
points have now been saved.
Figure 30-40-8
EM7537
If an error occurred during calibration, [FAIL] [Figure 30-

40-8] appears on the display screen. Redo the calibration
procedure until the calibration is successful.
Press the information button (Item 1) [Figure 30-40-1]

once to return to the engine speed menu.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Swash Plate Calibration - Neutral Range
The swash plate calibration for neutral range is available

if error code D9199 is active. This calibration records the
swash plate positions which will be used in the Safe Start
/ Stop function.

running and gear 1 must be engaged in order
to perform this procedure.

REMOTE START TOOL (SERVICE TOOL) KIT - P128112
TOOL (SERVICE TOOL) KIT - 3975015M1 on Page 10-
220-1.) Press the AUX button (Item 3) [Figure 30-40-9] for three
seconds until the swash plate calibration mode
Start the engine. Make sure that the creep function is [Figure 30-40-10] appears on the display screen.
disabled.
Figure 30-40-11
Figure 30-40-9
1
3 P128113
P122916
After two seconds, the neutral range calibration menu

Press the information button (Item 1) to cycle the display [Figure 30-40-11] will appear on the display screen.
screen (Item 2) [Figure 30-40-9] until the creep menu is
displayed. (See Operation & Maintenance Manual for the
correct procedure.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

Swash Plate Calibration - Neutral Range (Cont’d)
Figure 30-40-12
P128111
6. Put the Travel Direction Control in REVERSE

P128114 [Figure 30-40-13].
7. Slowly back up the machine until 1100 - 1200 rpm.

Press the AUX button (Item 3) [Figure 30-40-9] until Maintain for minimum two seconds.
{FWD} [Figure 30-40-12] appears on the display screen.
8. The neutral REVERSE point is automatically stored.
1. Apply Low Speed (See the Operation & Maintenance
Manual for the correct procedure). 9. Stop the machine and put the Travel Direction Control
in NEUTRAL.
2. Put the Travel Direction Control in FORWARD.
When the calibration is fully performed, the error code
3. Slowly move the machine forward until engine rpm D9199 should be cleared from the display panel.
reaches 1100 - 1200 rpm. Maintain for minimum two
seconds.
4. The neutral FORWARD point is automatically stored.
5. Stop the machine and put the Travel Direction Control

in NEUTRAL.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Swash Plate Calibration - Maximum Range
The swash plate calibration for maximum range is

available if error code D9299 is active. This calibration
records the swash plate positions which will be used in
the Safe Start / Stop function.

running and gear 1 must be engaged in order
to perform this procedure.

REMOTE START TOOL (SERVICE TOOL) KIT - P128112
220-1.) Press the AUX button (Item 3) [Figure 30-40-14] for
three seconds until the swash plate calibration mode
Start the engine. Make sure that the creep function is [Figure 30-40-15] appears on the display screen.
disabled.
Figure 30-40-16
Figure 30-40-14
1
3 P128113
P122916
After two seconds, the neutral range calibration menu

Press the information button (Item 1) to cycle the display [Figure 30-40-11] will appear on the display screen.
screen (Item 2) [Figure 30-40-14] until the creep menu is
displayed. (See Operation & Maintenance Manual for the
correct procedure.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC PUMP (CONT’D) 5. Stop the machine and put the Travel Direction Control
in NEUTRAL.
Swash Plate Calibration - Maximum Range (Cont’d)
Figure 30-40-19
Figure 30-40-17
P128111
P128117
6. Put the Travel Direction Control in REVERSE

Press the AUX button (Item 3) [Figure 30-40-14] quickly [Figure 30-40-19].
to enter the maximum range calibration menu
[Figure 30-40-17]. 7. Drive the machine backward to maximum rpm and
maintain for minimum two seconds.
Figure 30-40-18
8. The maximum REVERSE point is automatically
stored.
9. Stop the machine and put the Travel Direction Control

in NEUTRAL.
When the calibration is fully performed, the error code

D9299 should be cleared from the display panel.
P128114
Press the AUX button (Item 3) [Figure 30-40-9] until

{FWD} [Figure 30-40-12] appears on the display screen.
1. Apply Low Speed (See the Operation & Maintenance

Manual for the correct procedure).
2. Put the Travel Direction Control in FORWARD.
3. Drive the machine forward to maximum rpm and

maintain for minimum two seconds.
4. The maximum FORWARD point is automatically

stored.
TH.6534(X) / TH.7035(X) / TH.7038(X)

IMPORTANT
1
When repairing hydrostatic and hydraulic systems, 1
damage the system.
I-2003-0888
P125399
Page 70-110-1.)
Remove the four hoses (Item 1) [Figure 30-40-21].
Figure 30-40-20
2 Figure 30-40-22
1
P125397
Disconnect the two electrical connectors (Item 1) P125398

[Figure 30-40-21].
Disconnect the three hoses (Item 1) [Figure 30-40-21]. Install blocks to support the hydrostatic pump.
NOTE: Mark all hoses for correct installation. Remove the four mounting bolts (both sides) (Item 1)
[Figure 30-40-22].
For TH.6534(X) and TH.7038(X) telescopic handlers,
remove the piston pump. (See Removal And Installation Installation: Apply Loctite® #2701 to the bolt threads.
on Page 20-100-1.) Then tighten the bolts (Item 1) [Figure 30-40-22] to 139 -
140 N•m (102 - 103 ft-lb) torque.
For TH.7035(X) telescopic handler, remove the gear
pump. (See Removal And Installation on Page 20-101-1.) Remove the hydrostatic pump (Item 2) [Figure 30-40-22]
from the machine.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC PUMP (CONT'D)
1. Multi-Function Valve Assembly

2. O-ring
3. Charge Relief Valve
4. Plug
5. Lifting Bracket
6. Bolt
EM9680
TH.6534(X) / TH.7035(X) / TH.7038(X)

Parts Identification (Cont’d)
1. Orifice
2. Pin
3. Gasket
4. Filter Screen
5. O-ring
6. Solenoid
7. Plug
8. Bolt
9. Actuator
10. Coil
11. Nut
12. Screw
13. Solenoid, Safety
EM9681
TH.6534(X) / TH.7035(X) / TH.7038(X)

1. Roll Pin
2. Valve Plate
3. Retainer
4. Spring Seat
5. Spring
6. Washer
7. Cylinder Block
8. Snap Ring
9. Ball Guide Retainer
10. Slipper Guide
11. Piston
12. Filter Screen
13. Pin
14. Bearing Assembly
15. Swash Plate
16. Piston Pump Housing
16
12
12
13 14
13
11
14
8 15
6 10
9
4
7
2 5
EM7523
TH.6534(X) / TH.7035(X) / TH.7038(X)

1. Bolt
2. O-ring
3. Flange Adapter
4. Gasket
5. Thrust bearing
6. Coupling
7. Seal
8. Pressure Balance Plate
9. Ring
10. Charge Pump Gears
11. Valve Plate
12. Charge Pump Housing
13. Bushing
14. Pin
EM9682
TH.6534(X) / TH.7035(X) / TH.7038(X)

1. Piston Ring
2. O-ring
3. Servo Piston
4. Block
5. Swash Plate
6. Cylinder
7. Lock Plate
8. Bolt
9. Snap Ring
10. Bearing
11. Shaft
12. Seal
EM9683
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC PUMP (CONT'D) Figure 30-40-24
Shaft Disassembly
Clean the outside of the pump before disassembly.
Mark the outside of the pump for ease of assembly. 1
IMPORTANT
S38630
damage the system.
I-2003-0888 Remove the snap ring (Item 1) [Figure 30-40-24] from
the pump housing
Figure 30-40-23
Figure 30-40-25
1
1
S38629
S38631
Loosen the retainer bolt (Item 1). Remove the coupler

gear (Item 2) [Figure 30-40-23] from the shaft. Remove the seal (Item 1) [Figure 30-40-25] from the
housing.
NOTE: The seal may need to be punctured in order to

pull out the seal. Do not damage the pump
housing, shaft or bearing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Shaft Disassembly (Cont'd)
Figure 30-40-26
S38634
Remove the snap ring (Item 1) [Figure 30-40-28] from

S38632 the shaft.
Figure 30-40-29
the pump housing.
2
Figure 30-40-27
1
3
S38635
Press the bearing off the shaft. The bearing exists of

S38633 three parts (Items 1, 2 and 3) [Figure 30-40-29].
Remove the shaft and bearing assembly from the

housing [Figure 30-40-27].
NOTE: For easier removal, use a hammer and drifter

to tap lightly on the rear side of the shaft.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Relief Valves Disassembly And Assembly
Figure 30-40-30
1 4
2 3
3
2 EM1218
S10264
The valve has the following components: adjustable valve

S38636 housing (Item 1), spring (Item 2), spring (Item 3) and
spool (Item 4) [Figure 30-40-32].
• Charge pressure relief valve (gearset pump pressure Figure 30-40-33

relief) (Item 1) [Figure 30-40-30].
• High pressure relief valves (piston pump pressure

relief):
‘A’ port side (Item 2) [Figure 30-40-30]. 2
‘B’ port side (Item 3) [Figure 30-40-30].
Figure 30-40-31
1 S38636
Remove the A port side relief valve (Item 1) [Figure 30-

40-33].
Repeat for the B port side relief valve (Item 2)

[Figure 30-40-33].
S38636
Installation: Tighten the valves to 110 N•m (81 ft-lb)
torque.
Remove the charge pressure relief valve (Item 1)
[Figure 30-40-31].
Installation: Tighten the valve to 52 N•m (38 ft-lb)

torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Charge Pump Disassembly

1
Place the pump on the work surface with the charge
pump up.
Mark the pump housings for correct assembly.
Figure 30-40-34
1 1
2
S38639
1 Remove the gasket (Item 1) [Figure 30-40-36] from the

1
charge pump.
Figure 30-40-37
S38638 1
Remove the four bolts (Item 1) and remove the cover

(Item 2) [Figure 30-40-34] from the charge pump
housing.
Figure 30-40-35
1 S38640
Lift the pressure balance plate (Item 1) [Figure 30-40-

37] from the charge pump.
EM1220
Remove the thrust washer (Item 1) [Figure 30-40-35]

from the cover.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Charge Pump Disassembly (Cont'd)

1
Figure 30-40-38
S38643
Remove the valve plate (Item 1) [Figure 30-40-40].

S38641
Figure 30-40-41
Remove the coupler shaft (Item 1) [Figure 30-40-38].

2 1
Figure 30-40-39
EM1225
Remove the seal from the pressure balance plate

S38642 (Item 1) and the valve plate (Item 2) [Figure 30-40-41].
Remove the gearset (Item 1) and ring (Item 2)

[Figure 30-40-39] from the pump.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Piston Pump Disassembly

1
Figure 30-40-42
1 1
2 2
S38645
3
Remove the gasket (Item 1) [Figure 30-40-44].
S38644
Figure 30-40-45
Remove the two bolts (Item 1) first. Then remove the four
bolts (Item 2) [Figure 30-40-42] from the housing.
Remove the charge pump housing (including charge

pump) (Item 3) [Figure 30-40-42] from the pump
housing.
Figure 30-40-43
1
1
S38647
Tilt the pump housing on its side as shown [Figure 30-

40-45].
Remove the cylinder block / piston assembly (Item 1)

[Figure 30-40-45].
S38645
Remove the valve plate (Item 1) [Figure 30-40-43] from

the charge pump housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Piston Pump Disassembly (Cont'd)

1
Figure 30-40-46
S38650
Remove the ball guide retainer (Item 1) [Figure 30-40-

S38648 48] from the cylinder block.
Figure 30-40-49
Mark the piston assembly (Item 1) [Figure 30-40-46]
position. Remove the piston assembly from the cylinder
block.
Figure 30-40-47
1
S38651
Mark the servo cylinder position (Item 1) [Figure 30-40-

49]. Repeat for the other side.
S38649
NOTE: Also apply marks to distinguish the left
cylinder from the right.
Remove the pistons (Item 1) [Figure 30-40-47] from the
slipper guide. Remove both screws (Item 2) [Figure 30-40-49] from the
servo cylinder locking plate. Repeat for the other side.
Remove the servo cylinder (Item 1) [Figure 30-40-49]

from the housing. Repeat for the other side.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Piston Pump Disassembly (Cont'd)
Figure 30-40-50
EM1238
Remove the bronze slider block (Item 1) [Figure 30-40-

S38653 52] from the servo piston.
Figure 30-40-53
Remove the servo piston assembly (Item 1) [Figure 30-
Figure 30-40-51
1
1
S38654
Remove the swash plate (Item 1) [Figure 30-40-53] from

EM1237 the pump housing.
Remove the O-ring (Item 1) [Figure 30-40-51] from both

servo cylinders.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDROSTATIC PUMP (CONT'D) Solenoid Block Disassembly
Piston Pump Disassembly (Cont'd) Figure 30-40-55
Figure 30-40-54
1
1
1 1 1
S38656
S38655
Remove the six screws (Item 1) [Figure 30-40-55] from
the solenoid block.
Remove the two swash plate bearings (Item 1)
[Figure 30-40-54] from the swash plate. Figure 30-40-56
S38657
Remove the gasket (Item 1) [Figure 30-40-56] from the

pump housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Solenoid Block Disassembly (Cont'd)
Figure 30-40-57
1
1
3 EM1706
Remove the O-ring (Item 1) [Figure 30-40-59] from each

S38659
S38660
solenoid.
Figure 30-40-60
Remove the filter retaining ring (Item 1) and filter screen
(Item 2) from the orifice (Item 3) [Figure 30-40-57] in the
solenoid block.
NOTE: Install the filter screen (Item 2) [Figure 30-40-

57] with the mesh facing outward.
Figure 30-40-58
2
1 1
1
S38667
1 Remove the spool (Item 1) and spring (Item 2)

1 [Figure 30-40-60] from the solenoid block.
S38661
Remove the three screws (Item 1) [Figure 30-40-58]

from each solenoid.
Remove both solenoids.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Inspection
1
Figure 30-40-61
1
2 3 1
EM1710
Inspect the servo piston and seal rings (Item 1)

EM1225 [Figure 30-40-63] for wear. If worn, remove the seal
rings and expander O-rings from the piston.
Clean all parts in solvent and use air pressure to dry Install new expander O-rings into the grooves in the
them. DO NOT use cloth or paper as small pieces of servo piston. Carefully install the piston seal rings over
material can get into the system and cause damage. the expander rings. Do not overstretch the piston seal
rings.
Check the pressure balance plate (Item 1) and the valve
plate (Item 2) and charge pump gears (Item 3) Lubricate the seal rings and install them into the two
[Figure 30-40-61] for damage or wear. (disassembled) servo cylinders to allow the assembly to
set for 5 minutes for the seal rings to return to their
Figure 30-40-62 original size. Remove the servo cylinders afterwards.
Figure 30-40-64
EM1709 2
S38662
Check the valve plate [Figure 30-40-62], the surface
must be smooth and free of scratches. If scratches can
be felt with a finger nail, replace the part. Check the swash plate bearing race (Item 1) and bearing
rollers (Item 2) [Figure 30-40-64] for wear and damage.
Replace as needed.
Repeat for the other swash plate bearing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Inspection (Cont'd)
2
Figure 30-40-65
1
1
S38664
2
Check the shaft for wear or damage in the spline (Item 1)

S38649 and bearing areas (Item 2) [Figure 30-40-67].
Check the bearing for correct operation. Remove the race

Check each piston (Item 1) and piston shoe (Item 2) (Item 2) [Figure 30-40-67] from the shaft only if it is
[Figure 30-40-65] for wear or scratches. necessary to replace the bearing.
Figure 30-40-66 Figure 30-40-68
1
1 1
S38663 EM1715
S10264
Check the cylinder block bores (Item 1) [Figure 30-40- Inspect both high pressure relief valves. (See Relief
66] for wear or scratches. Valves Disassembly And Assembly on Page 30-40-16.)
If there is any defect in the cylinder block or pistons, the Replace O-rings (Item 1) [Figure 30-40-68] as needed.
complete rotating group must be replaced.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Piston Pump Assembly
IMPORTANT 1

damage the system.
I-2003-0888
S38654
Inspect all parts for wear or damage. Replace any worn Install the swash plate (Item 1) [Figure 30-40-70].
or damaged parts.
Figure 30-40-71
Always install new seals and O-rings. Lubricate all seals
Figure 30-40-69
1
1
1
EM1238
Install the bronze slider block (Item 1) [Figure 30-40-71]

onto the servo piston.
S38655
Install the two swash plate bearings (Item 1) [Figure 30-

40-69] onto the swash plate.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Piston Pump Assembly (Cont’d)
Figure 30-40-72
2 2
1 1
S38651
Check that the servo piston assembly (Item 1) is free of

S38653 play. Both gaps (Item 2) [Figure 30-40-74] must be zero
between both cylinders and the piston assembly.
Install the servo piston assembly (Item 1) [Figure 30-40- Figure 30-40-75
72] into the housing.
Figure 30-40-73
2
1
S38651
EM1237 Install the servo cylinder locking plate (Item 1) and both
screws (Item 2) [Figure 30-40-75]. Repeat for the other
side.
Install a new O-ring (Item 1) [Figure 30-40-73] on both
servo cylinders.
Install both servo cylinders until the marks are aligned.
NOTE: Respect right and left side servo cylinders.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-40-76
S38648
Install the piston assembly (Item 1) [Figure 30-40-78]

S38649 into the cylinder block.
Figure 30-40-79
Put the piston assemblies (Item 1) [Figure 30-40-76] into
the slipper guide.
Figure 30-40-77
S38647
Install the cylinder block / piston assembly (Item 1)

S38650 [Figure 30-40-79] into the pump housing.
NOTE: When installing, make sure the ball guide

Place the ball guide retainer (Item 1) [Figure 30-40-77] retainer (Item 1) [Figure 30-40-77] is kept in
onto the cylinder block. place.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 30-40-80 2 2
1
1 1
2 2
S38644
Lower the charge pump housing onto the pump housing.

S38645 Make sure the alignment pins (Item 2) [Figure 30-40-80]
are correctly installed.
Install the gasket (Item 1) [Figure 30-40-80]. Install and gradually tighten the four bolts (Item 1)
[Figure 30-40-82]. Tighten the bolts to 140 N•m (103 ft-
NOTE: Verify that both alignment pins (Item 2) lb) torque.
[Figure 30-40-80] are installed.
Tighten the two bolts (Item 2) to 25 N•m (18 ft-lb) torque.
Figure 30-40-81 Now re-check torque of the four bolts (Item 1) [Figure 30-
40-82].
S38645
Install the valve plate (Item 1) [Figure 30-40-81].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Charge Pump Assembly

2
Place the pump on the work surface with the charge
pump up.
Figure 30-40-83
1
2 1
S38642
Lubricate and install the gearset (Item 1) and ring (Item

2) [Figure 30-40-85].
Figure 30-40-86
S39209
Install the seals onto the pressure balance plate (Item 1) 1

and the valve plate (Item 2) [Figure 30-40-83].
Figure 30-40-84
S38641
Install the coupler shaft (Item 1) [Figure 30-40-86].
S38643
Install the valve plate (Item 1) [Figure 30-40-84].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Charge Pump Assembly (Cont'd)
Figure 30-40-87
1
EM1220
Install the thrust washer (Item 1) [Figure 30-40-89] onto

S38640 the charge pump cover. The coated side goes toward
charge pump coupling.
Install the pressure balance plate (Item 1) [Figure 30-40- Figure 30-40-90
87].
Figure 30-40-88 1
1
2 2 1
1
EM1219
S38639 Install the cover and the four bolts (Item 1) [Figure 30-
40-90]. Tighten the bolts to 92 N•m (68 ft-lb) torque.
Install the gasket (Item 1) [Figure 30-40-88].
NOTE: Verify that both alignment pins (Item 2)

[Figure 30-40-88] are installed.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Solenoid Block Assembly 2
Figure 30-40-91 1
S38659
S38660
2
Install the filter screen (Item 1) and filter retaining ring

S38667 (Item 2) into the orifice (Item 3) [Figure 30-40-93] in the
solenoid block.
Install the spring (Item 1) and spool (Item 2) [Figure 30- NOTE: Install the filter screen (Item 2) [Figure 30-40-
40-91] into the solenoid block. 93] with the mesh facing outward.
Figure 30-40-92 Figure 30-40-94
1
1
EM1706 S38658
Install a new O-ring (Item 1) [Figure 30-40-92] onto each Install the two orifices (Item 1) [Figure 30-40-94] into the
solenoid. pump housing. Tighten to 3 N•m (22 in-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Solenoid Block Assembly (Cont'd)

1
Figure 30-40-95
1 1
1 1
1
1
1
S38656
Install the six screws (Item 1) [Figure 30-40-97]. Tighten

S38661 to 14 N•m (10 ft-lb) torque.
Install the three screws (Item 1) [Figure 30-40-95] for

each solenoid. Tighten to 5 N•m (44 in-lb) torque.
Figure 30-40-96
2
1
S38657
Install the gasket (Item 1) and two alignment pins (Item 2)

[Figure 30-40-96] onto the pump housing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Shaft Assembly
IMPORTANT
damage the system.
I-2003-0888
S38633
Figure 30-40-98
Install the shaft and bearing assembly into the housing as

2 shown in [Figure 30-40-100].
Figure 30-40-101
1
3
S38635
Install the bearing onto the shaft in the order as shown

(Items 1, 2 and 3) [Figure 30-40-98].
S38668
Figure 30-40-99
Use a hydraulic press to position the bearing such that

the (second) snap ring seat is visible [Figure 30-40-101].
1
NOTE: Pressing the shaft down results in
compressing the spring (Item 5) on page 30-
40-11 located in the cylinder block (Item 1)
[Figure 30-40-66].
S38634
Install the snap ring (Item 1) [Figure 30-40-99].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Shaft Assembly (Cont'd)
Figure 30-40-102
S38630

S38669
Figure 30-40-105

1
Figure 30-40-103
S38629
Install the coupler gear (Item 1) flush with the pump shaft.
S38668 Fasten the retainer bolt (Item 2) [Figure 30-40-105].
Tighten the retainer bolt to 67 - 71 N•m (50 - 52 ft-lb)

Use a hydraulic press to install a new seal [Figure 30-40- torque.
103].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
DRIVE SYSTEM
DRIVE SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
AXLE AND DIFFERENTIAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Drive Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-10
Brake Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Brake Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-16
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-17
Pinion Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-22
Pinion Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-23
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-26
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-34
Brake Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-40
Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-43
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-45
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-48
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-53
AXLE AND DIFFERENTIAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-2
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-21-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-8
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-10
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Pinion Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-16
Pinion Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-17
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-20
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-28
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-34
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-42
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
TH.6534(X) / TH.7035(X) / TH.7038(X)

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Releasing The Brake For Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Brake Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Brake Cylinder Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Brake Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-5
Brake Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-5
STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Rear Driveshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Front Driveshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-13
TH.6534(X) / TH.7035(X) / TH.7038(X)

DRIVE SYSTEM TROUBLESHOOTING
Chart
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Massey Ferguson Service Personnel only.
PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 8, 11, 14
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Machine intensively operated or overloaded
20. Wheel loose
21. Beam housing bent
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
AXLE AND DIFFERENTIAL (FRONT) • Front Axle Removal (See Removal And Installation on
Page 40-30-1.), Front Steering Cylinder Removal.
Description (See Removal on Page 20-60-1.)
For photo clarity, the following axle procedures are done

with the complete axle assembly removed from the
machine. However, the planetary carrier, wheel hub,
steering knuckle and drive axle procedures can be done
with the axle assembly installed in the machine. For
complete axle repair, the following must be done:
Planetary Carrier Parts Identification
3
1
2 1. Seal
4 2. Bearing
3. Wheel stud
5 4. Wheel hub
2 5. O-ring
6. Snap ring
7. Ring gear
8. Ring gear support
9. Locking plate
10. Planet gear
11. Nut
12. Plug
13. Countersunk bolt
6 14. Planet gear carrier
7 15. Stud
8
6
10
2
11
14
9 6 12
15
11 5
13
EM9286
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLE AND DIFFERENTIAL (FRONT) (CONT’D) Figure 40-20-3
Planetary Carrier Disassembly
Figure 40-20-1 1 1
S2465X
S2465A
Remove the two securing bolts and lift the planet gear
S2463A carrier (Item 1) [Figure 40-20-3].
Figure 40-20-4
Loosen the two securing bolts (Item 1) [Figure 40-20-1].
NOTE: Loosen but do not remove the securing bolts

at this time. The bolts will keep the planetary
1
gear carrier from falling when prying it loose
in the next step.
Figure 40-20-2
1 2
S2466
S2464A
Loosen the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-20-2] by alternately forcing a
screwdriver into the appropriate slots.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Planetary Carrier Disassembly (Cont’d)
Figure 40-20-5 1
1
2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B [Figure 40-20-7] by pressing on the stud bolts.
Figure 40-20-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-20-5].
Figure 40-20-6
1
S2469
Partially remove the wheel hub (Item 1) [Figure 40-20-8]

S2467
using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-20-6].
points.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-9
1
1
1 1
1
S2473A
Remove the four snap rings (Item 1) [Figure 40-20-11].

S2470A
Figure 40-20-12
Remove the external bearing (Item 1) [Figure 40-20-9].
Figure 40-20-10
S2474A
With the help of a puller, remove the four planet wheel

S2471A
gears (Item 1) [Figure 40-20-12].
NOTE: Mark the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-20-
10] by hand.
TH.6534(X) / TH.7035(X) / TH.7038(X)


1
Figure 40-20-13
1 S2477A
Remove the sealing ring Item 1) from the wheel hub

S2475 (Item 2) [Figure 40-20-15].
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-20-16
[Figure 40-20-13].
1
Figure 40-20-14
S2478A
S2476 Remove the internal bearing (Item 1) [Figure 40-20-16].
Remove the ring gear support (Item 1) [Figure 40-20-

14].
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLE AND DIFFERENTIAL (FRONT) (CONT’D)
Figure 40-20-17
S2479A
Remove the external bearing races from the hub by

forcing a pin-driver into the appropriate slots on the hub
(Item 1) [Figure 40-20-17].
NOTE: Hammer in an alternate way so as to avoid

crawling or deformation of the bearing races.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle And Drive Axle Parts Identification
1. Snap ring
2. Ball bearing
3. Seal
4. Reduction bushing
5. O-ring
6. Drive axle
7. Thrust bushing
8. Centering ring
9. Cover
10. Plug
11. Pivot pin
12. Grease fitting
13. Tie rod assembly
14. Shim
15. Bushing
16. Nut
17. Washer
18. Stud
19. Steering case
(right)
20. Steering case (left)
21. Bolt
22. Articulated tie rod
23. Cylinder
24. Bushing assembly
EM9602
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle Disassembly
Figure 40-20-18
1 2
3
3
2
4 S38374
1
Using two levers, remove the top tie rod (Item 1)
complete with front sealing ring (Item 2) and shims
S2591
(Item 3) [Figure 40-20-20].
Figure 40-20-21
Loosen and remove the six bolts (Item 1) from the bottom
tie rod (Item 2) [Figure 40-20-18].
Loosen and remove the four nuts (Item 3), the four 2
washers and the four studs from the top tie rod (Item 4)
1
[Figure 40-20-18]. 3
Figure 40-20-19
UPPER TIE ROD BOTTOM TIE ROD

2
S1393
Configuration of the upper (Item 1) tie rod with shims

(Item 2) and the bottom tie rod (Item 3) [Figure 40-20-
21].
S2427
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-20-
19].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle Disassembly (Cont’d)
Figure 40-20-22
S2539
Remove the complete steering case (Item 1) [Figure 40-

20-22].
Figure 40-20-23
2 4
S1387
Use a puller to remove the centering ring (Item 1), the

sealing ring (Item 2) and the bushing (Item 3) from the
steering case (Item 4) [Figure 40-20-23].
NOTE: Mark the orientation of both centering and

sealing ring.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Drive Axle Disassembly
Figure 40-20-24
1
2
1 S1402
Remove the snap ring (Item 1) from the bushing unit

S2592 (Item 2) [Figure 40-20-26].
Figure 40-20-27
Loosen and remove the top and bottom check nuts
(Item 1) from the dowels (Item 2) [Figure 40-20-24]. 1
Figure 40-20-25
S1403
Position the entire drive axle (Item 1) under a press and

remove the bearing (Item 2) [Figure 40-20-27].
S2593
Remove the entire drive axle (Item 1) [Figure 40-20-25].
NOTE: To remove the drive axle use, if necessary, a

plastic hammer or a lever.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Drive Axle Disassembly (Cont’d)
Figure 40-20-28
2 1
S3567
Remove the snap ring (Item 1) from the bearing (Item 2)

[Figure 40-20-28].
Figure 40-20-29
2
1
S1404
Use a puller to remove the bearing (Item 1), the sealing

ring (Item 2) [Figure 40-20-29] and the O-ring.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Brake Group Parts Identification

1. Oil-level plug
2. Seal
3. Arm
4. Screw
5. Washer
6. Central body
7. Brake discs
8. Return spring
9. Piston
10. Pin screw
11. O-ring
12. Back-up ring
13. Regulation spring
14. Drive axle
EM8516A
TH.6534(X) / TH.7035(X) / TH.7038(X)

Brake Group Disassembly
Figure 40-20-30
1
1
S37106
Remove the tie rod from the steering case (See Removal
S37103 on Page 20-60-1.)
Install a sling under the arm (Item 1) [Figure 40-20-32] to

NOTE: Perform all operations on both arms. be removed and put the hoist under slight tension.
Remove the oil-level plug (Item 1) [Figure 40-20-30]. Figure 40-20-33
Figure 40-20-31
2 1
4
3
S37107
S37104 EM6817
Remove the bolts (Item 1) and washers (Item 2) that
secure the arm (Item 3) to the central body (Item 4)
Pressurize the brakes and, keeping them under pressure, [Figure 40-20-33].
inspect the linings "S" between the discs using tool T1
(Item 1) [Figure 40-20-31]. Minimum "S": 4,5 mm (0.177
in).
NOTE: Replace the brake discs and the intermediate

discs on both sides if necessary.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Brake Group Disassembly (Cont’d)
Figure 40-20-34
2 1
2
1
S37110
Remove the return springs (Item 1) from the piston (Item

1 S37108 2) [Figure 40-20-36].
NOTE: If the springs (Item 1) [Figure 40-20-36] are

Remove the arm (Item 1) together with the pack of the weak or deformed, replace them.
brake discs (Item 2) [Figure 40-20-34]. Place the arm on
a bench. Figure 40-20-37
Figure 40-20-35
2
1
1
1
1
1
S37111
S37109
Remove the pin screws (Item 1) that guide the piston
(Item 2) [Figure 40-20-37].
Remove the brake discs (Item 1) [Figure 40-20-35] and
mark their order of assembly. NOTE: If the screws must be replaced, there are
different colors for the different brake gap.
NOTE: If the discs do not need replacing, avoid (See Brake Group Assembly (Cont’d) on Page
switching their position. 40-20-41.)
Extract the drive axle (Item 2) [Figure 40-20-35] (See

Steering Knuckle Disassembly on Page 40-20-8.) and
(See Drive Axle Disassembly on Page 40-20-10.).
TH.6534(X) / TH.7035(X) / TH.7038(X)

Brake Group Disassembly (Cont’d)
Figure 40-20-38
1
S37112
Use low air pressure through the connection of the

braking circuit in order to extract the entire piston (Item 1)
[Figure 40-20-38].
NOTE: Hold on to the piston as it can be suddenly

ejected and damaged.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Parts Identification
10. Crown
11. Washer
12. Planetary gear
13. Differential carrier
14. Snap ring
15. Pin
16. Planet wheel gear
17. Friction washer
1. Ring nut
2. Central body
3. Set screw
4. Bolt
5. Middle cover
6. Differential
7. Taper roller bearing
8. O-ring
9. Top plug
EM8517A
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Disassembly
Figure 40-20-39
T13
S38864
1
S38862 Apply tool T13 and remove the ring nuts [Figure 40-20-
41].
Mark the position of the ring nuts (Item 1). Remove the NOTE: Clean the threaded parts of the ring nuts.
locking screw (Item 2) from the ring nuts (Item 1) [Figure
40-20-39]. Figure 40-20-42
Figure 40-20-40 1 2
1
1
1
S38865
S38863
Remove screws (Item 1) from the middle cover (Item 2)

Uniformly heat the ring nuts (Item 1) [Figure 40-20-40] [Figure 40-20-42].
up to a temperature of 80°C (176°F).
NOTE: Heating is meant to loosen the Loctite® on the

nut.
WARNING
AVOID BURN INJURY
Parts may be hot, use gloves when handling parts.
W-2762-1108
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Disassembly (Cont’d)

1
Figure 40-20-43
S2545
Remove the top plug (Item 1) [Figure 40-20-45].
S37203 Figure 40-20-46
Insert a screwdriver in the opposing slots then force and

remove the middle cover (Item 1) and the complete
differential unit (Item 2) [Figure 40-20-43].
1
NOTE: Support the pieces using a rod.
2
Figure 40-20-44
4
2
S1414
Remove the bolts (Item 1) from the ring gear (Item 2)

3 1 [Figure 40-20-46].
S1412
If the bearings need replacing, extract the bearing race

(Item 1 and 2) from the middle cover (Item 3) and central
body (Item 4) [Figure 40-20-44].
NOTE: Inspect for damaged O-rings (Item 5) [Figure

40-20-44].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-47
1
1
2
S1417
If the bearing needs to be replaced, extract the bearing

S1415 (Item 1) from the differential carrier (Item 2) [Figure 40-
20-49].
If the bearing needs to be replaced, extract the bearing Figure 40-20-50

(Item 1) and remove the ring gear (Item 2) [Figure 40-20-
47].
Figure 40-20-48
2
1
2
S1418
Remove the snap rings (Item 1) from the four pins

S1416 (Item 2) [Figure 40-20-50] of the planet wheel gears.
Remove the shim washer (Item 1) and the planetary gear

(Item 2) [Figure 40-20-48].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Disassembly (Cont’d) 1

2
Figure 40-20-51
T
2 1 2
1
S1422
Remove the tool pin (Item 1) and bushings (Item 2)

S1419 [Figure 40-20-53].
NOTE: In this condition the tool contains the pin.

Insert a tool T between two planet wheel gears (Item 1)
[Figure 40-20-51]. Figure 40-20-54
NOTE: Make sure that the tool is perfectly lined up

with the pins (Item 2) [Figure 40-20-51] when
locked.
Figure 40-20-52
3
2
3
1
S1423
2
Remove the tool with inside the pin of the planet wheel
gear [Figure 40-20-54].
S1421
Place the differential carrier (Item 1) under a press,

position a bushing (Item 2) and insert a tool pin (Item 3)
[Figure 40-20-52]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-20-51].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-55
1
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

40-20-55] in position and again lock the tool.
Repeat the operations for the extraction of the pin of the

second planet wheel gear (Item 2) [Figure 40-20-55].
Repeat the operations for the two remaining pins.
Figure 40-20-56
S1425
Remove the tool T and remove the planet wheel gears

(Item 1) and any shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-20-56].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Pinion Group Parts Identification
1. Check nut
2. Flange
3. O-ring
4. Guard
5. Shim washer
6. Seal
7. Ring nut
8. Pinion
9. Internal bearing
10. Spacer
11. Shim
12. Central body
13. External bearing
EM8518
TH.6534(X) / TH.7035(X) / TH.7038(X)

Pinion Group Disassembly
Figure 40-20-57 1
2
2
1
S37165
Remove the flange (Item 1) complete with guard (Item 2)

S37163 [Figure 40-20-59] with a puller.
Figure 40-20-60
If needed, heat the nut (Item 1) of the flange (Item 2)
[Figure 40-20-57] at 80°C (176°F).

nut.
1
WARNING
AVOID BURN INJURY
W-2762-1108
S37167
Figure 40-20-58
S37164
Position tool T20A (or T20B) (Item 1), to avoid pinion

rotation. Remove the nut and O-ring (Item 2) [Figure 40-
20-58].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Pinion Group Disassembly (Cont’d)
Figure 40-20-61
1
S37169
1
Install blocks T23 (Item 1) and, with a puller, push the
S37168 pinion (Item 2) [Figure 40-20-62] inwards with internal
bearing, spacer and shims.
Position wrench T22 (Item 1) onto the ring nut and use NOTE: The thrust blocks of the bearings remain in
T21 (Item 2) to hold the pinion. When loose, hold wrench the central body (Item 3) [Figure 40-20-62].
T22 (Item 1) [Figure 40-20-61] and rotate the pinion to
remove the ring nut. Figure 40-20-63
NOTE: If needed, heat the ring nut at approximately

80°C (176°F).
2
WARNING
AVOID BURN INJURY 3
W-2762-1108
S37170
Remove the pinion (Item 1), shims (Item 2) and spacer

(Item 3) [Figure 40-20-63].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-64
2
1 1
S37173
Insert a drift in the appropriate holes and remove the

S37171 thrust block of the internal bearing (Item 1) as well as the
shim washers (Item 2) [Figure 40-20-66].
Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-20-64].
Figure 40-20-65
S37172
Remove the thrust block of the external bearing with a

puller (Item 1) [Figure 40-20-65].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Pinion Group Assembly
Figure 40-20-67
T25C
DG
T24
T25A S37176
S1569 Partially insert the thrust block of the external bearing

(Item 1) [Figure 40-20-69].
Using a surface plate, reset a magnetic based dial Figure 40-20-70

indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm [1.2 in]).
Preset the indicator to approximately 2 mm (0.08 in).

T25B T24 T25C T25A
Figure 40-20-68
2
1
S1572
Install tension rod T25C, measurement ring T24 and front

guide tool T25A on the bearing race (Item 1) [Figure 40-
1
20-70].
S1570
Bring the internal bearing (Item 1), complete with its

bearing race, under the indicator (Item 2) [Figure 40-20-
68].
Determine overall thickness “D” of the bearing checking
the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the center and take

several measurements while rotating the
bearing race.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Pinion Group Assembly (Cont’d)
Figure 40-20-71 1
GB
GB
S1575
Install a depth gauge with long stem into a perfectly flat

bar T26A (Item 1) [Figure 40-20-73]; when the bar rests
S37178 on two gauge blocks “GB” of 57 mm (2.24 in) size, reset
the indicator.
Connect the tension rod to the press and move the thrust
block of the external bearing into its seat. Disconnect the
press and remove the tension rod [Figure 40-20-71].
Figure 40-20-74
NOTE: Before starting the next stage, make sure that
the thrust block has been completely inserted
into its seat.
2
Figure 40-20-72
3
4 1
2
1
S37181
Place bar T26A (Item 1) on gauged nut T26C (Item 2)

[Figure 40-20-74] and measure the size “A” at about
57 mm (2.24 in) corresponding to the maximum diameter
S37179 of arms centering.
See [Figure 40-20-75] for a sectional view.

Insert tool T26B (Item 1) complete with external bearing
(Item 2), measurement ring T24 (Item 3) and gauged ring
nut T26C (Item 4) [Figure 40-20-72]. Tighten manually.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-75
T24 T26B
T26C
S1579
Calculate size “C” which represents the second value for

S1577 calculating the size of the shims “S” that are to be placed
under the bearing race [Figure 40-20-77].
Calculate size “B” which will be the first useful value for Figure 40-20-78
calculating the size of the shims that are to be inserted
1
Figure 40-20-76
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578 to obtain the size “S” of the shim (Item 1) [Figure 40-20-
78] that will go under the bearing race.
Check the nominal size (X) marked on the pinion

(Item 1) [Figure 40-20-76] and add or subtract the
indicated variation (Y) so as to obtain size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-79
1
3 4 2
S37186
1
2 Position tools T26C (Item 1) and T26B (Item 2) complete

S37184 with tapered bearings (Item 3) and (Item 4) [Figure 40-
20-81].
Insert shim "S" (Item 1) and the thrust block of the Manually tighten until a rolling torque has been obtained.
internal bearing (Item 2) [Figure 40-20-79] in the central
body. Figure 40-20-82
NOTE: To hold shim "S" (Item 1) [Figure 40-20-79] in

position, apply grease.
1
Figure 40-20-80
S37187
2
Insert the stem of a depth micrometer in either side hole
of tool T26C (Item 1) [Figure 40-20-82]. Zero the
S37185 micrometer with a presetting of approximately 3 mm.
Position tool T25A (Item 1) and tension rod T25C (Item 2)

[Figure 40-20-80]. Connect the tension rod to the press,
fasten the thrust block and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the thrust block has been completely
inserted.
TH.6534(X) / TH.7035(X) / TH.7038(X)


1 S1
Figure 40-20-83
T26C
2 1 3
T26B
S1587
The variation is to be added to a set value of 0,12 -

S1585 0,13 mm, so as to obtain the size of shim “S1”
(Item 1) [Figure 40-20-85] which will be inserted
between the internal bearing (Item 2) [Figure 40-20-83]
Remove the micrometer and release tools and bearings and the distance piece (Item 1) [Figure 40-20-83] and
from the central body. subsequently, to determine the preload for the bearings.
Reinstall all and insert the spacer (Item 1) between both Figure 40-20-86
bearings (Items 2 and 3) [Figure 40-20-83]; manually
tighten the whole pack.
Figure 40-20-84
H
DDG
T26C 2
1 1
T26B S1588
Position the internal bearing (Item 1) and the pinion

S1586 (Item 2) [Figure 40-20-86] under a press. Press the
bearing onto the pinion.
Insert depth gauge into tool T26 and measure variation

“H” in relation to the zero setting performed in [Figure 40-
20-82].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-87
1
2
1
3 S37194
Connect the pinion (Item 1) [Figure 40-20-89] to the tie

S37192 rod T28A and T28B. Connect the tie rod T28C (see
special tools) to the press and block.
Install the pinion (Item 1), shim "S1" (Item 2) and spacer Figure 40-20-90
(Item 3) [Figure 40-20-87] in the main body.
NOTE: The thinner shims must be placed in-between

the thicker ones.
Figure 40-20-88
2
S37195
Apply Loctite® #243 to the thread of the ring nut (Item 1)

and screw the nut onto the pinion (Item 2) [Figure 40-20-
90].
S37193
Insert the external bearing (Item 1) [Figure 40-20-88] in

the central body in order to complete the pack arranged
as in the figure.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLE AND DIFFERENTIAL (FRONT) (CONT’D) NOTE: If torque does not reach the minimum value,
then the size of shim "S1" needs to be
Pinion Group Assembly (Cont’d) reduced.
Figure 40-20-91 NOTE: When calculating the increase or decrease in

size of shim "S1", bear in mind that a variation
of shim of 0,01 mm (0.00039 in) corresponds
to a variation of 0,6 N•m (5 in-lb) in the torque
of the pinion.
Figure 40-20-93
2
1
S37196
Apply special wrench T22 (Item 1) to the ring nut and bar-
hold T21 (Item 2) [Figure 40-20-91] to the pinion. Lock 3 2
the wrench T22 and rotate the pinion using a torque
wrench, up to a minimum required torque setting of 500
S37198
N•m (369 ft-lb).
Figure 40-20-92 Lubricate the outer surface of the new seal (Item 1) and
install it onto the central body (Item 2) using tool T27
(Item 3) [Figure 40-20-93].
Figure 40-20-94
1 2
S37197
Use the bar-hold T21 (Item 1) [Figure 40-20-92] and a

torque meter to check the pinion torque. Torque: 1,2 - 1,7
S37200
N•m (11 - 15 in-lb).
NOTE: If torque exceeds the maximum value, then Install the flange (Item 1) complete with the guard (Item
the size of shim "S1" between the bearing and 2) and secure it. For keying the flange (Item 1) [Figure
the spacer needs to be increased. If torque 40-20-94], use a plastic hammer if necessary.
does not reach the set value, increase the
torque setting of the ring nut in different NOTE: Make sure that the guard (Item 2) [Figure 40-
stages to obtain a maximum value of 570 N•m 20-94] is secured onto the flange and that it is
(420 ft-lb). not deformed.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-95
1
S37201
Apply Loctite® #243 to the threaded part of the pinion.

Position tool T20A (or T20B) (Item 1) [Figure 40-20-95]
and secure it in order to avoid rotation.
Insert the O-ring and the nut and tighten to 280 - 310
Figure 40-20-96
S37202
Remove blocks T23 (Item 1) [Figure 40-20-96] (used for

extracting the pinion).
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Assembly
1
Figure 40-20-97
2
2
S1534
With the help of another bar, position the second planet

S1532 wheel gear (Item 1) and the relative thrust washer
(Item 2) [Figure 40-20-99].
Insert the thrust washer (Item 1) and the planetary gear Figure 40-20-100
(Item 2) in the differential carrier (Item 3) [Figure 40-20-
97].
Figure 40-20-98
1
1
3
S1535
Insert the tool T between the two planetary gears and

S1533 line up the entire unit by pushing one bar
(Item 1) [Figure 40-20-100] all the way through until the
other is ejected.
Position the thrust washer (Item 1) and the first planet
wheel gear (Item 2). Temporarily hold them in position
using a bar (Item 3) [Figure 40-20-98].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Assembly (Cont’d)

2
1
Figure 40-20-101
2
1
1
S40983
Place the differential carrier under the press, position

S1536 bushing (Item 1) and insert the planet wheel pin
(Item 2) [Figure 40-20-103].
Lock tool T (Item 2) behind the planet wheel gears Figure 40-20-104
(Item 1) [Figure 40-20-101]. Then remove the bar.
Figure 40-20-102
2 1
1
S1539
S1537 Put a tool pin (Item 1) on top of the planet wheel pin
(Item 2) [Figure 40-20-104].
Install the snap rings (Item 1) onto the pins

(Item 2) [Figure 40-20-102].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-105
1
S1542
1
Position the second planetary gear (Item 1) in the

S1540 differential carrier (Item 2) [Figure 40-20-107].
Figure 40-20-108
Press the pin all the way down (Item 1) [Figure 40-20-
105].
Figure 40-20-106 1
2
S1543
Position the thrust washer (Item 1) on the ring gear

S1541 (Item 2) [Figure 40-20-108].
NOTE: In order to hold the shim washer in position,

Remove the tool pin, bushing and install the snap ring apply grease to it.
(Item 1) on the pin (Item 2) [Figure 40-20-106].
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pins.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-109
1
3
1
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races (Item 1) [Figure 40-20-111] in the central body
and in the middle cover.
Position the ring gear (Item 1) on the differential carrier Figure 40-20-112
(Item 2) and install the bolts (Item 3) [Figure 40-20-109]
with Loctite® #243.
3
Tighten the bolts to 128 - 142 N•m (95 - 105 ft-lb) torque. 1
2
NOTE: Tighten the bolts using the cross tightening
method.
Figure 40-20-110
S1547
T17
2
T17
1 Position the differential unit in the central body
(Item 1) with the help of a bar and install the middle
cover (Item 2) [Figure 40-20-112].
NOTE: Check the position of the O-ring

(Item 3) [Figure 40-20-112] and make sure
S1545 that the cover is installed with the hole (see
arrow on [Figure 40-20-112]) in the lower
position.
Install the bearing races (Items 1 and 2) [Figure 40-20-
110] using tool T17.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-113
2 T19
2
S1550
2
Pre-set the bearings by means of the ring nut situated on

the opposite side of the ring gear, so as to increase
S38866 pinion torque up to 1,4 - 2,1 N•m (12 - 19 in-lb) [Figure
40-20-115].
Lock the middle cover (Item 1) with four bolts
NOTE: If bearings are not new, check the static
(Item 2) [Figure 40-20-113].
torque. If bearings are new, check the
continuous torque.
Tighten the bolts to 24 - 26 N•m (18 - 20 ft-lb) torque.
Figure 40-20-116
Figure 40-20-114
1
A
T13
S1551
S38864
Install a dial indicator with rotary key “A” through the top
NOTE: If the ring nuts [Figure 40-20-114] are plug hole (Item 1). Position the indicator on the center of
removed, apply some Loctite® #243 to them. one of the teeth of the ring gear (Item 2) [Figure 40-20-
Tighten ring nut on the ring gear side until 116] and pre-set it to 1 mm (0.039 in) and reset it.
clearance between pinion and ring gear is
zero. Lock the ring gear. Turn the ring nut
back 90 - 180°.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-117
1
S38867
S1552 Apply Loctite® #243 to the bolts (Item 1) [Figure 40-20-

119], install them into one of the two holes and tighten.
Manually move the ring gear (Item 1) [Figure 40-20-117] Tighten the bolts to 24 - 26 N•m (18 - 19 ft-lb) torque.
in both directions in order to check the existing backlash
between the pinion and the crown. Install the plug in the hole (Item 1) [Figure 40-20-45]
after applying flexible gasket compound for seals to the
Figure 40-20-118 rims.
T13
S38864
Adjust the backlash between the pinion and the crown by

loosening one of the ring nuts [Figure 40-20-118] and
tightening the opposite to compensate.
Normal backlash: see table
CLEARANCE
RATIO
MINIMUM MAXIMUM
14 – 32 0.18 mm 0.23 mm
(0.0071 in) (0.0091 in)
NOTE: Difference between MINIMUM and MAXIMUM

clearance for whole circumference should not
exceed 0,09 mm (0.0035 in).
TH.6534(X) / TH.7035(X) / TH.7038(X)

Brake Group Assembly
Figure 40-20-120 2 3
4
2
3
5 1
EM6818
1 S37115
Lubricate the seals and install the piston (Item 1) into the
S37113 arm (Item 2) [Figure 40-20-122].
NOTE: Make sure that the piston seat fits into the
Clean the piston (Item 1) and the seats of slide and seal. stop pin (Item 3) [Figure 40-20-122] inside the
Replace the O-rings (Item 2 and 3) and the back-up rings arm.
(Item 4 and 5) [Figure 40-20-120]. Make sure that the
assembly side is correct. Figure 40-20-123
NOTE: Check the positioning of the back-up rings

(Items 4 and 5) [Figure 40-20-120].
Figure 40-20-121
1
1
1
S37116
1
2
Facilitate the insertion of the piston (Item 1) [Figure 40-
20-123] by lightly tapping around the edge with a plastic
S37114 hammer.
Insert the stroke automatic regulation springs (Item 1);

place them in line with the piston (Item 2) [Figure 40-20-
121].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Brake Group Assembly (Cont’d)
Figure 40-20-124
1 S37119
Slightly lubricate the brake discs (Item 1) and install them

S37117 in the arm following the correct sequence. Orient them so
that the oil circulation holes and the marks (Item 2)
[Figure 40-20-126] are perfectly lined up.
Install the pin screws (Item 1) [Figure 40-20-124] making
sure that they are all of the same color: NOTE: When installing the steel discs, the slot
corresponding to the oil level cap should
• White: 1 mm (0.039 in) gap; always be kept free.
• Yellow: 0,75 mm (0.029 in) gap;
• Blue: 0,5 mm (0.019 in) gap; Figure 40-20-127
Apply Loctite® #270 to the thread. Tighten the screws to

5 - 7 N•m (44 - 62 in-lb) torque.
Figure 40-20-125
2 1
1
1 S37120
Check that the positioning of the seal (Item 1) [Figure 40-

20-127] on the arm is intact, install the complete arm.
S37118 Lock it into position using two facing screws and washers.
Install the return springs (Item 1) on the piston (Item 2)

[Figure 40-20-125].
NOTE: Pay due attention not to deform the

connections of the springs.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Brake Group Assembly (Cont’d)
Figure 40-20-128
S37121
Check the flatness of the arms using tool T2 (Item 1)

[Figure 40-20-128] and finally lock the arms with the
screws and the washer, using the cross tightening
method. Tighten the screws to 298 N•m (220 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Drive Axle Assembly
Figure 40-20-129
1
T5 T6
1 2 S1399
3
3 Heat the bearing in oil at an approximate temperature of
S1397 100°C (212°F) and install the entire bearing (Item 1) on
the drive axle (Item 2) [Figure 40-20-131].
Using tools T5 and T6, insert the sealing ring (Item 1) Figure 40-20-132
and the bearing (Item 2) in the bearing (Item 3) [Figure
40-20-129].
NOTE: Carefully check the assembly side of the

sealing ring. 3
Figure 40-20-130
1
S1400
2 1
Install the snap ring (Item 1) on the axle shaft (Item 2).
After the bearing has cooled, install the O-ring
(Item 3) [Figure 40-20-132].
S1398
Install the snap ring (Item 1) on the bearing

(Item 2) [Figure 40-20-130].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Drive Axle Assembly (Cont’d)
Figure 40-20-133
S2592
Insert the drive axle and tighten the top and bottom
dowels (Item 1) [Figure 40-20-133]. Tighten to
maximum 15 N•m (11 ft-lb) torque.
NOTE: Center the point of the check dowels in the

slot.
Figure 40-20-134
1
2 1
2
S1507
Install the lock nuts (Item 1) on the dowels

(Item 2) [Figure 40-20-134] and tighten them to
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle Assembly
Figure 40-20-135
T7
1
1
S1496
Lubricate the splines of the drive axle and install the

S1447 steering case (Item 1) [Figure 40-20-137].
Pay attention not to damage the dust cover rings and the
Lubricate the bushing (Item 1) and the seat of the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-20-135], using tool T7. Figure 40-20-138
Figure 40-20-136
2
1 2
T8
1
S2395
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.033 in).
To be assembled under the upper tie rod
Lubricate the outer surface of the sealing ring (Item 1) (Item 2) [Figure 40-20-138].
and centering ring (Item 2) [Figure 40-20-136]. Install
them into their seat using tool T8.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle Assembly (Cont’d)
Figure 40-20-139
1
2
2
3
1
BOTTOM TIE ROD
S1500
3 UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S38990 oriented as shown in the inset. Lubricate the pivot area
(Item 2) and the seal (Item 1). Install the bottom tie rod
and the six bolts (Item 3) [Figure 40-20-141]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts in sequence using the
oriented as shown in the inset. Lubricate the pivot area cross tightening method, to 140 N•m (103 ft-lb) torque.
(Item 2) and the seal (Item 1). Install the upper tie rod
and shims (Item 3) [Figure 40-20-139], four studs, four Check for the correct assembly side of the seal
washers and four nuts. (Studs, washers and nuts not (Item 1) [Figure 40-20-141].
shown in photo.) Tighten to 140 N•m (103 ft-lb) torque.
Figure 40-20-142
Check the correct assembly side of the seal
(Item 1) [Figure 40-20-139].
Figure 40-20-140
S2568
Install a magnetic based dial indicator on the steering

S38375 housing. Check by means of a lever that there is no
vertical gap. In case there is any gap, determine the
width and reduce it by removing shims [Figure 40-20-
Lubricate the group with grease and mount it in the 142].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-143
S2569
Check the torque of the studs, which has to be 40 -

60 N•m (30 - 44 ft-lb). If the preliminary measured value
is too high, the shims have to be increased [Figure 40-
20-143].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Planetary Carrier Assembly
Figure 40-20-144
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-20-146] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-20-147
of the external bearing (Item 1) [Figure 40-20-144]
under the press.
Figure 40-20-145
1
2
1
S2587
T9A Install the bearing (Item 1) [Figure 40-20-147] into the

S2586 bearing race.
Lubricate the seats of the bearings and position the hub

(Item 1) on tool T9A. Position the bearing race
(Item 2) [Figure 40-20-145] (wide side up).
NOTE: Check that the bearing race is correctly

oriented.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Planetary Carrier Assembly (Cont’d)
Figure 40-20-148
1
2
3
T10
S1456
1
Insert the snap ring (Item 1) in order to secure the flange

S2588 (Item 2) in the crown (Item 3) [Figure 40-20-150].
NOTE: Make sure the snap ring (Item 1) [Figure 40-20-

Position tool T10 and press the sealing ring 150] is firmly seated in the groove.
(Item 1) [Figure 40-20-148] into its seat.
Figure 40-20-151
Figure 40-20-149
DOWN
T11
1
2
S1457
S1455
With the help of tool T11, insert the planet wheel gears
Insert the flange (Item 1) in the crown (Item 2) [Figure (Item 1) into the cover (Item 2) [Figure 40-20-151].
40-20-149].
Accurately check the orientation.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-152
S2470A
Install the external bearing (Item 1) [Figure 40-20-154].

S2473A
NOTE: Using a plastic hammer, drive the bearing to
the limit stop by lightly hammering around the
Install the four snap rings (Item 1) [Figure 40-20-152]. edge.
Figure 40-20-153
S2471A
Connect the steering bars and install the hub

(Item 1) [Figure 40-20-153].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-155
1
1
S2647
Cross tighten the nuts (Item 1) [Figure 40-20-157] in two

S2646 stages.
Initial torque setting: 120 N•m (88 ft-lb).

Install the complete crown flange (Item 1) [Figure 40-20-
155]. The final torque setting is 255 - 285 N•m (188 - 210 ft-lb)
torque.
NOTE: In order to fasten the flange, use a plastic
hammer and alternately hammer on several Figure 40-20-158
equidistant points.
Figure 40-20-156
1
2
S2466
S2467 Install the snap ring (Item 1) [Figure 40-20-158].
Apply silicone-based grease to the surface of the locking

plate (Item 1) that touches the crown flange (Item 2)
[Figure 40-20-156].
Install the locking plate (Item 1) [Figure 40-20-156].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-20-159 1
2
3 2
S2648
1 Lock the planetary carrier cover (Item 1) by tightening the

S2465A bolts (Item 2) [Figure 40-20-160]. Tighten the bolts to 40
- 50 N•m (30 - 37 ft-lb) torque.
Install the planetary carrier cover (Item 1) onto the hub

(Item 2) [Figure 40-20-159].
NOTE: Check that the O-ring (Item 3) [Figure 40-20-

159] is in good condition and in position.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Special Tools
MASSEY TOOL
IMAGE DESCRIPTION
FERGUSON PN NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
6912196 DIFFERENTIAL BEARING T17

INNER RINGS
6912197 PINION RING NUT T19

T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
AXLE AND DIFFERENTIAL (REAR) For photo clarity, the following axle procedures are done
with the complete axle assembly removed from the
Description machine. However, the planetary carrier, wheel hub,
steering knuckle and drive axle procedures can be done
with the axle assembly installed in the machine. For
complete axle repair, the following must be done:
Planetary Carrier Parts Identification
3
1
2 1. Seal
4 2. Bearing
3. Wheel stud
5 4. Wheel hub
2 5. O-ring
6. Snap ring
7. Ring gear
8. Ring gear support
9. Locking plate
10. Planet gear
11. Bearing
12. Nut
13. Plug
6 14. Countersunk bolt
7 15. Planet gear carrier
8 16. Stud
6 10
11
12
15
9 6 13
16
12 5
14
EM9286
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLE AND DIFFERENTIAL (REAR) (CONT’D) Figure 40-21-3
Planetary Carrier Disassembly
Figure 40-21-1 1
1
S2465X
S2465A
Remove the securing bolts and lift the planet gear carrier
S2463A (Item 1) [Figure 40-21-3].
Figure 40-21-4
Loosen the two securing bolts (Item 1) [Figure 40-21-1].
Figure 40-21-2
1
1 2
S2466
S2464A Remove the snap ring (Item 1) [Figure 40-21-4].
Remove the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-21-2] by alternately forcing a
screwdriver into the appropriate slots.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-5 1
1
2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B [Figure 40-21-7] by acting on the stud bolts.
Figure 40-21-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-21-5].
Figure 40-21-6 1
S2469
Partially extract the wheel hub (Item 1) [Figure 40-21-8]

S2467
using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-21-6].
points.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-9
1
1
1
1
1
S2473A
Remove the four snap rings (Item 1) [Figure 40-21-11].

S2470A
Figure 40-21-12
Remove the external bearing (Item 1) [Figure 40-21-9].
Figure 40-21-10
S2474A
With the help of a puller, remove the planet wheel gears

S2471A
(Item 1) [Figure 40-21-12].
NOTE: Note the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-21-
10] by hand.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-13 1
1 S2477A
Remove the sealing ring (Item 1) from the wheel hub

S2475 (Item 2) [Figure 40-21-15].
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-21-16
[Figure 40-21-13].
Figure 40-21-14 1
S2478A
S2476 Remove the internal bearing (Item 1) [Figure 40-21-16].
Remove the ring gear support (Item 1) [Figure 40-21-

14].
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLE AND DIFFERENTIAL (REAR) (CONT’D)
Figure 40-21-17
S2479A
Remove the external bearing races from the bearing

forcing a pin-driver into the appropriate slots on the hub
(Item 1) [Figure 40-21-17].
NOTE: Hammer in an alternate way so as to avoid

crawling or deformation of the bearing races.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle And Drive Axle Parts Identification
1. Snap ring
2. Ball bearing
3. Seal
4. Reduction bushing
5. O-ring
6. Drive axle
7. Thrust bushing
8. Centering ring
9. Cover
10. Plug
11. Pivot pin
12. Grease fitting
13. Tie rod assembly
14. Shim
15. Bushing
16. Nut
17. Washer
18. Stud
19. Steering case
(right)
20. Steering case (left)
21. Bolt
22. Articulated tie rod
23. Cylinder
24. Bushing assembly
EM9602
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle Disassembly
Figure 40-21-18
1 2
3
3
2
4 S38374
1
Using two levers, remove the top tie rod (Item 1)
complete with front seal (Item 2) and shims (Item 3)
S2591
[Figure 40-21-20].
Figure 40-21-21
Loosen and remove the six bolts (Item 1) from the bottom
tie rod (Item 2) [Figure 40-21-18].
Loosen and remove the four nuts (Item 3), the four
washers and the four studs from the top tie rod (Item 4) 2
[Figure 40-21-18]. 1
3
Figure 40-21-19
UPPER TIE ROD BOTTOM TIE ROD

2 S1393
Configuration of the upper (Item 1) tie rod with shims

(Item 2) and the lower tie rod (Item 3) [Figure 40-21-21].
S2427A
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-21-
19].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle Disassembly (Cont’d)
Figure 40-21-22
1 1
S2540
Remove the entire drive axle (Item 1) [Figure 40-21-24].

S2539
NOTE: To remove the drive axle use, if necessary, a

Remove the complete steering case (Item 1) [Figure 40- plastic hammer or a lever.
21-22].
Figure 40-21-23
3
1 2 3
4
S1387
Use a puller to remove the centering ring (Item 1), the

sealing ring (Item 2) and the bushing (Item 3) from the
NOTE: Mark the orientation of both centering and

sealing ring.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Parts Identification
10. Crown
11. Washer
12. Planetary gear
13. Differential carrier
14. Snap ring
15. Pin
16. Planet wheel gear
17. Friction washer
1. Ring nut
2. Central body
3. Set screw
4. Bolt
5. Middle cover
6. Differential
7. Taper roller bearing
8. O-ring
9. Top plug
EM8517A
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Disassembly
Figure 40-21-25
2
S38862
Mark the position of the ring nuts (Item 1). Remove the
S2541 set screw (Item 2) from the ring nuts (Item 1) [Figure 40-
21-27].
Remove the nuts (Item 1) [Figure 40-21-25]. Figure 40-21-28
Figure 40-21-26
1
S38863
1 S2542
Uniformly heat the ring nuts (Item 1) [Figure 40-21-28]
up to a temperature of 80°C (176°F).
Remove the complete arm (Item 1) [Figure 40-21-26].
nut.
WARNING
AVOID BURN INJURY
W-2762-1108
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Disassembly (Cont’d) 2
Figure 40-21-29 1
T13
S37203
Insert a screwdriver in the opposing slots then force and

S38864 remove the middle cover (Item 1) and the complete
differential unit (Item 2) [Figure 40-21-31].
Apply tool T13 and remove the ring nuts [Figure 40-21- NOTE: Support the pieces using a rod.
29].
Figure 40-21-32
NOTE: Clean the threaded parts of the ring nuts.
Figure 40-21-30 4
2
1 2
1
3 1
S1412
1
1 If the bearings need replacing, extract the bearing race
S38865 (Item 1 and 2) from the middle cover (Item 3) and central
body (Item 4) [Figure 40-21-32].
Remove screws (Item 1) from the middle cover (Item 2) NOTE: Inspect for damaged O-rings (Item 5) [Figure
[Figure 40-21-30]. 40-21-32].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-33
1
1
2
S1415
If the bearing needs to be replaced, extract the bearing

S2545 (Item 1) and remove the crown (Item 2) [Figure 40-21-
35].
Remove the top plug (Item 1) [Figure 40-21-33]. Figure 40-21-36
Figure 40-21-34
1
S1416
S1414
Remove the shim washer (Item 1) and the planetary gear
(Item 2) [Figure 40-21-36].
Remove the twelve bolts (Item 1) from the crown (Item 2)
[Figure 40-21-34].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-37 T
2 1 1 2
2
S1419
Insert a tool T between two planet wheel gears (Item 1)

S1417 [Figure 40-21-39].
NOTE: Make sure that the tool is perfectly lined up

If the bearing needs to be replaced, extract the bearing with the pins (Item 2) [Figure 40-21-39] when
(Item 1) from the differential carrier (Item 2) [Figure 40- locked.
21-37].
Figure 40-21-40
Figure 40-21-38
3
2
3
1
2
1
2
S1421
S1418
Place the differential carrier (Item 1) under a press,

Remove the snap rings (Item 1) from the four pins position a bushing (Item 2) and insert a tool pin (Item 3)
(Item 2) [Figure 40-21-38] of the planet wheel gears. [Figure 40-21-40]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-21-40].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-41
1 1
2
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

S1422 40-21-43] in position and again lock the tool.
Repeat the operations for the extraction of the pin of the

Remove the tool pin (Item 1) and bushing (Item 2) second planet wheel gear (Item 2) [Figure 40-21-43].
[Figure 40-21-41].
Repeat the operations for the two remaining pins.
NOTE: In this condition the tool contains the pin.
Figure 40-21-44
Figure 40-21-42
S1425
S1423
Remove the tool T and remove the planet wheel gears

Remove the tool with inside the pin of the planet wheel (Item 1) and the relative shim washers (Item 2) from the
gear [Figure 40-21-42]. differential carrier (Item 3) [Figure 40-21-44].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Pinion Group Parts Identification
1. Check nut
2. Flange
3. O-ring
4. Guard
5. Swinging support
6. Seal
7. Ring nut
8. Pinion
9. Internal bearing
10. Spacer
11. Shim
12. Central body
13. External bearing
14. Shim washer
EM6813
TH.6534(X) / TH.7035(X) / TH.7038(X)

Pinion Group Disassembly
Figure 40-21-45 1
2
2
1
S37165
Remove the flange (Item 1) complete with guard (Item 2)

S37163 [Figure 40-21-47] by means of a puller.
Figure 40-21-48
If needed, heat the check nut (Item 1) of the flange (Item
2) [Figure 40-21-45] at 80°C (176°F).
NOTE: Heating is meant to loosen the Loctite® on the 1

nut.
WARNING
AVOID BURN INJURY
W-2762-1108
Figure 40-21-46 S37166
Remove the swing support (Item 1) [Figure 40-21-48].
S37164
Position tool T20A (or T20B) (Item 1), to avoid pinion

rotation. Remove the nut and O-ring (Item 2) [Figure 40-
21-46].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-49
1
S37169
Apply blocks T23 (Item 1) and, with a puller, push the

S37167 pinion (Item 2) [Figure 40-21-51] inwards with internal
bearing, spacer and shims.
Remove the seal (Item 1) [Figure 40-21-49]. NOTE: The thrust blocks of the bearings remain in
the central body (Item 3) [Figure 40-21-51].
Figure 40-21-50
Figure 40-21-52
1
2
3
1
S37168
S37170
Position wrench T22 (Item 1) onto the ring nut and use
T21 (Item 2) to hold the pinion. When loose, hold wrench Remove the pinion (Item 1), shims (Item 2) and spacer
T22 (Item 1) [Figure 40-21-50] and rotate the pinion to (Item 3) [Figure 40-21-52].
remove the ring nut.
NOTE: If needed, heat the ring nut at approximately

80°C (176°F).
WARNING
AVOID BURN INJURY
W-2762-1108
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-53
2
1 1
S37173
Insert a drift in the appropriate holes and remove the

S37171 thrust block of the internal bearing (Item 1) as well as the
shim washers (Item 2) [Figure 40-21-55].
Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-21-53].
Figure 40-21-54
S37172
Remove the thrust block of the external bearing with a

puller (Item 1) [Figure 40-21-54].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Pinion Group Assembly
Figure 40-21-56
T25C
DG
T24
T25A S37176
S1569 Partially insert the thrust block of the external bearing

(Item 1) [Figure 40-21-58].
Using a surface plate, reset a magnetic based dial Figure 40-21-59

indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm [1.2 in]) [Figure 40-21-56].

T25B T24 T25C T25A
Figure 40-21-57
DG
1
S1572
Install tension rod T25C, measurement ring T24 and front

1 guide tool T25A on the bearing race of the external
bearing (Item 1) [Figure 40-21-59].
S1570
Bring the internal bearing (Item 1) [Figure 40-21-57],

complete with its bearing race, under the indicator.
Determine overall thickness “D” of the bearing checking

the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the center and take

several measurements while rotating the
bearing race.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-60
S37180
Install a centesimal comparator “DG1” with long stem into

S37178 bar T26A (Item 1) [Figure 40-21-62]. Zero the
comparator when the bar rests on two size - blocks “GB”
of 57 mm (2.24 in). Preset the comparator to
Connect the tension rod to the press and move the thrust approximately 2 mm (0.078 in) and zero again.
block of the external bearing into its seat. Disconnect the
press and remove the tension rod [Figure 40-21-60]. Figure 40-21-63
NOTE: Before starting the next stage, make sure that

the thrust block has been completely inserted
into its seat.
2
Figure 40-21-61
3
4 1
2
1
S37181
Place bar T26A (Item 1) on gauged nut T26C (Item 2)

[Figure 40-21-63] and measure the size “A” at about
57 mm (2.24 in) corresponding to the maximum diameter
S37179 of arms centering.
Insert tool T26B (Item 1) complete with external bearing

(Item 2), measurement ring T24 (Item 3) and gauged ring
nut T26C (Item 4) [Figure 40-21-61]. Tighten manually.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-64
T26C
T24
T26B
S1579
Calculate size “C” which represents the second value for

S1577 calculating the size of the shims “S” that are to be placed
Calculate size “B” which will be the first useful value for Figure 40-21-67
calculating the size of the shims that are to be inserted
1
Figure 40-21-65
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578 to obtain the size “S” of the shim (Item 1) [Figure 40-21-
67] that will go under the bearing race.
Inspect the nominal size (X) marked on the pinion

(Item 1) [Figure 40-21-65] and add or subtract the
indicated variation (Y) so as to obtain size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-68
1
3 4 2
S37186
1
2 Position tools T26C (Item 1) and T26B (Item 2) complete

S37184 with tapered bearings (Item 3) and (Item 4) [Figure 40-
21-70].
Insert shim "S" (Item 1) and the thrust block of the Manually tighten until a rolling torque has been obtained.
internal bearing (Item 2) [Figure 40-21-68] in the central
body. Figure 40-21-71
NOTE: To hold shim "S" (Item 1) [Figure 40-21-68] in

position, apply grease.
1
Figure 40-21-69
S37187
2
Insert the stem of a depth comparator "DDG" in either
side hole of tool T26C (Item 1) [Figure 40-21-71]. Zero
S37185 the comparator with a presetting of approximately 3 mm
(0.118 in).
Position tool T25A (Item 1) and tension rod T25C (Item 2)

[Figure 40-21-69]. Connect the tension rod to the press,
fasten the thrust block and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the thrust block has been completely
inserted.
TH.6534(X) / TH.7035(X) / TH.7038(X)


1 S1
Figure 40-21-72
T26C
2 1 3
T26B
S1587
The variation is to be added to a set value of 0,12 -

S1585 0,13 mm (0.004 - 0.005 in), so as to obtain the size of
shim “S1” (Item 1) [Figure 40-21-74] which will be
inserted between the internal bearing (Item 2) [Figure
Remove the indicator and release tools and bearings 40-21-72] and the distance piece (Item 1) [Figure 40-
from the central body. 21-72] and subsequently, to determine the preload for the
bearings.
Reinstall all and insert the distance piece (Item 1)
between both bearings (Item 2 and 3) [Figure 40-21-72]; Figure 40-21-75
manually tighten the whole pack.
Figure 40-21-73
H
DDG
2
T26C
1
1
T26B
S1588
S1586 Position the internal bearing (Item 1) and the pinion

(Item 2) [Figure 40-21-75] under a press. Force the
bearing onto the pinion.
Insert depth dial indicator into tool T26B-T26C and
measure variation “H” in relation to the zero setting
performed in [Figure 40-21-71].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-76
1
2
1
3 S37194
Connect the pinion (Item 1) [Figure 40-21-78] to the tie

S37192 rod T28A and T28B. Connect the tie rod T28C (see
special tools) to the press and block.
Install the pinion (Item 1), shim "S1" (Item 2) and spacer Figure 40-21-79
(Item 3) [Figure 40-21-76] in the main body.
NOTE: The thinner shims must be placed in-between

the thicker ones.
Figure 40-21-77
2
S37195
Apply Loctite® #243 to the thread of the ring nut (Item 1)

and screw the nut onto the pinion (Item 2) [Figure 40-21-
79].
S37193
Insert the external bearing (Item 1) [Figure 40-21-77] in

the central body in order to complete the pack arranged
as in the figure.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AXLE AND DIFFERENTIAL (REAR) (CONT’D) NOTE: If torque does not reach the minimum value,
then the size of shim "S1" needs to be
Pinion Group Assembly (Cont’d) reduced.
Figure 40-21-80 NOTE: When calculating the increase or decrease in

size of shim "S1", bear in mind that a variation
of shim of 0,01 mm (0.00039 in) corresponds
to a variation of 0,6 N•m (5 in-lb) in the torque
of the pinion.
Figure 40-21-82
2
1
S37196
Apply special wrench T22 (Item 1) to the ring nut and bar-
hold T21 (Item 2) [Figure 40-21-80] to the pinion. Lock 3 2
the wrench T22 and rotate the pinion using a torque
wrench, up to a minimum required torque setting of
S37198
500 N•m (369 ft-lb).
Figure 40-21-81 Lubricate the outer surface of the new seal (Item 1) and
install it onto the central body (Item 2) using tool T27
(Item 3) [Figure 40-21-82].
Figure 40-21-83
1
1
S37197
Use the bar-hold T21 (Item 1) [Figure 40-21-81] and a

torque meter to inspect the pinion torque. Torque: 1,2 -
S37199
1,7 N•m (11 - 15 in-lb).
NOTE: If torque exceeds the maximum value, then Install the swing support (Item 1) [Figure 40-21-83].
the size of shim "S1" between the bearing and
the spacer needs to be increased. If torque NOTE: Inspect that the swing support is properly
does not reach the set value, increase the oriented.
torque setting of the ring nut in different
stages to obtain a maximum value of 570 N•m
(420 ft-lb).
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-84
1 2 1
S37202
Remove blocks T23 (Item 1) [Figure 40-21-86] (used for

S37200 extracting the pinion).
Install the flange (Item 1) complete with the guard (Item

2) and fasten it. For keying the flange (Item 1) [Figure
40-21-84], use a plastic hammer if necessary.
NOTE: Make sure that the guard (Item 2) [Figure 40-

21-84] is securely fastened onto the flange
and that it is not deformed.
Figure 40-21-85
1
S37201
Apply Loctite® #243 to the threaded part of the pinion.

Position tool T20A (or T20B) (Item 1) [Figure 40-21-85]
and fasten it in order to avoid rotation.
Insert the O-ring and the nut and tighten it to 280 - 310
TH.6534(X) / TH.7035(X) / TH.7038(X)

Differential Assembly
1
Figure 40-21-87
2
2
S1534
With the help of another bar, position the second planet

S1532 wheel gear (Item 1) and the relative thrust washer
(Item 2) [Figure 40-21-89].
Insert the shim washer (Item 1) and the planetary gear Figure 40-21-90
(Item 2) in the differential carrier (Item 3) [Figure 40-21-
87].
Figure 40-21-88
1
1
3
S1535
Insert the tool T between the two planetary gears and

S1533 line up the entire unit by pushing the other bar (Item 1)
[Figure 40-21-90] all the way through until the other is
ejected.
Position the thrust washer (Item 1) and the first planet
wheel gear (Item 2). Hold them in position using a bar
(Item 3) [Figure 40-21-88].
TH.6534(X) / TH.7035(X) / TH.7038(X)


2
Figure 40-21-91 1
1
1
S40983
Place the differential carrier under the press, position

S1536 bushing (Item 1) and insert the planet wheel pin
(Item 2) [Figure 40-21-93].
Lock the tool behind the planet wheel gears Figure 40-21-94
(Item 1) [Figure 40-21-91]. Then remove the bar.
Figure 40-21-92
2 1
1
S1539
S1537 Put a tool pin (Item 1) on top of the planet wheel pin
(Item 2) [Figure 40-21-94].
Install the snap rings (Item 1) onto the pins

(Item 2) [Figure 40-21-92].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-95
1
1 S1542
Position the second planetary gear (Item 1) in the

S1540 differential carrier (Item 2) [Figure 40-21-97].
Figure 40-21-98
Press the pin all the way down (Item 1) [Figure 40-21-
95].
Figure 40-21-96 1
2
S1543
Position the shim washer (Item 1) on the crown

S1541 (Item 2) [Figure 40-21-98].
NOTE: In order to hold the shim washer in position,

Remove tool pin, bushing and install the snap ring apply grease to it.
(Item 1) on the pin (Item 2) [Figure 40-21-96].
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pins.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-99 1
3 1 2
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races (Item 1) in the middle cover and in the central body
(Item 2) [Figure 40-21-101].
Position the crown (Item 1) on the differential carrier Figure 40-21-102

(Item 2) and lock the bolts (Item 3) [Figure 40-21-99]
with Loctite® #243.
3
Tighten the bolts to 128 - 142 N•m (94 - 105 ft-lb) torque. 1
2
NOTE: Secure the bolts using the cross tightening
method.
Figure 40-21-100
S1547
T17
2
T17
1 Position the differential unit in the central body
(Item 1) with the help of a bar and install the middle
NOTE: Thoroughly inspect the state of the O-ring

(Item 3) [Figure 40-21-102] and make sure
S1545 that the cover is installed with the hole (see
arrow on [Figure 40-21-102]) in the lower
position.
Install the bearing races (Item 1 and 2) [Figure 40-21-
100] using tool T17.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-103
2 T19
2
S1550
2
Pre-set the bearings by means of the ring nut situated on

the opposite side of the crown, so as to increase pinion
S38866 torque up to 1,4 - 2,1 N•m (12 - 19 in-lb) [Figure 40-21-
105].
Lock the middle cover (Item 1) with bolts
NOTE: If bearings are not new, inspect the static
(Item 2) [Figure 40-21-103].
torque. If bearings are new, inspect the
continuous torque.
Tighten the bolts to 24 - 26 N•m (18 - 20 ft-lb) torque.
Figure 40-21-106
Figure 40-21-104
1
A
T13
S1551
S38864
Introduce a dial indicator with rotary key “A” through the

NOTE: If the ring nuts [Figure 40-21-104] are top plug hole (Item 1). Position the indicator on the center
removed, apply some Loctite® #243 to them. of one of the teeth of the crown (Item 2) [Figure 40-21-
Tighten ring nut on the crown side until 106] and pre-set it to 1 mm (0.039 in) and reset it.
clearance between pinion and crown is zero.
Lock the crown. Turn the ring nut back 90 -
180°.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-107
1
S38867
S1552 Apply Loctite® #243 to the bolts (Item 1) [Figure 40-21-

109], install them into one of the two holes and tighten.
Manually move the crown (Item 1) [Figure 40-21-107] in Tighten the bolts to 24 - 26 N•m (18 - 19 ft-lb) torque.
both directions in order to inspect the existing backlash
between the pinion and the crown. Install the plug in the hole (Item 1) [Figure 40-21-33 on
Page 40-21-13] after applying flexible gasket compound
Figure 40-21-108 for seals to the rims.
Figure 40-21-110
T13
S38864
S2542
Adjust the backlash between the pinion and the crown by

unloosing one of the ring nuts [Figure 40-21-108] and Reinstall the complete arms (Item 1) [Figure 40-21-110].
tightening the opposite to compensate.
Normal backlash: see table
CLEARANCE
RATIO
MINIMUM MAXIMUM
14 – 32 0.18 mm 0.23 mm
(0.0071 in) (0.0091 in)
NOTE: Difference between MINIMUM and MAXIMUM

clearance for whole circumference should not
exceed 0,09 mm (0.0035 in).
TH.6534(X) / TH.7035(X) / TH.7038(X)

Steering Knuckle Assembly
Figure 40-21-111
T17
1
S1496
Lubricate the terminal of the drive axle and install the

S1447 steering case (Item 1) [Figure 40-21-113].
Pay due attention not to damage the dust cover rings and
Lubricate the bushing (Item 1) and the seat of the the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-21-111], using tool T17. Figure 40-21-114
Figure 40-21-112
2
1 2
T8
1
S2395
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.0035
in). To be assembled under the upper tie rod
Lubricate the outer surface of the sealing ring (Item 2) [Figure 40-21-114].
(Item 1) and centering ring (Item 2) [Figure 40-21-112].
Install them into their seat using tool T8.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-115
1
2 2
3
1
BOTTOM TIE ROD
S1500
3 UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S38990 oriented as shown in the inset. Lubricate the pivot area
(Item 2) and the seal (Item 1). Install the bottom tie rod
and the six bolts (Item 3) [Figure 40-21-117]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts to 140 N•m (103 ft-lb)
oriented as shown in the inset. Lubricate the pivot area torque.
(Item 2) and the seal (Item 1). Install the upper tie rod
and shims (Item 3) [Figure 40-21-115], four studs, four Check for the correct assembly side of the seal
washers and four nuts. (Studs, washers and nuts not (Item 1) [Figure 40-21-117].
shown in photo.) Tighten to 140 N•m (103 ft-lb) torque.
Figure 40-21-118
Inspect the correct assembly side of the seal
(Item 1) [Figure 40-21-115].
Figure 40-21-116
S2568
Install a magnetic based dial indicator on the steering

S38375 housing. Inspect by means of a lever that there is no
vertical gap. In case there is any gap, determine the
width and reduce it by removing shims [Figure 40-21-
Lubricate the group with grease and mount it in the 118].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-119
S2569
Inspect the torque of the studs, which has to be between

30 - 60 N•m (22 - 44 ft-lb). If the preliminary measured
value is too high, the shims have to be increased [Figure
40-21-119].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-120
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-21-122] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-21-123
of the external bearing (Item 1) [Figure 40-21-120]
under the press.
Figure 40-21-121
1
2
1
S2587
T9A Install the bearing (Item 1) [Figure 40-21-123] into the

S2586 internal bearing race (wide side up).
Lubricate the seats of the bearings and position the hub

(Item 1) on tool T9A. Position the bearing race
(Item 2) [Figure 40-21-121] (wide side up).
NOTE: Inspect that the bearing race is correctly

oriented.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-124
1
2
3
T10
S1456
1
Insert the snap ring (Item 1) in order to secure the flange

S2588 (Item 2) in the crown (Item 3) [Figure 40-21-126].
NOTE: Make sure the snap ring (Item 1) [Figure 40-21-

Position tool T10 and press the sealing ring (Item 1) 126] is firmly seated in the groove.
[Figure 40-21-124] into its seat.
Figure 40-21-127
Figure 40-21-125
DOWN
T11
1
1
2
S1457
S1455
With the help of tool T11, insert the planet wheel gears
Insert the flange (Item 1) in the crown (Item 2) [Figure (Item 1) into the cover (Item 2) [Figure 40-21-127].
40-21-125].
Accurately check the orientation.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-128
S2470A
Install the external bearing (Item 1) [Figure 40-21-130].

S2473A
NOTE: Using a plastic hammer, drive the bearing to
the limit stop by lightly hammering around the
Install the four snap rings (Item 1) [Figure 40-21-128]. edge.
Figure 40-21-129 Figure 40-21-131
1
1
S2471A S2646
Connect the steering bars and install the hub Install the complete crown flange (Item 1) [Figure 40-21-
(Item 1) [Figure 40-21-129]. 131].
NOTE: In order to fasten the flange, use a plastic

hammer and alternately hammer on several
equidistant points.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-132
1
1
2
S2466

S2467
Figure 40-21-135
Apply silicone-based grease to the surface of the locking

plate (Item 1) that touches the crown flange (Item 2)
2
[Figure 40-21-132].
3
Install the locking plate (Item 1) [Figure 40-21-132].
Figure 40-21-133
1
S2465A
1
Install the planetary carrier cover (Item 1) onto the hub

(Item 2) [Figure 40-21-135].
NOTE: Inspect that the O-ring (Item 3) [Figure 40-21-

135] is in good condition and in position.
S2647
Cross tighten the nuts (Item 1) [Figure 40-21-133] in two

stages.
Initial torque setting: 120 N•m (88 ft-lb).
The final torque setting is 255 - 285 N•m (188 - 210 ft-lb)
torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-21-136
S1468
Lock the planetary carrier cover (Item 1) by tightening

the bolts (Item 2) [Figure 40-21-136]. Tighten the bolts
to 40 - 50 N•m (30 - 37 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Special Tools
MASSEY TOOL
IMAGE DESCRIPTION
FERGUSON PN NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
6912196 DIFFERENTIAL BEARING T17

INNER RINGS
6912197 PINION RING NUT T19

T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27
TH.6534(X) / TH.7035(X) / TH.7038(X)

FRONT AXLE Figure 40-30-2
Fully retract the telescoping boom. Raise the boom and

install the boom stop. (See Installing The Approved
Boom Stop on Page 10-150-1.)
WARNING
S38617
immediately. Lift the front of the machine and place jack stands (Item
W-2145-0290
1) [Figure 40-30-2] under the frame as shown.
Relieve hydraulic pressure. Place a block in front and behind one of the rear wheels.
Figure 40-30-1 Remove the eight lug nuts and washers (Item 1) [Figure
40-30-1] from each front wheel.
Remove both front wheels.

1
Figure 40-30-3
S1954
2
Loosen the eight lug nuts and washers (Item 1) [Figure
40-30-1] on each front wheel.
S1951
Installation: Tighten the lug nuts (Item 1) [Figure 40-30-
1] to 360 N•m (266 ft-lb) torque.
Remove the four nuts (Item 1) from both front fender
mount brackets (Item 2) [Figure 40-30-3].
Remove the front fenders.
Installation: Tighten the bolts to 90 - 100 N•m (66 - 74 ft-

lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

FRONT AXLE (CONT’D) Figure 40-30-6
Figure 40-30-4
1 1
S38298
Remove the four mounting bolts (Item 1) [Figure 40-30-

S39180 6] on each side.
Installation: Apply Loctite® #243 or equivalent to the

Remove the four drive shaft mounting bolts (Item 1) thread of the mounting bolts (Item 1) [Figure 40-30-6]
[Figure 40-30-4] and remove the two clamps from the (Both sides). Tighten to 490 - 550 N•m (361 - 405 ft-lb)
front axle U-joint. torque.

thread of the bolts (Item 1) [Figure 40-30-4] and tighten
to 33 - 41 N•m (24 - 30 ft-lb) torque.
IMPORTANT
Figure 40-30-5
damage the system.
I-2003-0888
Figure 40-30-7
S38618
Using a jack, apply upward pressure to lift and support

the front axle [Figure 40-30-5].
S38619
Gently lower the front axle [Figure 40-30-7]

approximately 100 mm (4 in).
TH.6534(X) / TH.7035(X) / TH.7038(X)

FRONT AXLE (CONT’D) Figure 40-30-10
Figure 40-30-8
1
1
S38622

S38621 right (operator’s view) side of the front axle.
Remove the hose (Item 1) [Figure 40-30-8] from the left

(operator’s view) side of the front axle.
IMPORTANT
Figure 40-30-9
2 damage the system.
I-2003-0888
Figure 40-30-11
S38620
Remove the hose (Item 1) and disconnect the wire

harness (Item 2) [Figure 40-30-9] from the left
(operator’s view) side of the front axle.
S38623
Have an assistant balance the axle on the jack and lower

the jack slowly while rolling the axle out from under the
frame [Figure 40-30-11].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
AXLE TOE-IN Figure 40-40-3
Adjustment
The axle is removed from the machine for photo clarity,

1 3
but this procedure can be completed with the axle
installed in the machine.
2
Turn the steering wheel until the steering cylinder rod is
positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
Figure 40-40-1
S2056
If measurement is not the same, adjust both tie rod ends

(Item 1) by loosening or tightening the track rods (Item 2)
[Figure 40-40-3] of both tie rods until the measurement
is the same.
1 Tighten the nut (Item 3) [Figure 40-40-3] to 360 N•m

(266 ft-lb) torque.
S2056
Install two identical, straight bars (Item 1) [Figure 40-40-

1] onto the wheel hub and secure them using lug nuts.
NOTE: The two bars must be parallel to the ground.
Figure 40-40-2
S2057
Measure the distance between the ends of the two bars

[Figure 40-40-2]. The measurement must be equal.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
PARKING BRAKE Figure 40-50-2
Releasing The Brake For Towing

1
The towing procedure is described earlier in this manual.
(See TOWING THE TELESCOPIC HANDLER on Page
10-40-1.)
Adjustment
Figure 40-50-1
S38727
2 2
3 4 7. Install the cap (Item 1) [Figure 40-50-2].
WARNING
S38218 UNEXPECTED MACHINE MOVEMENT CAN CAUSE
1. Apply hydraulic pressure of 9 - 20,7 MPa (90 - 207
adjusting screws to bypass the park brake
bar) (1300 - 3000 psi) to the brake (using a hand
system.
pump or portapower).
2. Turn the adjustment screw (Item 1) [Figure 40-50-1] W-2808-0909
until the brake is clamped onto the disc. Turn back
90°.
3. Loosen the nut (Item 3) and adjust the bolt (Item 2)

until it makes contact with the bumpstop (Item 4) on
the mounting bracket, then turn the bolt (Item 2)
[Figure 40-50-1] back 90°.
4. Hold the bolt (Item 2) in place while tightening the nut

(Item 3) [Figure 40-50-1] against the inner nut to 41 -
47 N•m (30 - 35 ft-lb) torque.
5. Turn the adjustment screw (Item 1) [Figure 40-50-1]

back 180°.
6. Release the hydraulic pressure and remove the hand

pump or portapower.
TH.6534(X) / TH.7035(X) / TH.7038(X)

PARKING BRAKE (CONT'D) Brake Cylinder Disassembly And Assembly
Brake Cylinder Removal Remove the brake cylinder from the machine. (See Brake
Cylinder Removal on Page 40-50-2.)
Figure 40-50-3
Figure 40-50-5
1
2
S38672
S38673
Remove the rubber cap (Item 1) [Figure 40-50-3].

Remove the nuts (Item 1) and bolt (Item 2) [Figure 40-
Figure 40-50-4 50-5].
Figure 40-50-6
2
1
3
S38671
S38674
Remove the pressure sensor (Item 1) [Figure 40-50-4]
and its fittings.
Remove the brake pads (Item 1) [Figure 40-50-6] from
Loosen the inner bolt (Item 2) [Figure 40-50-4] until the the brake cylinder.
brake pads show a gap.
Inspect the brake pads (Item 1) [Figure 40-50-6] for
Loosen the two bolts (Item 3) [Figure 40-50-4] and wear.
remove the brake cylinder.
TH.6534(X) / TH.7035(X) / TH.7038(X)

PARKING BRAKE (CONT'D) Figure 40-50-9
Brake Cylinder Disassembly And Assembly (Cont’d)
Figure 40-50-7
1
S38721
Remove the set of springs (Belleville washers) (Item 1)

S38675 [Figure 40-50-9].
Figure 40-50-10
Remove the cylinder cover (Item 1) [Figure 40-50-7].
NOTE: Be careful when removing the cylinder cover

(Item 1) [Figure 40-50-7]. The cover is under TOP
spring pressure.
Figure 40-50-8
S38722
2
Assembly: Verify that the Belleville washers are installed
as shown in [Figure 40-50-10].
S38726
Remove the two O-rings (Items 1 and 2) [Figure 40-50-

8].
TH.6534(X) / TH.7035(X) / TH.7038(X)

PARKING BRAKE (CONT'D) Figure 40-50-13
Brake Cylinder Disassembly And Assembly (Cont’d)
Figure 40-50-11
4 1
1
3
2
S38725
Remove the O-ring (Item 1) and back-up ring (Item 2)

S38723 [Figure 40-50-13].
Remove the O-ring (Item 3) and back-up ring (Item 4)

Remove the piston (Item 1) [Figure 40-50-11]. [Figure 40-50-13].
Figure 40-50-12
S38724
Inspect the piston surface for damage (Item 1)

[Figure 40-50-12].
TH.6534(X) / TH.7035(X) / TH.7038(X)

PARKING BRAKE (CONT'D) Brake Cylinder Installation
Brake Disc Removal And Installation Figure 40-50-15
Figure 40-50-14
1
2 3
1
1 1
S38671
S38251
Position the brake cylinder on the disc.
Remove the front driveshaft. (See Front Driveshaft Install the mounting bolts (Item 1) [Figure 40-50-15] far
Removal And Installation on Page 40-70-1.) enough to support the brake.
Remove the brake cylinder. (See Brake Cylinder Tighten the adjustment screw (Item 2) clockwise until the
Removal on Page 40-50-2.) brake pads are clamped onto the disc. Make sure the bolt
(Item 3) [Figure 40-50-15] does not protrude out far
Remove the four bolts (Item 1) [Figure 40-50-14]. enough to make contact with the mounting bracket at this
time.
Remove the brake disc (Item 2) [Figure 40-50-14].
Figure 40-50-16
Measure the thickness of the brake disc. Replace the
brake disc if thickness is below 9,5 mm (0.374 in).
1
3
2
S38727
Tighten the mounting bolts (Item 1) until they make

contact with the urethane springs (Item 2), then tighten
240° more. This puts the proper amount of preload on the
urethane springs (Item 2) [Figure 40-50-16].
Tighten the nuts (Item 3) [Figure 40-50-16] against the

mounting bracket. Tighten to 271 N•m (200 ft-lb) torque.
The brake is now ready for adjustment. (See Adjustment

on Page 40-50-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
STEERING ANGLE ADJUSTMENT Figure 40-60-3
Adjustment
The axle is removed from the machine for photo clarity,

but this procedure can be completed with the axle
installed in the machine.
Figure 40-60-1
37° - 45°
S2062
Turn the steering wheel completely to the other side

[Figure 40-60-3] and repeat above procedure.
S38218
Use an angle gauge, to obtain a reading of the correct

angle [Figure 40-60-1]:
• 45° = Tire sizes 400x20 / 400x24

• 42° = Tire size 460x24
• 37° = Tire size 500x24
Figure 40-60-2
S2061
Adjust the stop (Item 1) [Figure 40-60-2] as needed.

Tighten the lock nut to 150 N•m (110 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
DRIVESHAFT Front Driveshaft Removal And Installation
Rear Driveshaft Removal And Installation Figure 40-70-3
Figure 40-70-1
1
1
2
1
1
2
2
S38223
S38220
Remove the four drive shaft mounting bolts (Item 1) and
remove the two clamps (Item 2) [Figure 40-70-3] from
Remove the four drive shaft mounting bolts (Item 1) and the parking brake disc U-joint.
the rear axle U-joint. Installation: Apply Loctite® #243 or equivalent to the
threads of the bolts (Item 1) [Figure 40-70-3] and tighten
Installation: Apply Loctite® #243 or equivalent to the to 33 - 41 N•m (24 - 30 ft-lb) torque.
to 33 - 41 N•m (24 - 30 ft-lb) torque. Figure 40-70-4
Figure 40-70-2
1
1
2 1
2
S38222
S38221
Remove the four drive shaft mounting bolts (Item 1)
[Figure 40-70-4] and remove the two clamps from the
Remove the four drive shaft mounting bolts (Item 1) and front axle U-joint.
the gear box U-joint. Installation: Apply Loctite® #243 or equivalent to the
Installation: Apply Loctite® #243 or equivalent to the to 33 - 41 N•m (24 - 30 ft-lb) torque.
to 33 - 41 N•m (24 - 30 ft-lb) torque. Remove the drive shaft out the front of the machine.
Remove the drive shaft out the rear of the machine.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
SERVICE BRAKE Figure 40-80-1
Description
There is a bleed screw located on each side of the front

axle differential housing.
Air trapped in the brake lines can cause a spongy feel

and / or delayed activation of the service brake.
1
Use the following procedure to remove air from the brake
circuit.
S39118
WARNING
Figure 40-80-2
immediately. 1
W-2145-0290
WARNING
S2014
Put jackstands under the front and rear of the Remove the caps and loosen the two bleed screws (Item
machine before running engine for service. 1) [Figure 40-80-1] and [Figure 40-80-2].
W-2718-0208
With the aid of an assistant, start the engine and apply
Bleeding The Brake Circuit the service brake until a continuous stream of clean
hydraulic fluid, with no air, flows from the inside bleed
Lift and block the machine. (See Procedure on Page 10- screws (Item 1) [Figure 40-80-1] and [Figure 40-80-2].
10-1.)
Stop the engine and tighten the two inside bleed screws
NOTE: Position the jack stands to allow starting the (Item 1) [Figure 40-80-1] and [Figure 40-80-2].
machine and driving the wheels.
Lower the machine and test for proper brake operation.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
REAR AXLE Figure 40-90-2
WARNING
1 1
immediately.
W-2145-0290
S39142

Lift the rear of the machine and place jack stands (Item 1)
Figure 40-90-1 [Figure 40-90-2] under the frame as shown.
Remove the eight lug nuts and washers (Item 1) [Figure

40-90-1] from both rear wheels.
1
Remove both rear wheels.
Figure 40-90-3
S1954
Loosen the eight lug nuts and washers (Item 1) [Figure

40-90-1] on both rear wheels. 2
S1951
Remove the four nuts (Item 1) from both rear fender

mount brackets (Item 2) [Figure 40-90-3].
Remove the rear fenders.
TH.6534(X) / TH.7035(X) / TH.7038(X)

REAR AXLE (CONT’D) Figure 40-90-6
Figure 40-90-4 1
2
2
1
1
1 S39144

S39177 the left hand side of the rear axle.
Remove the electrical harness (Item 2) [Figure 40-90-6]

Remove the tie-straps (Item 1) and disconnect the from the machine.
centering sensor electrical harness (Item 2) [Figure 40-
90-4] from the steering cylinder. NOTE: Remove any tie-straps if needed.
Remove the four drive shaft mounting bolts (Item 3) Figure 40-90-7
[Figure 40-90-4] and remove the two clamps from the
rear axle U-joint.
Installation: Apply Loctite® #243 or equivalent to the 1

to 33 - 41 N•m (24 - 30 ft-lb) torque.
Figure 40-90-5
S39145
1
the right hand side of the rear axle.
P125340
Disconnect the connector (Item 1) [Figure 40-90-5]

located on the cab side below the boom.
TH.6534(X) / TH.7035(X) / TH.7038(X)

REAR AXLE (CONT’D) Figure 40-90-10
Figure 40-90-8
1
S39178

S39143 the rear mount bracket.

Roll the floor jack under the rear axle and apply upward threads of the bolts (Item 1) [Figure 40-90-10] and
pressure to the rear axle [Figure 40-90-8]. tighten to 490 - 550 N•m (361 - 405 ft-lb) torque.
S39179 S39143
Remove the two bolts (Item 1) [Figure 40-90-9] from the Have an assistant balance the axle on the jack and lower
front mount bracket. the jack slowly while rolling the axle out from under the
frame [Figure 40-90-11].
to 490 - 550 N•m (361 - 405 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
GEAR BOX Figure 40-100-3
Remove the engine / hydrostat assembly. (See Removal

Remove the brake disc. (See Brake Disc Removal And

Installation on Page 40-50-5.) 2
Figure 40-100-1
3
1 1
S40896
2
Remove the plug (Item 1) [Figure 40-100-3] and drain

the gear box oil into a container.
Remove the two hoses (Item 2) from the gear control

Figure 40-100-4
S38234
Disconnect the low speed connector (Item 1) [Figure 40- 1

100-1] from the hydrostatic drive motor.

hydrostatic drive motor.
Figure 40-100-2
1 2
S38235
Support the gear box with a hoist (Item 1) [Figure 40-

2
100-4].
2
S38233
Remove the hydrostatic hoses (Item 1) [Figure 40-100-

2] from the hydrostatic drive motor.

the hydrostatic drive motor.
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR BOX (CONT’D) Figure 40-100-7

1
Figure 40-100-5 2
3 3
1 S38237
Install a chain hoist and lifting strap (Item 1) to lift and

S38236
support the hydrostatic drive motor (Item 2) [Figure 40-
100-7].
Remove the two mounting bolts (Item 1) [Figure 40-100- Remove the four mounting bolts (Item 3) [Figure 40-100-
5]. 7] from the hydrostatic drive motor.
Figure 40-100-6 Installation: Tighten the mounting bolts to 190 - 210

Remove the hydrostatic drive motor (Item 2) [Figure 40-

1 100-7] from the gear box housing.
Figure 40-100-8
S38235

6].
S38247
Remove the gear box and hydrostatic drive motor
assembly and place it on a bench.
Installation: Replace the O-ring (Item 1) [Figure 40-
100-8].
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR BOX (CONT’D)
12
1. O-ring 2
1
2. Vent 1 8 3
3. Cover 4
13 4
4. Seal 5
6 5
5. Shim 6
3
6. Ball bearing 12
14 3 12
7. Gear
8. Flange
3
9. Elastic pin 14
7
10. Pin
27 6
11. Housing 34
12. Bolt
13. Nut
14. Washer 16
15. Plate
20
16. Needle bearing 19 15 7
16 10 12
17. Shaft 7 14
18. Selector sleeve 18
24 17 11
19. Magnetic plug
20. Spacer 23 15 6
1 4 3
21. Switch 12 4 20
12 14
4 8
22. Boot 14 9 12
21 1
23. Spring 22 1 14
25
24. Ball 12
1 1 14
25. Cylinder bolt 12 13
27 26 31
26. Cylinder 28 1
1 32
27. Plug
29 1
28. Rod 30
29. Piston 10 33
30. Cover plate
31. Selector shaft
32. Slide pin
33. Selector fork
34. Connector
EM9285
TH.6534(X) / TH.7035(X) / TH.7038(X)

Disassembly
Figure 40-100-9
1
2
2
1 1
S38243
Remove the O-ring (Item 1) and the flange (Item 2)

S36547 [Figure 40-100-11].
Remove the gear control cylinder. (See Removal on Page

Remove the four bolts (Item 1) from the motion input 20-70-1.)
Figure 40-100-12
Remove the motion input cover (Item 2) [Figure 40-100-
9].
Figure 40-100-10
S36543
Remove the plug (Item 1) [Figure 40-100-12] with the

washer and the rpm sensor.
S38242
Remove the nut (Item 1) from the flange (Item 2)

[Figure 40-100-10].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-100-13
1
3
2
3 2
S36546
1
Remove the screw (Item 1), spring (Item 2) and neutral
position ball (Item 3) [Figure 40-100-15] (hydraulic
S36544
version).
Remove the gear-in-position switch (Item 1), O-ring (Item Figure 40-100-16
2) and washer (Item 3) [Figure 40-100-13].
Figure 40-100-14
3 2 1 2
1
3
S36546
Remove the screw (Item 1) and disconnect the connector

S36545
(Item 2) to remove the speed sensor cable (Item 3)
[Figure 40-100-16].
Remove the screw (Item 1), spring (Item 2), and gear-
and-neutral position spindle (Item 3) [Figure 40-100-14]
(mechanical version).
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-100-17
1 1
1
2 1
S36554
Remove the fourteen bolts (Item 1) [Figure 40-100-19].

S36551
Figure 40-100-20
Remove the four bolts (Item 1) from the cover (Item 2)

[Figure 40-100-17].
Figure 40-100-18
1
3 1
S36555
Remove the cover (Item 1) [Figure 40-100-20].
S36553
NOTE: Take care not to damage surfaces.
Remove the cover (Item 1) and install the spacers (Item

2) [Figure 40-100-18] onto the cover to keep them in the
correct position until reassembly.
NOTE: The notch (Item 3) [Figure 40-100-18] must be

facing upward.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-100-21
2 1
S36558
Remove the bearing (Item 1) [Figure 40-100-23] if it

S36556
needs replacing.
Figure 40-100-24
Pay attention to the position of the pins (Item 2)

[Figure 40-100-21].
Figure 40-100-22
S36559
Install the bearing (Item 1) [Figure 40-100-24] into the

gear box.
2
S36557
Remove the gear (Item 1), needle bearings (Item 2) and

spacer (Item 3) [Figure 40-100-22] from the gear box.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-100-25
1 2
S36562
Install the oil shield plate into position, 5 - 5,5 mm

S36560
(0.197 - 0.217 in) from box surface [Figure 40-100-27].
Figure 40-100-28
Remove the oil shield plate (Item 1) [Figure 40-100-25]
only if necessary.
NOTE: The oil inlet (Item 2) [Figure 40-100-25] must

face upward.
Figure 40-100-26
2
1 1
1
S36563
Remove the bolts (Item 1) from the flow regulator plate

(Item 2) [Figure 40-100-28].
S36561
Install the oil shield plate (Item 1) with oil inlet facing
upward [Figure 40-100-26].
Apply Loctite® #510 on the outside [Figure 40-100-26].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-100-29
1
2 S36566
Remove the lower shaft (Item 1) [Figure 40-100-31].

S36564
Figure 40-100-32
Remove the plate (Item 1) and pull out coupling (Item 2)

and fork (Item 3) [Figure 40-100-29] at the same time.
Figure 40-100-30
1
2
1 3
2
S36567
Remove the entire shaft (Item 1) and the flow regulator

plate (Item 2) [Figure 40-100-32].
S36565
Check sliding blocks (Item 1), pin (Item 2), and sliding
coupling (Item 3) [Figure 40-100-30].
Replace if worn.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-100-33
S36570
Assemble the lower shaft [Figure 40-100-35].

S36568
Figure 40-100-36
Disassemble the entire lower shaft [Figure 40-100-33].
Figure 40-100-34 1
S36571
Remove the upper shaft (Item 1) [Figure 40-100-36].

S36569
NOTE: In case of replacement, the shaft is supplied
already assembled.
Progressive arrangement of parts installed onto the lower
shaft [Figure 40-100-34].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 40-100-37
S36574
Pull out the sealing ring (Item 1) [Figure 40-100-39] of

S36572
the cover.
Figure 40-100-40
Pull out the sealing ring (Item 1) [Figure 40-100-37].
Figure 40-100-38
S36575
S36573
Install a new sealing ring [Figure 40-100-40].
Install a new sealing ring (Item 1) [Figure 40-100-38].
TH.6534(X) / TH.7035(X) / TH.7038(X)

GEAR BOX (CONT’D)
Figure 40-100-41
1 2
S36576
Remove the sealing ring (Item 1) from the motion input

Figure 40-100-42
S36577
Remove the bearing (Item 1) from the cover (Item 2)

[Figure 40-100-42] of the gear box.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly
Figure 40-100-43
2
1
S36580
Apply Loctite® #510 on surfaces and bolts (Item 1).

S36578
Install the cover (Item 2) [Figure 40-100-45] on the gear
box.
Install the bearing in the cover of the gear box Figure 40-100-46
[Figure 40-100-43].
Figure 40-100-44
1
1
S36581
S36579
Tighten the four bolts (Item 1) [Figure 40-100-46] to 49 -
51 N•m (36 - 38 ft-lb) torque.
Install the new sealing ring in the motion input cover

[Figure 40-100-44].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 40-100-47
S36584
Assemble the entire lower shaft (Item 1) and the flow

S36582
regulator plate (Item 2) [Figure 40-100-49].
Figure 40-100-50
Lubricate the lip of the sealing ring (Item 1) [Figure 40-
100-47] with grease.
Figure 40-100-48
S36585
Position the shaft (Item 1) [Figure 40-100-50] so that the

S36583
bearing protrudes approximately 5 mm (0.197 in) from
the cover of the gear box.
Install the motion upper shaft (Item 1) [Figure 40-100-

48].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 40-100-51
1
S36588
Install bolts (Item 1) [Figure 40-100-53].

S36586
Figure 40-100-54
Temporarily re-assemble the cover (Item 1) [Figure 40-

100-51] with bolts.
NOTE: Make sure that the recess (Item 2) [Figure 40-

100-51] faces upward.
Figure 40-100-52
1
3 1
S36589
Tighten bolts (Item 1) [Figure 40-100-54] to 25 - 26 N•m

2 (18 - 19 ft-lb) torque.
S36587
Simultaneously insert fork and sliding blocks (Item 1),

coupling (Item 2) and flow regulator plate (Item 3)
[Figure 40-100-52].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 40-100-55
2
1
3 1
S36592
Apply Loctite® #510 to the surface and assemble the

S36590
Figure 40-100-58
Re-assemble needle bearings (Item 1), gear (Item 2) and
spacer (Item 3) [Figure 40-100-55].
NOTE: Position spacer (Item 3) underneath needle

1
bearings (Item 1) [Figure 40-100-55].
Figure 40-100-56
1 1
S36593
Install the cover (Item 1) [Figure 40-100-58].
S36591
Check the insertion of pins (Item 1) [Figure 40-100-56].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 40-100-59
3
1 1
2
S36546
Lubricate components and install ball (Item 1), spring

1 (Item 2) and screw (Item 3) [Figure 40-100-61] (hydraulic
S36594
version).
Tighten the 14 bolts (Item 1) [Figure 40-100-59] in a Tighten screw to 25 N•m (18 ft-lb) torque.
crisscross manner to 49 - 51 N•m (36 - 38 ft-lb) torque.
Figure 40-100-62
Figure 40-100-60
1 2 3
2 3
S36544
S36545
Install the gear-in position switch (Item 1) with washer

Lubricate components and install spindle (Item 1), spring (Item 2) and O-ring (Item 3) [Figure 40-100-62].
(Item 2) and screw (Item 3) [Figure 40-100-60]
(mechanical version). Tighten screw (Item 1) [Figure 40-100-62] to 25 N•m (18
ft-lb) torque.
Tighten screw (Item 3) [Figure 40-100-60] to 25 N•m (18
ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 40-100-63
S36800
1 Install the bearing [Figure 40-100-65].

S36543
Install the plug (Item 1) [Figure 40-100-63] with washer

and revolution indicator.
Tighten the plug (Item 1) [Figure 40-100-63] to 25 N•m

(18 ft-lb) torque.
Figure 40-100-64
1 1
S36551
Remove bolts (Item 1) and remove the temporarily

assembled cover (Item 2) [Figure 40-100-64].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 40-100-66
1
2
S38249
A
Apply Loctite® #510 on the surface, lubricate the sealing
S36801
ring, insert the distance washers and install the cover
(Item 1) with the slot (Item 2) [Figure 40-100-68] facing
upward.
Measure dimension "A" between the bearing and the box
plane using an depth gauge [Figure 40-100-66].
Figure 40-100-69
NOTE: If parts are not replaced, use disassembled
distance washers.
Figure 40-100-67
1
B S38250
Install bolts (Item 1) [Figure 40-100-69]. Apply Loctite®

#510 or equivalent to the threads before installation.
S38248
Tighten bolts to 49 - 51 N•m (36 - 38 ft-lb) torque.
Measure dimension "B" on the cover, between the
bearing plane and bearing support [Figure 40-100-67].
Calculate the dimension of the distance washers
required:
S = Dimension B – Dimension A
Example: B = 5,2 mm (0.20 in); A = 4,6 mm (0.18 in);

Backlash = 0,2 - 0,3 mm (0.0079 - 0.0118 in);
Distance washer required = 0,4 - 0,3 mm (0.0157 -

0.0118 in)
TH.6534(X) / TH.7035(X) / TH.7038(X)

Assembly (Cont’d)
Figure 40-100-70
2
3
S38242
S36546
Install the nut (Item 1) [Figure 40-100-72].
Tighten the nut (Item 1) [Figure 40-100-72] to 260 - 280

Install the connector (Item 1) with the screw (Item 2) to N•m (192 - 207 ft-lb) torque.
install the speed sensor cable (Item 3) [Figure 40-100-
70].
Figure 40-100-71
S38243
Install the flange (Item 1) and the O-ring (Item 2)

[Figure 40-100-71].
TH.6534(X) / TH.7035(X) / TH.7038(X)

MAINFRAME
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

FIXED BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
INNER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

WEAR PADS (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-1

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

ATTACHMENT CARRIER (QUICK-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
STEERING COLUMN COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

DASH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

JOYSTICK PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
OPERATOR CAB Figure 50-10-2
Figure 50-10-1
4 3
2
1
P125341
1
Remove the A/C hose (Item 1) from the drier, and the A/C
S38006 hose (Item 2) [Figure 50-10-2] from the expansion valve.
NOTE: Plug the A/C hoses to prevent contamination.

[Figure 50-10-1]. (See Installing The Approved Boom Remove the heater hoses (Items 3 and 4) [Figure 50-10-
Stop on Page 10-150-1.) 2] from the heater.
Stop the engine. Figure 50-10-3
Remove the Starter switch key.
Remove the fuel tank. (See Removal And Installation on

Page 50-70-1.) 1 1
Remove the operator seat. (See Removal And

Remove the refrigerant from the A/C system. (See 2

Reclamation And Charging With Recovery / Charging
Unit on Page 80-40-1.)
S38084
Disconnect the ground (-) cable from the battery. (See
Removing And Installing The Battery on Page 60-20-3.)
cab.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 50-10-4
1
1
1
2
2
1 2
1
S39811
3
1 Remove the four bolts (Item 1) and remove the cover

P125412 (Item 2) [Figure 50-10-5]
Figure 50-10-6
Remove all the hoses (Item 1) [Figure 50-10-4] from the
steering valve and the brake valve.
1
Disconnect the two electrical connectors (Item 2) [Figure 1
50-10-4]. 2
Remove the tubeline (Item 3) [Figure 50-10-4] from the

brake valve.
1 3
WARNING P125340

sufficient force to enter a person’s body by Disconnect the four electrical connectors (Item 1) [Figure
penetrating the skin. This can cause serious injury 50-10-6].
physician familiar with this injury is not received Disconnect the red / white cable (Item 2) [Figure 50-10-
immediately. 6].
W-2145-0290
Remove the ground wires (Item 3) [Figure 50-10-6].
NOTE: Mark all hoses and electrical connectors for

correct installation.
IMPORTANT
damage the system.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 50-10-7
1
1
S38128
Remove the two cab mount bolts (Item 1) [Figure 50-10-

S38127 9] from the back of the cab.
Remove the floor mat.

Install a hoist to lift and support the cab [Figure 50-10-7].
Figure 50-10-10
Figure 50-10-8
1
1
S38128
S38126
Remove the cab mount bolt (Item 1) [Figure 50-10-10]

Remove the cab mount bolt (Item 1) [Figure 50-10-8] and washer from the cab floor.
from the front right hand side of the cab.
TH.6534(X) / TH.7035(X) / TH.7038(X)

OPERATOR CAB (CONT’D)
Figure 50-10-11
S38130
Lift and remove the cab [Figure 50-10-11].
TH.6534(X) / TH.7035(X) / TH.7038(X)

OPERATOR SEAT
Figure 50-20-1
1 1
P125380

washers (on each corner of the plate).
Remove the seat.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
FIXED BOOM Figure 50-30-3
Removal
Remove the lift and self leveling cylinders. (See LIFT 2

CYLINDER on Page 20-20-1.) and (See SELF
LEVELING CYLINDER on Page 20-30-1.)
Lower the boom and position horizontally on wooden

blocks.
Remove the inner boom. (See Removal And Installation 1

on Page 50-40-1.)
Figure 50-30-1 S39167
1 Remove the two nuts (Item 1) and the retainer bolt (Item
1
2) [Figure 50-30-3] from the boom pivot pin.
Figure 50-30-4
S38102
S39410
Install two lifting chains to the rear and two chains to the
front of the boom [Figure 50-30-1].
Figure 50-30-2 S39168
Remove the plastic cap (Item 1) [Figure 50-30-4].
P125394
Slightly bring the chains under tension, in order to safely

remove the boom pivot pin [Figure 50-30-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

FIXED BOOM (CONT’D) Installation
Removal (Cont’d) Figure 50-30-7
Figure 50-30-5
1
P125394
S39169
Carefully lift and install the boom onto the machine
[Figure 50-30-7].
Remove the boom pivot pin [Figure 50-30-5].
Align the holes for installing the boom pivot pin (Item 1)
Figure 50-30-6 [Figure 50-30-7] while lowering the boom with the hoist.
Install the boom pivot pin (Item 1) [Figure 50-30-7].
Figure 50-30-8
P125394
2
Carefully lift and remove the boom from the machine
[Figure 50-30-6].
S39167
Install the retainer bolt (Item 1) and the two nuts (Item 2)
[Figure 50-30-8] onto the boom pivot pin.
TH.6534(X) / TH.7035(X) / TH.7038(X)

FIXED BOOM (CONT’D)
Figure 50-30-9
S39168
Install the plastic cap (Item 1) [Figure 50-30-9].
Figure 50-30-10
S38102
Grease the boom pivot (Item 1) [Figure 50-30-10] (one

place).
Position the boom horizontally on wooden blocks.
Install the inner boom. (See Removal And Installation on

Page 50-40-1.)
Install the lift and self leveling cylinders. (See LIFT

CYLINDER on Page 20-20-1.) and (See SELF
LEVELING CYLINDER on Page 20-30-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
INNER BOOM Figure 50-40-3
Figure 50-40-1
1 1
S38932
Remove the eight bolts (Item 1) [Figure 50-40-3] and

S39170 remove the four side wear pads. (Both sides).

Position the boom horizontally using wooden blocks lb) torque.
[Figure 50-40-1].
Figure 50-40-4
Extend the inner boom for approximately 500 mm (20 in).
Figure 50-40-2
S39188
P123046 Lift the boom and rest the attachment carrier onto a
suitable stand, such that the lower wear pads become
free of pressure [Figure 50-40-4].
remove the two top wear pads.
NOTE: Mark the original position of each wear pad.

lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

INNER BOOM (CONT’D) Figure 50-40-7

1
Figure 50-40-5
1 S38930
Disconnect the ACD harness connector (Item 1)

S38940 [Figure 50-40-7] (if equipped).
Figure 50-40-8
Remove the six bolts (Item 1) [Figure 50-40-5] and
remove the two bottom wear pads. 1
Installation: Apply Loctite® #243 to the threads and

tighten the bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.
NOTE: DO NOT use fingers to remove the bottom

wear pads.
NOTE: When installing the wear pads, make sure to

install the correct color (same color as was
removed).
Figure 50-40-6
S38931
Remove the six hoses (Item 1) [Figure 50-40-8] from the

tubelines.
1 1
S39070
Remove the two bolts (Item 1) (both sides) and remove

the cover (Item 2) [Figure 50-40-6] from the back of the
boom.
TH.6534(X) / TH.7035(X) / TH.7038(X)

INNER BOOM (CONT’D) Figure 50-40-11
Figure 50-40-9
S38938
Slide the inner boom from the fixed boom. Before the
S38936 inner boom is completely removed, position a hoist and
lifting strap on the inner boom. Carefully continue to
remove the inner boom completely [Figure 50-40-11].
Remove the bolt (Item 1) [Figure 50-40-9] from the
cylinder. NOTE: Support the attachment carrier with a pallet
and pallet truck.
Installation: Tighten the mounting bolt (Item 1)
[Figure 50-40-9] to 760 N•m (560 ft-lb) torque. Figure 50-40-12
IMPORTANT
damage the system.
I-2003-0888
Figure 50-40-10
S39171
Install the inner boom on adequate stands [Figure 50-

40-12].
S38937
Install a wooden block (Item 1) [Figure 50-40-10] under

the extension cylinder (as shown).
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
WEAR PADS (FRONT) Installation: Apply Loctite® #2700 to the threads and
Figure 50-50-3
(See SERVICE SCHEDULE on Page 10-50-1.) for the
service interval when to replace the wear pads.
Extend the inner boom for approximately 500 mm (20 in).
Figure 50-50-1
1
S39188
Lift the boom and rest the attachment carrier onto a

suitable stand, such that the lower wear pads become
free of pressure [Figure 50-50-3].
P123046
Figure 50-50-4

remove the two top wear pads from in between the inner 1
and fixed boom.
Installation: Apply Loctite® #2700 to the threads and 1

NOTE: Mark the original position of each wear pad. 1
Figure 50-50-2
1
S38940
Remove the six bolts (Item 1) [Figure 50-50-4] and

1 1 remove the two bottom wear pads.

tighten the bolts to 43- 47 N•m (32 - 35 ft-lb) torque.
NOTE: DO NOT use fingers to remove the bottom

wear pads.
S38932
NOTE: When installing the wear pads, make sure to

Remove the eight bolts (Item 1) [Figure 50-50-2] and install the correct color (same color as was
remove the four side wear pads from in between the inner removed).
and fixed boom. (Both sides)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
WEAR PADS (REAR) Figure 50-51-2
(See SERVICE SCHEDULE on Page 10-50-1.) for the

service interval when to replace the wear pads. 3
1
Remove the inner boom. (See Removal And Installation 2
on Page 50-40-1.) 4
4
3
Figure 50-51-1 3
1
2
5
S39161
Remove the two screws (Item 1) and remove the side

wear pad (Item 2) [Figure 50-51-2].
1 Repeat for the other three side wear pads (Item 3)

[Figure 50-51-2].
Remove the six screws (Item 4) and remove the bottom

S39162
wear pads (Item 5) [Figure 50-51-2].

With the inner boom supported, remove the six screws tighten the screws to 43 - 47 N•m (32 - 35 ft-lb) torque.
(Item 1) and remove the two top wear pads (Item 2)
[Figure 50-51-1]. NOTE: Make sure that the surface of the boom is
cleaned before installing the pads.
tighten the screws to 43 - 47 N•m (32 - 35 ft-lb) torque. NOTE: When installing the wear pads, make sure to
install the correct color (same color as was
NOTE: Make sure that the surface of the boom is removed).
cleaned before installing the pads.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
ENGINE COVER
Gas Cylinder Removal And Installation

WARNING
Page 10-160-1.)
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
Add a support to prevent the cover from closing when the
death.
gas cylinder is removed. W-2113-0288
Figure 50-60-1
Remove the gas cylinder. (See Gas Cylinder Removal

1 Figure 50-60-3
P125261 1
Figure 50-60-2
P125393
Remove the two hinge mounting bolts (Item 1) [Figure

50-60-3].
Installation: Apply Loctite® #242 to the threads of the

bolts (Item 1) prior to assembly. Tighten the bolts (Item 1)
1 [Figure 50-60-3] to 10 - 12 N•m (88 - 106 in-lb) torque.
Remove the engine cover.
P125260
Remove the retainer clips (Item 1) [Figure 50-60-1] and

[Figure 50-60-2] at both of the ball joints ends. Remove
the ball joints from the ends.
Remove the gas cylinder.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
FUEL TANK Figure 50-70-3
Figure 50-70-1
S38291
1
Fully support the fuel tank using an appropriate lifting

S39066 device [Figure 50-70-3].
Figure 50-70-4
Install a suitable container, large enough to contain all
fuel from the fuel tank, under the drain plug (Item 1)
[Figure 50-70-1].
Remove the drain plug (Item 1) [Figure 50-70-1].

1
2
Remove the operator cab floor mat.
1
Figure 50-70-2
1
1 2
S38086
Remove the four bolts (Items 1 and 2) [Figure 50-70-4].

threads of the bolts. Tighten the two rear bolts (Item 1)
[Figure 50-70-4] to 25 - 30 N•m (18 - 22 ft-lb) torque.
Tighten the two front bolts (Item 2) [Figure 50-70-4] to
2 S39137
5 - 6 N•m (44 - 53 in-lb) torque.
Remove the bolts (Item 1) and remove the step (Item 2)

[Figure 50-70-2].
NOTE: Support the step while removing the bolts.
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL TANK (CONT'D) Figure 50-70-7
Figure 50-70-5
1 1
S38087
2

S40653
thread of the bolt. Tighten the bolt (Item 1) [Figure 50-
Remove the two screws (Item 1) and filter cover (Item 2) 70-7] to 25 - 30 N•m (18 - 22 ft-lb) torque.
[Figure 50-70-5].
Figure 50-70-8
Figure 50-70-6
1 1
S38088
S40654

Remove the filter (Item 1) [Figure 50-70-6].
70-8] to 25 - 30 N•m (18 - 22 ft-lb) torque.
Lower the fuel tank for approximately 200 mm (8 in).
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL TANK (CONT'D) Figure 50-70-11
Figure 50-70-9
S38094
Remove the fuel tank [Figure 50-70-11].

S38090
Disconnect the fuel level sensor connector (Item 1)

[Figure 50-70-9].
Figure 50-70-10
S38095
Remove the fuel return hose (Item 1) [Figure 50-70-10]

from the fuel tank.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
ATTACHMENT CARRIER (QUICK-TACH) Figure 50-80-3
Figure 50-80-1
S39147
Remove the tilt cylinder lower pivot pin (Item 1)

S39120
[Figure 50-80-3].
Figure 50-80-4
Tilt the attachment carrier forward and place it on a flat
surface [Figure 50-80-1].
1
Figure 50-80-2
S39121
Remove the pivot pin retainer bolt (Item 1) [Figure 50-

S39146
80-4].

[Figure 50-80-2] from the tilt cylinder lower pivot pin.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ATTACHMENT CARRIER (QUICK-TACH) (CONT’D)
Figure 50-80-5
S39122
Remove the attachment carrier pivot pin (Item 1)

[Figure 50-80-5].
Installation: Apply grease using a grease pump.
Figure 50-80-6
S39123
Remove the attachment carrier [Figure 50-80-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

COUNTERWEIGHT Figure 50-90-3
Figure 50-90-1
S39140
Slowly move the counterweight backward until it is

S39139 stopped by the inner frame [Figure 50-90-3].
Figure 50-90-4
Support the counterweight using a fork lift and pallet
[Figure 50-90-1].
NOTE: Counterweight mass is approximately 855 kg

(1885 lb). Use a fork lift rated for this mass.
Figure 50-90-2
1
S39141
Lower the counterweight and remove it from under the

machine [Figure 50-90-4].
1
EM7532
Remove the three bolts (Item 1) [Figure 50-90-2] from

inside the opening.
Installation: Tighten the mounting bolts (Item 1)

[Figure 50-90-2] to 370 - 410 N•m (273 - 302 ft-lb)
torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
FENDER
Figure 50-100-1
S38680
Remove the four nuts (Item 1) from the fender mount

bracket (Item 2) [Figure 50-100-1].
Remove the fender.

lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
STEERING COLUMN COVER Figure 50-110-3
Figure 50-110-1
1
S40899
1 1

S38732 remove the blower hose from the blower.
Remove the steering column cover.

from the steering column cover.
Installation: Tighten the screws to 2 - 4 N•m (13 - 35 in-

lb) torque.
Figure 50-110-2
1
1
P125389
Remove the four screws (Item 1) [Figure 50-110-2] from

the steering column cover.

lb) torque.
Lower the steering column cover.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
DASH COVER Figure 50-120-3

1
Figure 50-120-1
S38299
Pull out the Hazard Lights switch (Item 1) [Figure 50-

P125390 120-3], disconnect the connector and remove the switch.
Pull out the indicator panel (Item 2) [Figure 50-120-3],

Remove the cap (Item 1) [Figure 50-120-1] from the disconnect the connector and remove the panel.
steering wheel.
Figure 50-120-4
Figure 50-120-2
1
1 1
1
S39051
P125391

Remove the nut (Item 1) [Figure 50-120-2] from the windscreen blower.
steering wheel.
Remove the steering wheel (Item 2) [Figure 50-120-2].
Remove the signal lever. (See Removal And Installation

on Page 60-60-1.)
Remove the instrument panels. (See Right Instrument

And Indicator Panel Removal And Installation on Page
60-80-1.)
Remove the display. (See Removal And Installation on

Page 60-70-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

DASH COVER (CONT’D) Figure 50-120-7
Removal And Installation (Cont’d) 1

Figure 50-120-5
S39054
Lift the dash cover (Item 1) [Figure 50-120-7].

S39052
Figure 50-120-8
Remove the two screws (Item 1) [Figure 50-120-5] from

the dash cover.

lb) torque.
Figure 50-120-6 1
S39055
1
1 Loosen the clamp (Item 1) [Figure 50-120-8] and

remove the blower hose from the blower.
S39053

from the dash cover.

lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

DASH COVER (CONT’D)
Figure 50-120-9
1
1
1
S39056
Loosen the three clamps (Item 1) [Figure 50-120-9] and

remove the three blower hoses from the blowers.
Remove the dash cover.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
JOYSTICK PANEL Figure 50-130-3
Figure 50-130-1
1
1
1
S38732

P125390 from the steering column cover.

Remove the cap (Item 1) [Figure 50-130-1] from the lb) torque.
steering wheel.
Figure 50-130-4
Figure 50-130-2
1
1
1
1
2
P125389
P125391
Remove the four screws (Item 1) [Figure 50-130-4] from

Remove the nut (Item 1) [Figure 50-130-2] from the the steering column cover.
steering wheel.
Remove the steering wheel (Item 2) [Figure 50-130-2]. lb) torque.
Remove the signal lever. (See Removal And Installation Lower the steering column cover.
on Page 60-60-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

JOYSTICK PANEL (CONT’D) Figure 50-130-7
Figure 50-130-5
1
1
1 1
2
S39245
1
Remove the temperature control knob (Item 1) and the

S39051 nut (Item 2) [Figure 50-130-7] and washer underneath.
Figure 50-130-8
windscreen blower.
Figure 50-130-6
1
1
1 1
1 1
S39244

P125392 joystick panel.
Lift the joystick panel.

the dash cover. NOTE: Slightly lift the dash cover for easier removal
of the joystick panel.
Remove the joystick. (See Removal And Installation on
Page 60-170-1.) Mark and remove all harnesses from the joystick panel.
Remove the joystick panel.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Fuses And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Removing And Installing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Rear Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Rear Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Front Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Front Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Right Instrument And Indicator Panel Removal And Installation . . . . . . . . . . . . . . . . 60-80-1
Left Instrument Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
BOOM ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
FRONT WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

TOP WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

REAR WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

TH.6534(X) / TH.7035(X) / TH.7038(X)

PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
INCHING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool (Service Tool) - MEL1563 . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) - 3975015M1 . . . . . . . . . . . . . . . . . . 60-150-1
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
LLMI / LLMC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

System Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Longitudinal Load Moment Indicator (LLMI) Description . . . . . . . . . . . . . . . . . . . . 60-180-2
Longitudinal Load Moment Controller (LLMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-4
Longitudinal Load Moment Controller (LLMC) Override Switch . . . . . . . . . . . . . . . 60-180-4
LLMC Calibration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-5
LLMI / LLMC Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-7
LLMI / LLMC Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-10
LLMS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-12
LLMS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-13
LLMC Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-14
TH.6534(X) / TH.7035(X) / TH.7038(X)

8 7 6 5 4 3 2 1
HARNESSES OVERVIEW SCHEMATIC INDEX

H MACHINE SPECIFICATION PAGE 1 H
DESIGNATION PN
FUSES RELAYS OVERVIEW PAGE 2
ELECTRICAL SCHEMATIC HARNESS ENGINE
HARNESS DEF TANK

7257478
7302260
CONNECTORS ASSIGNMENT
CONTROLLERS CONNECTION
PAGE 3
PAGE 4, 5
NxG TLS HARNESS FRAME 7257484 POWER

GROUND
PAGE 6
PAGE 7
PF2 Stage 4 ENGINE

HARNESS LOWER CAB 7257479
G CAN BUS PAGE 8 G
HARNESS UPPER CAB 7162048 IGNITION & ENGINE PAGE 9
HARNESS BOOM 6M 7162054 LOWER CAB PAGE 10
LOWER CAB, UPPER CAB PAGE 11
HARNESS BOOM 7M 7162055
13 June 2016
TRANSMISSION PAGE 12
HARNESS BOOM WORK LIGHT 6M 7179216 BRAKES PAGE 13
HARNESS BOOM WORK LIGHT 7M 7178823 STEERING PAGE 14
F WORKGROUP PAGE 15 F
HARNESS BLUE WL LEFT 7178982
WORKGROUP PAGE 16
HARNESS BLUE WL RIGHT 7179236
LLM SYSTEM PAGE 17
AUXILIARY HYDRAULIC PAGE 18
STANDARD LIGHTS PAGE 19
WORK LIGHTS PAGE 20
E Machines Serial Number (n° de série machines): ENGINE PAGE 21 E
ENGINE SCR PAGE 22
ENGINE HARNESS SUPPLIER PAGE 23
TL34.65HF 30kph 130HP: From B41N
TL34.65HF 40kph 130HP: From B41P
TH.6534 30kph 130HP: From B41R
TH.6534 40kph 130HP: From B41S
D D
TL35.70 30kph 100HP: From B3ZS

TL35.70 40kph 100HP: From B3ZT
TH.7035 30kph 100HP: From B3ZZ
TH.7035 40kph 100HP: From B411
C C
TL38.70HF 30kph 130HP: From B3ZU
TL38.70HF 40kph 130HP: From B3ZV
TH.7038 30kph 130HP: From B412 WIRING SCHEMATIC
TH.6534 (S/N B41R11001 - B41R99999)
TH.7038 40kph 130HP: From B413
B TH.6534X (S/N B41S11001 - B41S99999) B
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
Sheet 1 of 23
A (PRINTED OCTOBER 2016)
A
Printed In Belgium 7257477 (0)
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
FUSES FUNCTION
H FUSE LOCATION SIZE(A) CIRCUIT FUNCTION 1 FUNCTION 2 FUNCTION 3 FUNCTION 4 FUNCTION 5 WIRE CATEGORIES FOR COLORS AND NUMBER RANGE H
RADIO, DOME LIGHT
F1 FRC1 (CAB) 20 BATTERY GATEWAY CONTROLLER IGNITION SWITCH DIAG. CONNECTOR BATT WARNING LIGHTS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
POWER SUPPLY
F2 FRC1 (CAB) 7,5 IGNITION DISPLAY CONTROLLER LLMI DIAG. CONNECTOR IGN SHUNT KEY SWITCHES BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
F3 FRC1 (CAB) 10 IGNITION FRONT WIPER WASHERS FNR LEVER BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
F4 FRC1 (CAB) 20 IGNITION REAR/ROOF WIPER LLMC RADIO IGNITION BEACON
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
F5 FRC1 (CAB) 25 IGNITION HVAC HEATER/BLOWER FAN INVERTER
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
F6 FRC1 (CAB) 15 IGNITION HEAD LIGHTS TURN LIGHTS HORN
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
F7 FRC1 (CAB) 15 IGNITION LOW BEAM LIGHTS HIGH BEAM LIGHTS
G F8 FRC1 (CAB) 7,5 IGNITION SUSPENSION SEAT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL G
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
F9 FRC1 (CAB) 7,5 LIGHTS POSITION LIGHTS LEFT FOG LIGHT
CONTROLLER SUPLY
5000 THROUGH 5999 YELLOW YEL
F10 FRC1 (CAB) 7,5 LIGHTS POSITION LIGHTS RIGHT (5V, 8V)
F11 FRC1 (CAB) 20 IGNITION CAB WORK LIGHTS LIGHTS 6000 THROUGH 6999 PINK PNK
F12 FRC1 (CAB) 20 IGNITION BOOM WORK LIGHTS BLUE WORK LIGHTS OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
F21 FRC2 (FRAME) 15 IGNITION DRIVE CONTROLLER ENGINE 8000 THROUGH 8999 TAN TAN
F22 FRC2 (FRAME) 15 IGNITION WORKGROUP CONTROLLER COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
F23 FRC2 (FRAME) 10 BATTERY ACD BATTERY SUPPLY
F F24 FRC2 (FRAME) 10 IGNITION ACD IGNITION SUPPLY
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
F
F25 FRC2 (FRAME) 7,5 IGNITION LOW SPEED DEFEAT HYD MOTOR RELAYS FUNCTION
F26 FRC2 (FRAME) 5 IGNITION JOYSTICK WHEELS ALIGNMENT RETRACT SWITCH REAR SHAFT SENSOR IGNITION SIGNAL RELAY LOCATION FUNCTION 1
FRC2 (FRAME) R1 FRC1 (CAB) LOW BEAM

F27 15 IGNITION REAR DIVERTER 2 BOOM DRAIN VALVE P.B. ACCU VALVE
FRC2 (FRAME) R2 FRC1 (CAB) HIGH BEAM

F28 10 IGNITION STOP LIGHTS REVERSE LIGHT BACK UP ALARM
FRC2 (FRAME) TRACTOR TRAILER BRAKE R3 FRC1 (CAB) BLUE WORK LIGHTS
F29 5 IGNITION
VALVE
ALTERNATOR R4 FRC1 (CAB) CAB WORK LIGHTS
F41 FC3 (ENGINE) 25 IGNITION STARTER
EXCITATION
E F42 FC3 (ENGINE) 10 IGNITION AIR HEATER RELAY
ENGINE COMPONENTS
POWER SUPPLY
R5 FRC1 (CAB) BOOM WORK LIGHTS E
R6 FRC1 (CAB) FAN INVERTOR
F43 FC3 (ENGINE) 25 BATTERY ENGINE ECU
R7 FRC1 (CAB) SPARE
F44 (DEF TANK) 15 IGNITION DCU
R8 FRC1 (CAB) SPARE
F45 (DEF TANK) 10 IGNITION HOSE HEATERS
R9 FRC2 (FRAME) LOW SPEED
F46 (DEF TANK) 15 IGNITION COOLING FAN MOTOR
R10 FRC2 (FRAME) REVERSE & BACKUP ALARM
F50 MEGAFUSE 150 IGNITION MAIN IGNITION POWER AIR HEATER
R11 FRC2 (FRAME) STOP LIGHTS
R12 FRC2 (FRAME) TRACTOR TRAILER BRAKE
D R13 FRC2 (FRAME) DEFEAT HYD MOTOR

D
R14 FRC2 (FRAME) BOOM DRAIN VALVE
R15 FRC2 (FRAME) P.B. ACCU VALVE RELAY
R16 FRC2 (FRAME) REAR DIVERTER
FRC 1 R20 ENGINE ECU RELAY
R21 ENGINE STARTER RELAY
R22 ENGINE AIR HEATER RELAY
FC 3 R25 ENGINE FUEL PUMP
C R26 ENGINE HOSE HEATER MAIN RELAY C

R27 ENGINE HOSE 1 HEATER RELAY
STOP R30 ENGINE DEF COOLING FAN RELAY
WIRING SCHEMATIC
B FRC 2 B
TH.6534 (S/N B41R11001 - B41R99999)
STOP TH.6534X (S/N B41S11001 - B41S99999)
R TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
A TH.7038X (S/N B41311001 - B41399999) A
Printed In Belgium 7257477 (0) Sheet 2 of 23
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
ENGINE CONNECTORS ASSIGNMENT FRAME CONNECTORS ASSIGNMENT CAB CONNECTORS ASSIGNMENT CAB CONNECTORS ASSIGNMENT LIGHTS CONNECTORS ASSIGNMENT
CONNECTOR DESCRIPTION PINS SHEET CONNECTOR DESCRIPTION PINS SHEET CONNECTOR DESCRIPTION PINS SHEET CONNECTOR DESCRIPTION PINS SHEET
H C100 ENGINE TO FRAME 29
6,8,12,13,
C400 HYDRAULIC OIL TEMPERATURE 2 15 C200 ICON DISPLAY CLUSTER 8 14,18,19 C280 SUSPENSION SEAT MOTOR 2 10
CONNECTOR DESCRIPTION PINS SHEET
H
14 C302 FRONT LIGHTS LEFT 6 19
C101 LS PUMP CONNECTION 10 16 C401 BACKUP ALARM 2 19 C205 REAR AUX/HYD HOOK SWITCH 10 18 C281 FRONT WIPER MOTOR 6 10
C303 REAR LIGHTS LEFT 6 19
C103 FUEL PUMP 2 9 C402 GEAR 1 VALVE 2 12 C210 IGNITION KEY SWITCH 6 9 C282 SEAT SWITCH 2 10
C304 FRONT LIGHTS RIGHT 6 19
C104 ENGINE TO DEF COOLING FAN 3 22 C403 GEAR 2 VALVE 2 12 C211 AC SWITCH 3 10 C284 QUICKTACH POWER SWITCH 10 18 C305 REAR LIGHTS RIGHT 6 19
C105 DEF COOLING FAN 2 22 C412 BOOM UP 2 15 C212 BLOWER SPEED SWITCH 5 10 C287 WATER IN FUEL SWITCH 2 21 C306 LICENSE PLATE LIGHT 2 20
C109 ELECTRONIC BATTERY DISC. 2 6 C413 BOOM DOWN 2 15 C213 HEATER AND BLOWER MOTOR 5 10 C288 DESOX SWITCH 10 22
C307 TRAILER PLUG 7 19
C111 FUSE F46 2 22 C414 TILT UP 2 15 C214 THERMOSTAT MODULE 3 10 C290 DIAGNOSTIC CONNECTOR 7 8, 16
C332 LIGHTS TO BOOM 2 20
G C112 FUSE F44 2 22 C415 TILT DOWN 2 15 C215 EMREGENCY STOP SWITCH 4 21 C295 CUSTOMER INTERFACE 3 16
C333 FRAME TO BLUE LIGHT LEFT 2 20 G
C113 FUSE F45 2 22 C416 BOOM EXTEND 2 15 C216 FAN INVERTER SWITCH 10 9 T26 LOWER CAB GND 1 7 C334 FRAME TO BLUE LIGHT RIGHT 2 20
C115 VARIABLE FAN SPEED 2 9 C417 BOOM RETRACT 2 15 C218 SHUNT KEY 2 17 T50, T51 AC PRESSURE SWITCH 1 10 T70, T71 BLUE WORK LIGHT LEFT 1 20
C116 FAN INVERTER 2 9 C418 AUX A4 VALVE 2 15 C219 GEAR SELECT SWITCH 10 12 T59, T60 CAB BUZZER 1 10 T72, T73 BLUE WORK LIGHT RIGHT 1 20
C117 SWASH PLATE SENSOR 4 12 C419 AUX B4 VALVE 2 15 C221 FLASHER RELAY 6 19 T68, T69 SHUNT KEY 1 17
C118 ENGINE CROSSOVER 4 21 C420 RETRACT SWITCH 4 15 C222 THROTTLE PEDAL SENSOR 6 21 C601 REAR WIPER MOTOR 2 11
C120 DRIVE PUMP FORWARD 2 12 C421 CRAB STEER VALVE 2 14 C224 LEFT LEVER 12 10,12,19 C602 ROOF WIPER MOTOR 3 11
C121 DRIVE PUMP REVERSE 2 12 C422 4 WHEEL STEER 2 14 C225 FNR LEVER 6 12 C603 CAR RADIO SUPPLY 8 11
F C122 DOSING SUPPLY MODULE 12 22 C423 SAFETY VALVE 2 16 C227 12V SOCKET 2 10 C604 CAR RADIO SPEAKERS 8 11 F
C123 AC COMPRESSOR CLUTCH 2 10 C424 HORN 2 10 C229 CAB TO LLMI SENSOR 8 17 C605 FRONT LEFT WORK LIGHT 2 20
C124 TMAF SENSOR 4 21 C425 STEERING PRESS. SENSOR LS PUMP 3 14 8,10,12, C606 FRONT RIGHT WORK LIGHT 2 20
C230 CAB TO FRAME 40 14,16,17,
C125 LS PUMP CONTROL VALVE 2 16 C427 RETRACT SWITCH 2 4 15 18,19,20 C607 REAR WORK LIGHT 2 20
BOOM CONNECTORS ASSIGNMENT
C130 LOW SPEED 2 12 C431 REAR DIVERTER 1 2 18 C232 CAB TO UPPER CAB 4 11,20 C608 DOME LIGHT 3 11
CONNECTOR DESCRIPTION PINS SHEET
C131 DEFEAT VALVE 2 12 6,8,9,10, C620 ROOF WIPER SWITCH 10 11
C432 REAR DIVERTER 2 2 18 C233 CAB TO ENGINE 24
21 C433 BOOM ACD TO FRAME 8 8, 16
C140 DEF TANK INTERFACE 14 8, 22 C433 FRAME TO BOOM ACD 8 8,16 C235 CAB TO IGNITION 1 6 C621 BEACON SWITCH 10 11
C501 ACD CONNECTOR 7 8, 16
C141 1ST/2ND GEAR SWITH 2 12 C435 FRONT/REAR DIVERTER SWITCH 2 18 C237 LLMI 6 8, 17 T32 UPPER CAB GND 1 7
E C143 STEERING PRESSURE SENSOR 3 14 8, 17 T78, T79 BEACON 1 11
C504 BOOM WORK LIGHT LEFT 2 20 E
C436 BOOM ANGLE SENSOR 8 15 C238 LLMC 6
C505 BOOM WORK LIGHT RIGHT 2 20
C144 INLET PRESSURE SENSOR 3 16 8,10,12, T84, T85 SPEAKER RIGHT 1 11
C451 REAR SHAFT SPEED SENSOR 2 12 C240 DISPLAY (BLACK CONNECTOR) 12
19,22
C145 OUTLET PRESSURE SENSOR 3 16 C452 REAR WHEELS ALLIGNMENT 3 14 9,12,13, T86, T87 SPEAKER LEFT 1 11
C241 DISPLAY (GRAY CONNECTOR) 12
22
C150 TRACTOR TRAILER BRAKE VALVE 2 13 C453 FRONT WHEELS ALLIGNMENT 3 14 C242 WIPER SWITCH 10 10
C151 HOSE 1 HEATER 2 22 C455 GERMAN BRAKE RESERVE PRESSURE 3 13 C243 FUEL LEVEL SENSOR 2 10
C152 HOSE 2 HEATER 2 22 C456 PARK BRAKE PRESSUE SWITCH 2 13 C244 CAB TO FUEL LEVEL SENSOR 3 10
C153 HOSE 3 HEATER 2 22 C458 PARK BRAKE VALVE 2 13 C247 LLMI TO SENSOR 4 17
C459 SERVICE BRAKE PRESSURE SENSOR 3 13 C248 LLMC TO SENSOR 4 17

D C155 TANK HEATING VALVE
REDUCTION AGENT METERING.
2 22
C460 QUICTACH POWER VALVE 2 18 C250 KEYLESS PAD (KSS) 6 8, 9

D
C156 2 22
VALVE
C461 P.B. ACCU VALVE 2 13 C251 BRAKE INCHING POTENTIOMETER 3 12
C157 SCR INLET TEMPERATURE 2 22
C465 POWER LIFT 2 18 C252 ECO MODE SWITCH 10 12
C159 ENVIRONMENTAL TEMPERATURE 2 22
TRAILER PRESSURE RELEASE
C467 10 13 C253 SMART HANDLING SYSTEM SWITCH 10 16
C160 DOC TEMPRATURE 2 22 SWITCH
8,22 C701 BOOM DRAIN VALVE 2 18 C254 CREEP ENABLE SWITCH 10 12

C161 DEF TANK 4
C703 BOOM SUSPENSION VALVE 2 18 C256 JOYSTICK 4 8, 15
C163 NOX PRETREATMENT 4 8,21
T35 FRAME GND 1 7 C257 ACD LH SKI SWITCH 10 18

C164 NOX POSTTREATMENT 4 8.21
HYDRAULIC FILER 1
C258 ACD ATTACH SWITCH 10 18
C C169 ENGINE DIAGNOSTIC CONNECTOR 8 8 T80, T81
(CLOGGING INDICATOR 1)
HYDRAULIC FILER 2
1 15
C259 ACD RH SKI SWITCH 18

C
C235 IGNITION TO CAB 1 6 T82, T83 1 15
(CLOGGING INDICATOR 2)
C260 STEER MODE SWITCH 10 14
C287 WATER IN FUEL SENSOR 2 21
T1, T2 C261 PARK BRAKE SWITCH 10 13

MEGAFUSE F50 1 6
T5,T6,T7,T8 AIR HEATER RELAY 1 21

C265 FRONT WASHER MOTOR 2 10
WIRING SCHEMATIC
T10, T11, T12 C267 WASHER SWITCH 10 10
ELECTRONIC BATTERY DISC. 1 6
T16 ALTERNATOR B+ 1 9
C270 WARNING SWITCH 10 19 TH.6534 (S/N B41R11001 - B41R99999)
T43 ALTERNATOR EXCITATION 1 9
C272 FOG LIGHT SWITCH 10 19
TH.6534X (S/N B41S11001 - B41S99999)
TH.7035 (S/N B3ZZ11001 - B3ZZ99999) B
BRAKE FAIL PRESSURE LAMP
B T18, T19 STARTER B 1 9
C273
BRAKE FAIL ELECTRIC LAMP
4 13
4W STEER LAP
T20 STARTER S 1 9 C275 4 14
CRAB STEER LAMP
T23 ENGINE GND 1 6, 7 C276 TRAILER INDICATOR LAMP 4 19 TH.7035X (S/N B41111001 - B41199999)
T24, T25 AIR HEATER 1 21 TH.7038 (S/N B41211001 - B41299999)
T29 ECU CASE GND 1 7
T30 BATTERY POSITIVE 1 6

TH.7038X (S/N B41311001 - B41399999)
T31 BATTERY NEGATIVE 1 6 Sheet 3 of 23
A T33 DCU CASE GND 1 22

A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
J1 CONNECTOR ASSIGNMENT (GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENT (DRIVE CONTROLLER) J3 CONNECTOR ASSIGNMENT (WORKGROUP CONTROLLER)
H H
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 BRAKE FAIL ELECTRIC LAMP B-1 ENGINE OIL PRESSURE A-1 DRIVE PUMP FORWARD RETURN B-1 P.B.ACCU VALVE RELAY FDBK A-1 BOOM EXTEND RETURN B-1 SPARE
A-2 SAFETY VALVE RETURN B-2 POWER SUPPLY A-2 SPARE B-2 POWER SUPPLY A-2 BOOM DOWN RETURN B-2 POWER SUPPLY
A-3 BLUE WORKLIGH RELAY B-3 POWER SUPPLY A-3 LOW SPEED RELAY B-3 POWER SUPPLY A-3 SPARE B-3 POWER SUPPLY
A-4 FRONT ALIGNMENT LAMP B-4 CRAB STEER VALVE A-4 DEFEAT HYD MOTOR RELAY B-4 DRIVE PUMP FORWARD A-4 SPARE B-4 BOOM EXTEND
A-5 STARTER RELAY B-5 4 WHEEL STEER VALVE A-5 P.B.ACCU VALVE RELAY B-5 DRIVE PUMP REVERSE A-5 SPARE B-5 BOOM RETRACT
A-6 REAR ALIGNMENT LAMP B-6 VARIABLE FAN SPEED A-6 DEF COOLING FAN RELAY B-6 AUX A4 VALVE A-6 SPARE B-6 BOOM UP
G A-7 FAN INVERTER RELAY B-7 WORKLIGHT RELAY A-7 REVERSE LIGHT RELAY B-7 AUX B4 VALVE A-7 SPARE B-7 BOOM DOWN
G
A-8 FUEL SOLENOID RELAY B-8 CAN LO 1 A-8 CREEP STATUS B-8 CAN LO 1 A-8 SPARE B-8 CAN LO 1
A-9 GLOW PLUGS RELAY B-9 CAN HIGH 1 A-9 STOP LIGHT RELAY B-9 CAN HIGH 1 A-9 SPARE B-9 CAN HIGH 1
A-10 CAB BUZZER B-10 INCHING POTENTIOMETER A-10 DRIVE PUMP REVERSE RETURN B-10 SWASH PLATE SENSOR 1 A-10 TILT UP RETURN B-10 BOOM ANGLE 2
A-11 RESERVED B-11 IVS SWITCH (ST4) A-11 DEFEAT HYD MOTOR RELAY FDBK B-11 PARK BRAKE PRESSURE SENSOR A-11 SPARE B-11 SPARE
A-12 PARK BRAKE SW (NO) B-12 FUEL LEVEL HYDRAULIC FILTER CLOGGING A-12 SPARE B-12 SPARE
A-12 STOP LIGHT RELAY FDBK B-12
INDICATOR
A-13 CRANKING POSITION B-13 SPARE A-13 RETRACT SWITCH 1 (NO) B-13 TILT UP
A-13 HIGH/LOW SPEED SWITCH B-13 GEAR 1 VALVE
F A-14 CRAB STEER SWITCH B-14 CAN HI 2
A-14 GEAR SELECTOR SWITCH B-14 SPARE A-14 SHUNT KEY POSITION B-14 SPARE F
A-15 ENGINE SPEED (ST3A) B-15 GND A-15 SPARE B-15 GND
A-15 REAR SHAFT SPEED B-15 GND
A-16 EMERGENCY STOP SWITCH B-16 GND A-16 SPARE B-16 GND
A-16 SPARE B-16 GND
A-17 FUEL PUMP RELAY B-17 SENSOR GND
A-17 TRACTOR TRAILER BRAKE VALVE B-17 SENSOR GND A-17 SPARE B-17 SENSOR GND
A-18 BRAKE FAIL PRESSURE LAMP B-18 ANALOG THROTTLE PEDAL (ST4) GERMAN RESERVE BRAKE
A-18 AUX B4 RETURN B-18 A-18 BOOM RETRACT RETURN B-18 HYDRAULIC OIL TEMPERATURE
PRESSURE
A-19 FRONT ALIGNMENT STATUS B-19 SAFETY VALVE
A-19 SPARE B-19 GEAR 2 VALVE A-19 SPARE B-19 TILT DOWN
A-20 SPARE B-20 CAN LO 2
A-20 LS PUMP INLET PRESSURE (ST3A) B-20 SPARE A-20 SPARE B-20 SPARE
E A-21 ACD LH SKI UP B-21 ATTACHMENT RUN
A-21 POSITION LIGHTS STATUS B-21 IGNITION SIGNAL A-21 RETRACT SWITCH 1 (NC) B-21 IGNITION SIGNAL E
A-22 ACD RH SKI UP B-22 IGNITION POSITION TRACTOR TRAILER BRAKE
A-22 B-22 FNR LEVER A-22 RETRACT SW 2 (NO) B-22 QUICKTACH POWER SWITCH
A-23 B-23 RELAY FDBK
REAR ALIGNMENT STATUS SENSOR SUPPLY 5V
A-23 SPARE B-23 SENSOR SUPPLY 5V A-23 SPARE B-23 SENSOR SUPPLY 5V
A-24 ACD LH SKI DOWN B-24 SMART HANDLING SYSTEM
A-24 SPARE B-24 BOOM ANGLE 1
A-24 SPARE B-24 SWASH PLATE SENSOR 2
A-25 SPARE B-25 BATTERY DISCONNECT
A-25 SPARE B-25 QUICKTACH POWER
A-25 STEERING PRESSURE SENSOR B-25 SPARE
A-26 VARIABLE FAN SPEED FDBK B-26 SPARE
A-26 BOOM UP RETURN B-26 SPARE
A-26 PARK BRAKE VALVE RETURN B-26 PARK BRAKE VALVE
A-27 SPARE
A-27 TILT DOWN RETURN
A-27 AUX A4 RETURN
A-28 ACD ATTACH SKI RIGHT
D A-29 4 WHEEL STEER SWITCH
A-28 FNR LEVER REVERSE
A-28 SPARE
D
A-29 SPARE
A-29 SPARE
A-30 ACD RH SKI DOWN
A-30 SPARE
A-30 TRAILER PRESSURE RELEASE SWITCH
A-31 ACD ATTACH SKI LEFT
A-31 RETRCAT SW 2 (NC)
A-32 DESOX INHIBIT SWITCH A-31 FNR LEVER FORWARD
A-32 SPARE
A-33 SEAT SWITCH A-32 SERVICE BRAKE PRESSURE
A-33 SPARE
A-34 IGNITION FDBK A-33 1ST/2ND GEAR SWITCH
A-34 SPARE
A-34 LOW SPEED RELAY FDBK
C C
WIRING SCHEMATIC
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
B B
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
Sheet 4 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
J6 CONNECTOR ASSIGNMENT (AUXILIARY CONTROLLER)
H PIN FUNCTION PIN FUNCTION H
A-1 BOOM SUSPENSION RETURN B-1 SPARE
A-2 SPARE B-2 POWER SUPPLY

Connector C241 Connector C240
A-3 BOOM DRAIN RELAY B-3 POWER SUPPLY
C240, C241 CONNETCOR ASSIGNMENT (DISPLAY CONTROLLER)
A-4 SPARE B-4 SPARE
PIN FUNCTION PIN FUNCTION
A-5 BOOM SUSPENSION LAMP B-5 REAR DIVERTER 1
C240-1 POWER SUPPLY C241-1 FAN INVERTER SWITCH
A-6 REAR DIVERTER 2 B-6 BOOM SUSPENSION
C240-2 GND C241-2 ECO MODE STATUS
G A-7 SPARE B-7 SPARE

C240-3 CAN HI C241-3 ACTIVE DESOX STATUS G
A-8 SPARE B-8 CAN LO 1
C240-4 CAN LO C241-4 INHIBIT DESOX STATUS
A-9 SPARE B-9 CAN HIGH 1 C240-5 IGNITION INPUT C241-5 SPARE
A-10 LP PUMP CONTROL VALVE RETURN B-10 SPARE C240-6 SPARE C241-6 SPARE
A-11 SPARE B-11 SPARE C240-7 CREEP SWITCH C241-7 SPARE
A-12 SPARE B-12 SPARE C240-8 HIGH BEAM STATUS C241-8 SPARE
A-13 SPARE B-13 LS PUMP CONTROL VALVE C240-9 FORCED DESOX SWITCH C241-9 PARK BRAKE SW (NC)
A-14 BOOM DRAIN RELAY FEEDBACK B-14 CAN HIGH 2 C240-10 SPARE C241-10 SPARE
F A-15 SPARE B-15 GND C240-11 TURN SIGNAL STATUS C241-11 SPARE F
C240-12 SPARE C241-12 ECO MODE ENABLE SWITCH
A-16 SPARE B-16 GND
A-17 SPARE B-17 SENSOR GND
A-18 SPARE B-18 SPARE

COMPONENTS SUPPLIED BY 5 VDC
A-20 LS PUMP INLET PRESSURE SENSOR B-20 CAN LO 2 J1B-23, POWER SUPPLY 5 VDC J1B-17, GROUND 0 VDC
CONNECTOR DESCRIPTION SHEET CONNECTOR DESCRIPTION SHEET
A-21 REAR AUX SW B-21 IGNITION SIGNAL
E GATEWAY CONTROLLER J1 E
C251-C INCHING POTENTIOMETER 12 C251-A INCHING POTENTIOMETER 12
A-23 SPARE B-23 SENSOR SUPPLY 5V
C222-F THROTTLE PEDAL 20, 12 C222-C, D THROTTLE PEDAL 12,12
LS PUMP OUTLET RESSURE
A-24 SPARE B-24 C457-B FUEL LEVEL SENSOR 10
SENSOR
A-26 SPARE B-26 SPARE DRIVE CONTROLLER J2

A-27 SPARE C117-4 SWASH PLATE SENSOR 12 C117-1 SWASH PLATE SENSOR 12
A-28 SPARE C144-A INLET PRESSURE SENSOR 12,15 C144-B INLET PRESSURE SENSOR 15
D A-29 SPARE C425-B STEERING PRESSURE SENSOR 12,14 C425-A STEERING PRESSURE SENSOR 12,14 D
C455-B GERMAN BRAKE RESERVE PRESSURE 13,12 C455-A GERMAN BRAKE RESERVE PRESSURE 13,12
A-30 REAR HOOK SW
C456-B PARK BRAKE PRESSURE 13,12 C456-A PARK BRAKE PRESSURE 13,12
A-31 REAR DIVERTER 2 FDBK
A-32 SPARE
C459-B SERVICE BRAKE PRESSURE 13,12 C459-A SERVICE BRAKE PRESSURE 13,12
Connector A
A-33 REAR DIVERTER SWITCH
C451-4 REAR SHAFT SPEED 12 C451-5 REAR SHAFT SPEED 12 Connector B
WORKGROUP CONTROLLER J3
A-34 SPARE
C436-1,4 BOOM ANGLE SENSOR 15 C436-7,8 BOOM ANGLE SENSOR 15
C400-B HYDRAULIC OIL TEMPERATURE 15
C ACRONYMS DESCRIPTION C
AC AIR-CONDITIONING
ACD ATTACHMENT CONTROL DEVICE
DRV DRIVE CONTROLLER
EMEA EUROPE, MIDDLE EAST, AFRICA WIRING SCHEMATIC

FNR FORWARD, NEUTRAL, REVERSE
TH.6534 (S/N B41R11001 - B41R99999)
GTW GATEWAY CONTROLLER
HVAC HEATING VENTILATION AIR-CONDITIONING

TH.6534X (S/N B41S11001 - B41S99999)
B KSS KEYLESS START SYSTEM TH.7035 (S/N B3ZZ11001 - B3ZZ99999) B
LLMI LONGITUDINAL LOAD MOMENT INDICATOR
LLMC LONGITUDINAL LOAD MOMENT CONTROLLER

TH.7035X (S/N B41111001 - B41199999)
LS LOAD SENSING TH.7038 (S/N B41211001 - B41299999)
RSS RUN, START, STOP
TH.7038X (S/N B41311001 - B41399999)
WGP WORKGROUP CONTROLLER
Sheet 5 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
POWER H
G G
C235
C100
F F
E E
D D
C C233 C
WIRING SCHEMATIC
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999) B
B
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
Sheet 6 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
GROUND H
G G
T35
F F
T26
E E
LOWER CAB GROUNDS FRAME GROUNDS
D D
T23
C C
T29 T32
WIRING SCHEMATIC
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
B TH.7035 (S/N B3ZZ11001 - B3ZZ99999) B
TH.7035X (S/N B41111001 - B41199999)
UPPER CAB GROUNDS
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
T35
Sheet 7 of 23
A ENGINE GROUNDS
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
LOWER CAB
H
CAN BUS H
G G
FRAME
F F
C290
VEHICLE
DIAGNOSTIC
E CONNECTOR E
C100
ENGINE D34
C233
D D
C230 C100 ECU
C C
C140
C169
ENGINE
DIAGNOSTIC
B CONNECTOR WIRING SCHEMATIC B
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
A A
(PRINTED OCTOBER 2016) TH.7038X (S/N B41311001 - B41399999)
Sheet 8 of 23
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H ENGINE, H
IGNITION
G G
GATEWAY CONTROLLER
F F
DISPLAY
CONTROLLER
E E
C233
D D
C116
C115
C C
WIRING SCHEMATIC
C103
TH.6534 (S/N B41R11001 - B41R99999)

T16 T18 T19 T20
B+ B S R
TH.6534X (S/N B41S11001 - B41S99999)
B TH.7035 (S/N B3ZZ11001 - B3ZZ99999) B
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
Sheet 9 of 23
A HARNESS ENGINE
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H LOWER CAB H
INTERNALLY CONNECTED
WITH PIN 1 - SEE SHEET 18/G5
G G
GATEWAY CONTROLLER
F M
F
E E
P
C244-B C244-A
C230
C233
D D
HARNESS FRAME
C282
C243
C424
C C
C280
C227
C123
C281
C265
12V SOCKET
15 Amps max.
WIRING SCHEMATIC
B B
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
HARNESS ENGINE TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
A (PRINTED OCTOBER 2016) TH.7038X (S/N B41311001 - B41399999) A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS FRAME
H LOWER CAB H
UPPER CAB
G G
F F
C232
E E
D D
C604
C603
C602
C608
C601
RADIO
SUPPLY
- -
C + +
C
HARNESS UPPER CAB WIRING SCHEMATIC

TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
B B
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
Sheet 11 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H
TRANSMISSION H
WITH PIN 1 - SEE SHEET 18/G5
G G
C230
HARNESS FRAME
DRIVE CONTROLLER GATEWAY

CONTROLLER
F F
DISPLAY
CONTROLLER
E E
D D
C100
C251
C451
C402
C403
C C
C131
C117
C141
C121
C130
C120
B WIRING SCHEMATIC B
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
A HARNESS ENGINE A
(PRINTED OCTOBER 2016) TH.7038X (S/N B41311001 - B41399999)
Sheet 12 of 23
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H BRAKES H
G G
F F
DRIVE CONTROLLER
DISPLAY
GATEWAY
CONTROLLER
E E
D D
C100
C C
C461
C150
C458
C456
C455
C459
WIRING SCHEMATIC
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
B B
P P P TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
EMEA TRACTOR
TH.7038 (S/N B41211001 - B41299999)
GERMAN TRACTOR & ITALIAN
OPTION OPTION OPTION TH.7038X (S/N B41311001 - B41399999)
HARNESS ENGINE HARNESS FRAME
Sheet 13 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H STEERING H
G G
GATEWAY DRIVE
CONTROLLER CONTROLLER
F F
E E
C230 C100
D D
HARNESS ENGINE
C425
C143
C P P
C
TRACTOR TRACTOR
C421
C452
C422
C453
LS PUMP GEAR PUMP

WIRING SCHEMATIC
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999) B
B
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
HARNESS FRAME TH.7038X (S/N B41311001 - B41399999)
Sheet 14 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS FRAME
H
LS PUMP
WORKGROUP H
P P
G G
WORKGROUP CONTROLLER DRIVE CONTROLLER
F F
E E
D D
C C
C436
C414
C418
C419
C420
C427
C412
C413
C416
C400
C415
C417
WIRING SCHEMATIC
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
B B
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
HYDRAULIC BLOCK
TH.7038X (S/N B41311001 - B41399999)
Sheet 15 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
HARNESS FRAME HARNESS LOWER CAB
WORKGROUP H
G G
C290
AUXILIARY CONTROLLER GATEWAY
CONTROLLER
F F
VEHICLE
DIAGNOSTIC
CONNECTOR
E C101
E
C230
D D
C423
C125
C145
C144
C P P
C
LS PUMP
WIRING SCHEMATIC
HARNESS ENGINE
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
B TH.7035 (S/N B3ZZ11001 - B3ZZ99999) B
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
Sheet 16 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H LLM SYSTEM H
(EMEA ONLY)
G G
C238 C237 C230
F F
LLMC CONTROLLER LLMI DISPLAY WORKGROUP

CONTROLLER
E E
HARNESS FRAME
C248
C247
C229
D D
C C
LLMI & LLMC WIRING SCHEMATIC

TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
B B
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
Sheet 17 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
HARNESS LOWER CAB
AUXILIARY H
HYDRAULIC
G G
C230
F F
AUXILIARY CONTROLLER
WORKGROUP
CONTROLLER
E E
D D
C433
C460
HARNESS BOOM 7M
C C
C501
ACD CONNECTOR
C431
C432
C435
C701
C703
WIRING SCHEMATIC
B TH.6534 (S/N B41R11001 - B41R99999) B
TH.6534X (S/N B41S11001 - B41S99999)
REAR AUXILIARY
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
BOOM OPTION
OPTION TH.7035X (S/N B41111001 - B41199999)
HARNESS FRAME
TH.7038 (S/N B41211001 - B41299999)
A TH.7038X (S/N B41311001 - B41399999) A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H STD H
SEE SHEET 12/H7 AND

SHEET 10/G2
LIGHTS
WITH PIN 1
G G
DISPLAY DRIVE CONTROLLER

CONTROLLER
F F
E E
C230
D D
C C
C303
C302
C305
C304
WIRING SCHEMATIC B
B
C307
TH.6534 (S/N B41R11001 - B41R99999)

TH.6534X (S/N B41S11001 - B41S99999)
TRAILER
PLUG TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
HARNESS FRAME TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
A TH.7038X (S/N B41311001 - B41399999) A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H WORK H
LIGHTS
G G
GATEWAY CONTROLLER
F F
E E
C232 C230
D D
HARNESS FRAME
C333 C334 C332
C C
WIRING SCHEMATIC
C607
C606
C605
C504
C505
TH.6534 (S/N B41R11001 - B41R99999)

TH.6534X (S/N B41S11001 - B41S99999)
B B
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
HARNESS UPPER CAB HARNESS BLUE LIGHTS HARNESS BOOM WK LIGHTS
TH.7038X (S/N B41311001 - B41399999)
Sheet 20 of 23
A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H ENGINE D34 H
G G
ECU DCM 3.7

F F
E E
GATEWAY CONTROLLER
C118
C233
C4
D D
C222-ST4
C287
C124
C163
C164
C C
Q / t°
P
WIRING SCHEMATIC
B B
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
SUPPLIER VEHICLE ENGINE HARNESS HARNESS LOWER CAB TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
ENGINE HARNESS
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
A TH.7038X (S/N B41311001 - B41399999) A
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS ENGINE
H ENGINE D34 (SCR) H
C104 C140
G G
C122
F DCU F
DISPLAY
CONTROLLER
HARNESS LOWER CAB
E E
T33
C140
D D
C157
C160
C159
C C
U U U
t° t° t°
HARNESS ENGINE
C155
C156
C151
C152
C153
C105
C161
WIRING SCHEMATIC B
B
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
TH.7035 (S/N B3ZZ11001 - B3ZZ99999)
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
A HARNESS DEF TANK
(PRINTED OCTOBER 2016) TH.7038X (S/N B41311001 - B41399999) A
Sheet 22 of 23
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
ENGINE HARNESS H
U U
t° t°
G G
F F
ECU DCM 3.7
E E
C118 C4
VEHICLE
ENGINE HARNESS
D D
P
U U U t° U
t° t° U/P
C C
WIRING SCHEMATIC
TH.6534 (S/N B41R11001 - B41R99999)
TH.6534X (S/N B41S11001 - B41S99999)
B TH.7035 (S/N B3ZZ11001 - B3ZZ99999) B
TH.7035X (S/N B41111001 - B41199999)
TH.7038 (S/N B41211001 - B41299999)
TH.7038X (S/N B41311001 - B41399999)
Sheet 23 of 23
A
8 7 6 5 4 3 2 1
ELECTRICAL SYSTEM INFORMATION

WARNING
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Massey Ferguson Service servicing machine. Read and understand the
Personnel only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
Warning light comes ON. 5, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuses And Relay Location / Identification
Description The electrical system is protected by fuses and relays in

three locations:
The telescopic handler has a 12 volt, negative ground
alternator charging system. The electrical system is • in the cab below the dashboard. (See Cab on Page
protected by fuses in three locations. (See Fuses And 60-10-3.)
Relay Location / Identification on Page 60-10-2.) • on the front frame left of the boom. (See Frame on
Page 60-10-4.)
The fuses will protect the electrical system when there is • in the front left corner of the engine compartment.
an electrical overload. The cause of an overload must be (See Engine Compartment on Page 60-10-5.)
found before starting the engine again.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-3
Fuses And Relay Location / Identification (Cont’d)

5 9 11 13 15
Cab 1 6 17
Figure 60-10-1 2 18
3 19
4 20
7 10 12 14 16
1 8
S38028
2
The location and description are shown below and in

[Figure 60-10-3].
S38026 REF DESCRIPTION AMP REF DESCRIPTION AMP

1 A/C and Heater / 25 11 Blue Worklights R
ACD Switches
Loosen the retainer screw (Item 1) and remove the / Fan Inverter
console cover (Item 2) [Figure 60-10-1].
2 Headlights / 15 12 Fan Inverter R
Direction Lights /
Figure 60-10-2
Horn
3 Low/High Beam 15 13 High Beam R
4 Ignition feedback 7,5 14 Not Used R
1 on Gateway
controller /
Suspension Seat
(If equipped)
5 Cab light / 20 15 Low Beam R
Gateway
Controller /
2 Ignition Key
Switch / Radio /
1 Warning Lights
6 Display Panel / 7,5 16 Not Used R
S38027
LLMI / Shunt key /
Switches
7 Front Wiper / 10 17 Park Lights Left / 7,5
Remove retainer screws (Item 1) and remove the cover Washers / Fog Light
(Item 2) [Figure 60-10-2] to check or replace fuses or Emergency Stop /
relays. Travel Direction
Lever
8 Rear and Roof 20 18 Park Lights Right 7,5
Wiper / LLMC /
Radio Ignition /
Beacon (If
equipped)
9 Cab Work Lights R 19 Cab Work Lights 20
10 Boom Worklight R 20 Boom and Blue 20
Work Lights
R - Relay
TH.6534(X) / TH.7035(X) / TH.7038(X)

Frame 5 7 9 11 13
1 14 17
Figure 60-10-4
2 18
1 3 19
20
2
4 6 8 10 12 16 15
1 S38056

1
[Figure 60-10-6].
S38058 REF DESCRIPTION AMP REF DESCRIPTION AMP

1 Not Used — 11 Defeat Valve R
Remove the three bolts (Item 1) and remove the cover 2 Not Used — 12 Trailer Brake R
(Item 2) [Figure 60-10-4]. Valve (Tractor)
3 Not Used — 13 Ignition Power 10
Figure 60-10-5 Supply
4 Trailer Brake 5 14 Battery Power 10
Valve Supply
5 Rear Diverter R 15 Work Group 15
2 Controller
6 Low Speed R 16 Drive Controller 15
7 Park Brake R 17 Stop Lights / 10
Accu Valve Reverse Light /
Back Up Alarm
8 Back-up Alarm / R 18 Boom Drain Valve 15
Reverse Light / Rear Diverter 2
1 9 Boom Drain Valve R 19 Joystick / Wheels 5
Alignment /
Retract Switch /
S38059 Rear Shaft
Sensor / Ignition
Signal
Remove the two retainer screws (Item 1) (both sides) and 10 Brake Light R 20 Low Speed 7.5
remove the cover (Item 2) [Figure 60-10-5] to check or / Defeat Valve
replace fuses or relays.
R - Relay
TH.6534(X) / TH.7035(X) / TH.7038(X)

Engine Compartment
Figure 60-10-7
1 3
1
2 4
P125016
6 Stop the engine, raise the engine cover and remove the
7
5 fan (Item 1) [Figure 60-10-8] to access the relays and
fuses of the DEF / AdBlue® system.
Figure 60-10-9
8 9
1 4
S38030 3
P120494
2
S38061
P125239

[Figure 60-10-7]. Three fuses and a relay for the DEF / AdBlue® tank
cooling fan (Item 1) [Figure 60-10-8] are located near the
DEF / AdBlue® tank. Four relays for the DEF / AdBlue®
REF DESCRIPTION AMP
heater are located behind the controller [Figure 60-10-
1 Starter / Alternator 25 9].
2 Not Used —
REF DESCRIPTION AMP
3 Fuel Shutoff / Fuel Pump / Engine Temperature 10
Switch 1 DCU Controller (F44) 15
4 Not Used — 2 Hose Heaters (F45) 10
5 Master Fuse 100 3 Cooling Fan Motor (F46) 15
6 Starter Relay R 4 DEF Cooling Fan Relay (R30) R
7 Glow Plug Relay R 5 Heater Relays R
8 Fuel Shutoff Relay R
9 Fuel Pump Relay R R - Relay
R - Relay
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
BATTERY
Battery Maintenance
Figure 60-20-1
P-09589 P-09590
The battery cables must be clean and tight [Figure 60-

20-1]. Check electrolyte level in the battery. Add distilled
water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and
water solution.
Put Massey Ferguson Battery Saver or grease on the

battery terminals and cable ends to prevent corrosion.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
TH.6534(X) / TH.7035(X) / TH.7038(X)

BATTERY (CONT’D) Keep cables away from moving parts. Start the engine.
Using A Booster Battery (Jump Starting) After the engine has started, remove the ground (-) cable
(Item 2) [Figure 60-20-2] first.
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the Remove the cable from the positive (+) terminal (Item 1)
operator’s seat and one person to connect and [Figure 60-20-2].
disconnect the battery cables.
The key switch (if equipped) or start switch (if equipped) Close the engine cover.
must be OFF. The booster battery must be 12 volt.
WARNING IMPORTANT
BATTERY GAS CAN EXPLODE AND CAUSE Damage to the alternator can occur if:
SERIOUS INJURY OR DEATH • Engine is operated with battery cables
Keep arcs, sparks, flames and lighted tobacco away disconnected.
from batteries. When jumping from booster battery • Battery cables are connected when using a fast
make final connection (negative) at machine frame. charger or when welding on the Telescopic
Handler. (Remove both cables from the battery.)
Do not jump start or charge a frozen or damaged • Extra battery cables (booster cables) are
battery. Warm battery to 16°C (60°F) before connected wrong.
connecting to a charger. Unplug charger before I-2345-0311
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
Open the engine cover.
Figure 60-20-2
2
1
P126243
Connect the end of the first cable to the positive (+)

terminal of the booster battery. Connect the other end of
the same cable to the positive (+) terminal (Item 1)
[Figure 60-20-2] of the telescopic handler battery.
Connect the end of the second cable to the ground (-)

terminal of the booster battery. Connect the other end of
the same cable to the ground (-) terminal (Item 2)
[Figure 60-20-2] of the telescopic handler battery.
TH.6534(X) / TH.7035(X) / TH.7038(X)

BATTERY (CONT’D) Figure 60-20-4
Removing And Installing The Battery

2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
1
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
P123775
and wash eye with clean, cool water for at least 15
minutes.
Always disconnect the ground (-) cable (Item 1)
If electrolyte is taken internally drink large quantities [Figure 60-20-4] first to prevent sparks.
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Disconnect the positive (+) battery cable (Item 2)
W-2065-0807 [Figure 60-20-2] at the battery disconnect.
Open the engine cover. Installation: Tighten the bolt to 5 - 10 N•m (44 - 88 in-lb)
torque. Tighten the nut to 11 - 17 N•m (8 - 12 ft-lb) torque.
Figure 60-20-3
Remove the battery together with positive cable.
Figure 60-20-5
1 5
4
3
P125333
Remove the clamp (Item 1) [Figure 60-20-3]. P123776
Loosen the clamp (Item 2) and reposition the exhaust

(Item 3) [Figure 60-20-3] for easy access. Remove the positive (+) battery cable (Item 1)
[Figure 60-20-5] from the battery.
Remove the bolt (Item 4) and the battery cover (Item 5)
[Figure 60-20-3]. Install the positive (+) battery cable on the new battery.
Installation: Tighten the bolt to 5 - 10 N•m (44 - 88 in-lb)

torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

BATTERY (CONT’D)
Be aware that vehicle batteries contain gases that are
Removing And Installing The Battery (Cont’d) flammable and can explode violently. The following
precautions should be taken before making battery
Figure 60-20-6 connection:
• Wear eye protection.
• Remove all jewelry.
• Keep spectators away.
In the event of a battery explosion, acid should be

flushed away immediately. Seek medical help as
soon as possible.
D-1032-1210
Figure 60-20-7
1 5
P-09589 P-09590
Always clean the battery terminals and cable ends when

installing a new or used battery [Figure 60-20-6]. 4
3
When installing the battery, do not touch any metal parts
with the battery terminals.
Connect and tighten the battery cables. Connect the 2

ground (-) cable last to prevent sparks.
P125333
WARNING Install the battery cover (Item 1) with the bolt (Item 2)
[Figure 60-20-7].
BATTERY GAS CAN EXPLODE AND CAUSE
Reposition the exhaust (Item 3) and install the clamps
(Item 4 and 5) [Figure 60-20-7]. Tighten the clamps to 40
Keep arcs, sparks, flames and lighted tobacco away
N•m (30 ft-lb) torque.
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
TH.6534(X) / TH.7035(X) / TH.7038(X)

ALTERNATOR If the belt tension is out of the suggested range for belts,
tighten the belt to the recommended tension for used
Belt Adjustment belts in the table below. (See Belt Replacement on Page
60-30-2.)
interval (See SERVICE SCHEDULE on Page 10-50-1.)
and contact your Massey Ferguson dealer for FREQUENCY TENSION
replacement parts. Suggested range 126,19 - 148,78 Hz 400 - 556 N
(90 - 125 lbf)
Belt Checking
Used belt 148,07 - 160,95 Hz 550 - 650 N
Run the engine for more than five minutes. (124 - 146 lbf)
New belt 156,79 - 169,01 Hz 617 - 717 N
Check the whole belt drive visually for damage. Replace (139 - 161 lbf)
damaged parts. (See Belt Replacement on Page 60-30-
2.)
Use the following data for the tension meter:
Unit Weight 13,7 g/rib.m or 82,2 g/m (0.15 oz/rib.ft

or 0.88 oz/ft)
Number of Ribs 6 (belt pk, construction MT610)
Span Length 276,5 mm (10.9 in)
Figure 60-30-1
P125238
Check the belt tension with a tension meter in the middle

of the span between the crankshaft pulley and the water
pump pulley [Figure 60-30-1].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ALTERNATOR (CONT’D) Removal And Installation
Belt Replacement Stop the engine and open the engine cover. (See
Figure 60-30-3
Remove the air conditioning belt. (See Belt Replacement
on Page 80-20-2.)
Figure 60-30-2
1 1
P123775
5 2
Disconnect the ground (-) cable (Item 1) [Figure 60-30-3]
from the battery.
4 P123726
Installation: Tighten the nut (Item 1) [Figure 60-30-3] to
5 - 10 N•m (44 - 88 in-lb) torque.
Loosen the adjusting nut (Item 1) to loosen the tension
from the alternator belt (Item 2) [Figure 60-30-2].
Figure 60-30-4
Loosen the top (Item 3) and bottom (Item 4) alternator
mounting bolts [Figure 60-30-2].
Remove the belt from the pulleys.
Inspect the pulleys for wear. 2

1
Install new belt.
Tighten the adjusting nut (Item 5) to bring the alternator

belt (Item 2) [Figure 60-30-2] to the recommended
tension for new belts. (See Belt Checking on Page 60-30-
1.)
P125306
NOTE: Make sure that the adjusting bolt head makes
contact with the alternator bracket.
Remove the two bolts (Item 1) and cover (Item 2) [Figure
Tighten the top alternator mounting bolt (Item 3) [Figure 60-30-4].
60-30-2] to 22 N•m (16 ft-lb) torque.
Remove the air conditioning belt (if equipped). (See Belt
Tighten the bottom alternator mounting bolt (Item 4) Replacement on Page 80-20-2.)
[Figure 60-30-2] to 30 N•m (22 ft-lb) torque.
After belt replacement let the engine run for five minutes
and check the alternator belt. (See Belt Checking on
Page 60-30-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

ALTERNATOR (CONT’D) Figure 60-30-7
Figure 60-30-5
2
1
4 P126670
2
Lower the alternator and remove the two nuts (Items 1
P123726 and 2) [Figure 60-30-7] and remove the connector and
charge cable from the back of the alternator.
Loosen the adjusting nut (Item 1) to release tension from Installations: Tighten nut (Item 1) to 7 - 8 N•m (66 - 71
the alternator belt (Item 2) [Figure 60-30-5]. in-lb) torque and nut (Item 2) [Figure 60-30-7] to 3 -
4 N•m (24 - 34 in-lb) torque.
Loosen the top bolt (Item 3) and remove the bottom bolt
(Item 4) [Figure 60-30-5].
Remove the belt (Item 2) [Figure 60-30-5] from the

pulley.
Figure 60-30-6
P126669
While supporting the alternator, remove the bolt (Item 1)

and nut assembly (Item 2) [Figure 60-30-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
STARTER
Testing
Figure 60-40-1
Bat
S
M
Cranking
Motor
A-1992
The Starter switch must be in the OFF position.
The battery must be at full charge.
The cable connections on the battery must be clean and

tight.
Connect a jumper wire between S terminal and BAT

terminal [Figure 60-40-1].
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 60-40-2
Bat
S
M
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.
TH.6534(X) / TH.7035(X) / TH.7038(X)

STARTER (CONT’D) Disconnect the connector (Item 3) [Figure 60-40-4].
Removal And Installation Installation: Tighten the nut (Item 3) [Figure 60-40-4] to
3 - 4 N•m (26 - 35 in-lb) torque.
Turn the Starter switch OFF and remove the key.
Figure 60-40-5
Page 10-160-1.) 1

Figure 60-40-3 1
2
2
1
1
P125304
Remove the three bolts (Item 1) and remove the starter

(Item 2) [Figure 60-40-5].
NOTE: The starter is not serviceable. If starter is

P125306 damaged the entire assembly must be
replaced.
Remove the two bolts (Item 1) and cover (Item 2)

[Figure 60-40-3].
Figure 60-40-4
3
2
P125305
Move the cap (Item 1) and disconnect the connectors

from the starter signal terminal (Item 2) [Figure 60-40-4].

15 - 17 N•m (11 - 12 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LIGHTS Figure 60-50-3
Rear Light Removal And Installation RIGHT REAR LIGHT
Figure 60-50-1
1
S38258
Disconnect the electrical connector (Item 1) [Figure 60-

S38254 50-2] and [Figure 60-50-3].
Figure 60-50-4
Remove the nut (Item 1) and shift the cover (Item 2)
[Figure 60-50-1] off the rear light support.
Figure 60-50-2 2 2
LEFT REAR LIGHT
1
1
S38255
Pull the cable (Item 1) [Figure 60-50-4] out of the rear

S38259 light support.
Remove the two nuts (Item 2) [Figure 60-50-4].
TH.6534(X) / TH.7035(X) / TH.7038(X)

LIGHTS (CONT'D)
Rear Light Bulb Replacement
Figure 60-50-5
1
1
1 1
S38681
Remove the four lens retainer screws (Item 1)

[Figure 60-50-5]. Remove the lens.
Figure 60-50-6
1 1 1
1
S38682
Replace any bulbs (Item 1) [Figure 60-50-6] if

necessary.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LIGHTS (CONT'D) Figure 60-50-9
Front Light Removal And Installation
Figure 60-50-7
1
LEFT FRONT LIGHT
2
S38260
1 Pull the cable (Item 1) [Figure 60-50-9] out of the front

S38256 light support.
Remove the nut (Item 2) and remove the front light (Item
Figure 60-50-8 3) [Figure 60-50-9].
RIGHT FRONT LIGHT
S38257

50-7] and [Figure 60-50-8].
TH.6534(X) / TH.7035(X) / TH.7038(X)

LIGHTS (CONT'D)
Front Light Bulb Replacement
Figure 60-50-10
1
1
S38686
Remove six screws (Item 1) [Figure 60-50-10] from the

light.
Figure 60-50-11
3
2 1
1
S38687
Disconnect the connectors (Item 1). Remove and replace

the lights (Item 2 and 3) [Figure 60-50-11].
NOTE: Do not touch glass of halogen bulb with your

fingers or allow bulb to come in contact with
oils. If contaminated, clean the bulb with mild
alcohol and a clean cloth.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SIGNAL LEVER Figure 60-60-2
Figure 60-60-1
P125396
Figure 60-60-3
P126571
2
Rotate the Starter switch key (Item 1) [Figure 60-60-1] to
the left and remove the key, to disconnect power supply
from the battery.
2
P125395
Remove the four screws (Item 1) [Figure 60-60-2] and

[Figure 60-60-3].
Remove both halves of the cover (Item 2) [Figure 60-60-

3].
TH.6534(X) / TH.7035(X) / TH.7038(X)

SIGNAL LEVER (CONT’D) Figure 60-60-6
Figure 60-60-4 2
1
1
2
P125388
Remove the screw (Item 1) and cover (Item 2)

P125389 [Figure 60-60-6] from the signal lever.
Figure 60-60-7
Loosen the retainer screw (Item 1) and remove the
console cover (Item 2) [Figure 60-60-4].
Figure 60-60-5
P125387

S38297 the signal lever.
Route the harness out of the cowling and remove the

Disconnect the signal control wire connector (Item 1) signal lever.
[Figure 60-60-5].
TH.6534(X) / TH.7035(X) / TH.7038(X)

DISPLAY

Remove the main instrument panel. (See Right

Instrument And Indicator Panel Removal And Installation
on Page 60-80-1.)
Figure 60-70-1
1 1
S39050
Remove the two knob nuts (Item 1) [Figure 60-70-1].
Pull out the display (Item 2) [Figure 60-70-1].
Figure 60-70-2
1 2
S36729
Disconnect the two connectors (Item 1) [Figure 60-70-2].
Remove the display (Item 2) [Figure 60-70-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
INSTRUMENT PANELS Left Instrument Panel Removal And Installation
Right Instrument And Indicator Panel Removal And Disconnect the ground (-) cable from the battery. (See
Installation Removing And Installing The Battery on Page 60-20-3.)
Disconnect the ground (-) cable from the battery. (See Figure 60-80-3
Figure 60-80-1 1
1 1
1 1
P126557
P126567 Remove the four screws (Item 1) [Figure 60-80-3] from

the left instrument panel.
Remove the four screws (Item 1) [Figure 60-80-1]. Disconnect the harness connectors from the back of the
left instrument panel.
Figure 60-80-2
NOTE: Mark all connectors for ease of installation.
Remove the left instrument panel.
P125386
Disconnect the harness connectors from the back of the

right instrument and indicator panel (Item 1) [Figure 60-
80-2].
NOTE: Mark all connectors for ease of installation.
Remove the right instrument and indicator panel (Item 1)

[Figure 60-80-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
BOOM ANGLE SENSOR Figure 60-90-3
Removal And Installation 2

1
Figure 60-90-1
1 1 4
S39433
2
Remove the nut (Item 1) from the connecting rod (Item 2)
S39070 and remove the rod from the boom angle sensor (Item 3)
[Figure 60-90-3].
Remove the two bolts (Item 1) (both sides) and remove Remove the two screws (Item 4) from the boom angle
the cover (Item 2) [Figure 60-90-1] from the back of the sensor (Item 3) [Figure 60-90-3].
boom.
Remove the boom angle sensor (Item 3) [Figure 60-90-
Figure 60-90-2 3].
NOTE: Calibrate the boom angle sensor after

2 installation. (See Calibration on Page 60-90-2.)
S39396
Disconnect the electrical connector (Item 1) from the

boom angle sensor (Item 2) [Figure 60-90-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

BOOM ANGLE SENSOR (CONT’D) Figure 60-90-5
Calibration
Connect the service tool to the telescopic handler.

(See REMOTE START TOOL (SERVICE TOOL) KIT -
MEL1563 on Page 10-210-1.)
3975015M1 on Page 10-220-1.)
Figure 60-90-4
2
EM7539
Fully lower the boom (display is showing [DOWN°])

[Figure 60-90-5].
Press the joystick lockout button (Item 3) [Figure 60-90-

4] once to validate and move to the next step.
3 1
Figure 60-90-6
P126178
Press the information button (Item 1) to cycle the display

screen (Item 2) [Figure 60-90-4] until the boom angle

4] for 3 seconds until the boom angle calibration mode
[Figure 60-90-5] appears on the display screen.
NOTE: A service tool must be connected to the

telescopic handler in order to perform this
procedure. EM7540
Fully raise the boom (display is showing [UP°])

[Figure 60-90-6].

4] once to validate and finish the procedure.
BOOM LENGTH BOOM ANGLE

6 m (19.69 ft) -4°; 60.8°
7 m (22.97 ft) -4°; 60.8°
TH.6534(X) / TH.7035(X) / TH.7038(X)

BOOM ANGLE SENSOR (CONT’D)
Figure 60-90-7
EM8037

appears on the display screen. The two calibration points
have now been saved.
Figure 60-90-8
EM7537

90-8] appears on the display screen. Redo the calibration
procedure until the calibration is successful.
Press the information button (Item 1) [Figure 60-90-4]

once to return to the engine hour menu.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
FRONT WIPER MOTOR Figure 60-100-3
Remove the dash cover. (See Removal And Installation

on Page 50-120-1.) 1
Figure 60-100-1
1
1
S38265
2 2 Remove both nuts (Item 1) [Figure 60-100-3].
Figure 60-100-4
S38262
1
Flip the wiper covers (Item 1) and remove the two nuts
(Item 2) [Figure 60-100-1]
Figure 60-100-2
2
S38265
Remove both plastic rings and seals (Item 1) [Figure 60-

100-4].
S38261
Remove the wiper arms (Item 1) [Figure 60-100-2] from

the wiper motor shafts.
Remove the window washer tube (Item 2) [Figure 60-

100-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

FRONT WIPER MOTOR (CONT’D)
Figure 60-100-5
S38264
Disconnect the front wiper connector (Item 1) [Figure 60-

100-5] from the main harness.
Figure 60-100-6
S38263
Remove the wiper motor (Item 1) [Figure 60-100-6] from

inside the cab.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TOP WIPER MOTOR Figure 60-110-3
Figure 60-110-1
1
1
1
2
1 S38270
1
Disconnect the rear window washer tube (Item 1)
S38267 [Figure 60-110-3].
Disconnect the rear wiper motor connector (Item 2)

Remove the five screws (Item 1) [Figure 60-110-1] from [Figure 60-110-3].
the upper panel.
Figure 60-110-4
Figure 60-110-2
3
2
1
1
S38269
S38268
Disconnect the left speaker electrical connectors (Item 1)

Disconnect the right speaker electrical connectors (Item [Figure 60-110-4].
1) [Figure 60-110-2].
Remove the roof panel.
Disconnect the roof console electrical connectors (Item
2) [Figure 60-110-2].
Disconnect the cab light electrical connector (Item 3)

[Figure 60-110-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TOP WIPER MOTOR (CONT’D) Figure 60-110-7
Figure 60-110-5
1 S38272
Flip open the wiper cover (Item 1) and remove the nut
S38271 (Item 2) [Figure 60-110-7].
Figure 60-110-8
Disconnect the top wiper electrical connector (Item 1)
[Figure 60-110-5].
Figure 60-110-6
1
S38272
2
S38273
Remove the plastic ring and rubber seal (Item 2)
[Figure 60-110-8].
Remove the window washer tube (Item 1) [Figure 60-
110-6]. Remove the nut (Item 3) [Figure 60-110-8].
Remove the cap (Item 2) [Figure 60-110-6]. Remove the top wiper motor from inside the operator
cab.
TH.6534(X) / TH.7035(X) / TH.7038(X)

REAR WIPER MOTOR Figure 60-120-3
Figure 60-120-1
1 1
2
S38270
1
1
Disconnect the rear window washer tube (Item 1)
S38267 [Figure 60-120-3].
Disconnect the rear wiper motor connector (Item 2)

Remove the five screws (Item 1) [Figure 60-120-1] from [Figure 60-120-3].
the upper panel.
Figure 60-120-4
Figure 60-120-2
3
2
1
1
S38269
S38268
Disconnect the left speaker electrical connectors (Item 1)

Disconnect the right speaker electrical connectors (Item [Figure 60-120-4].
1) [Figure 60-120-2].
Remove the roof panel.
Disconnect the roof console electrical connectors (Item
2) [Figure 60-120-2].
Disconnect the cab light electrical connector (Item 3)

[Figure 60-120-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

REAR WIPER MOTOR (CONT’D) Figure 60-120-7
Figure 60-120-5
1
2
S38277

S38275
Remove the plastic ring (Item 2) [Figure 60-120-7].
Remove the two screws (Item 1) [Figure 60-120-5]. Remove the cap (Item 3) [Figure 60-120-7].
Figure 60-120-6 Figure 60-120-8
3 1
1 2
S38276 S38278
Remove the window washer tube (Item 1) [Figure 60- Remove the nut (Item 1) [Figure 60-120-8].
120-6].
Remove the rear wiper motor inside the operator cab.
Flip open the wiper cover (Item 2) and remove the nut
(Item 3) [Figure 60-120-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

REAR WIPER MOTOR (CONT’D)
Figure 60-120-9
S38279
Inspect the grommets (Item 1) [Figure 60-120-9].

Replace if necessary.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
PEDAL ASSEMBLY Figure 60-130-3

Figure 60-130-1 1
2 2
1 1
S39148
2 Remove the three fittings (Item 2) [Figure 60-130-3].
S38084 Figure 60-130-4

cab.
Figure 60-130-2
1
1 S39061

2 inside the operator cab.
5
1
P125412
Disconnect the two hoses (Item 1), the tubeline (Item 2)

and the pressure sensor (Item 3) from the brake valve
(Item 4) [Figure 60-130-2].
NOTE: Some additional hoses may need to be

disconnected from the steering valve in order
to disconnect the tubeline.
TH.6534(X) / TH.7035(X) / TH.7038(X)

PEDAL ASSEMBLY (CONT’D)
Figure 60-130-5
1
S39132

inside the operator cab.
Remove the pedal assembly.
Figure 60-130-6
S39151
Remove the two bolts (Item 1) and remove the brake

valve (Item 2) [Figure 60-130-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

INCHING SENSOR Figure 60-140-3

Figure 60-140-1
1 S39062
Remove the screws (Item 1) [Figure 60-140-3].
Installation: Perform the adjustment procedure after

installation. (See Calibration on Page 60-140-2.)
S39060
Remove the switch.
Remove the cover (Item 1) [Figure 60-140-1] from the

inching sensor.
Figure 60-140-2
S39061
Disconnect the connector (Item 1) [Figure 60-140-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

INCHING SENSOR (CONT’D) Figure 60-140-5
Calibration

220-1.)
Figure 60-140-4
2
EM7535
Fully release the brake pedal (display is showing [UP])

[Figure 60-140-5].

validate and move to the next step.
1
3 Figure 60-140-6
P126177
Press the information button (Item 1) to cycle the display

screen (Item 2) [Figure 60-140-4] until the engine hours
Press the AUX button (Item 3) [Figure 60-140-4] for 3

seconds until the inching calibration mode [Figure 60-
140-5] appears on the display screen.
NOTE: A service tool must be connected to the

telescopic handler in order to perform this
procedure. EM7536
Position the brake pedal at the brake point (end of

inching) (display is showing [BR]) [Figure 60-140-6].
NOTE: The brake point is the pedal position where

the brake pedal first touches the brake valve.
NOTE: Approximately the first half of the total brake

pedal travel is for inching control.

validate and move to the next step.
TH.6534(X) / TH.7035(X) / TH.7038(X)

INCHING SENSOR (CONT’D) Figure 60-140-9
Figure 60-140-7
EM7537

EM7537 140-9] appears on the display screen. Redo the
calibration procedure until the calibration is successful.
Fully press the brake pedal (display is showing [DN]) Press the information button (Item 1) [Figure 60-140-4]
[Figure 60-140-7]. once to return to the engine hour menu.

validate and finish the procedure.
Figure 60-140-8
EM8037

appears on the display screen. The three calibration
points have now been saved.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool) -
3975015M1
Connecting Remote Start Tool (Service Tool) -
MEL1563 Figure 60-150-2
Figure 60-150-1
1 2
2
3
1
P-76450
P16119 The tools listed will be needed to do the following

procedure:
Order from Massey Ferguson Parts P/N: 3975015M1 -
are:
Remote Start Tool (Service Tool) Kit. Kit Includes:
• MEL1563 - Remote Start Tool
• 3975016M1 - Remote Start Tool (Service Tool)
• MEL1565 - Service Tool Harness Control
• 3975017M1 - Telescopic Handler Service Tool
• MEL1566 - Service Tool Harness Communicator
Harness
(Computer Interface)
• 3975018M1 - Computer Service Tool Harness
• 3975019M1 - BOSS® Service Tool Harness
NOTE: Make all connections with the key in the OFF
position.
NOTE: Make all connections with the key in the OFF
position.
The Service PC (Item 1) with the remote start tool (Item
2) [Figure 60-150-1]. When connected to the telescopic
The Service PC (Item 1) with the Remote Start Tool
handler, the Service PC is used to monitor, conduct
(Service Tool) (Item 2) [Figure 60-150-2]. When
diagnostic and load software.
connected to the telescopic handler, the Service PC is
used to monitor, conduct diagnostics, and upgrade
Connect the Service Tool Harness Communicator
software.
(MEL1566) (Item 3) [Figure 60-150-1] to the designated
serial port on the Service PC. Connect the Remote Start Tool (Service Tool) Computer
Service Tool Harness (Item 3) [Figure 60-150-2] to the
NOTE: The recommended serial cable length should designated serial port on the Service PC.
not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing NOTE: The recommended serial cable length should
communication errors. not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
Connect the other end to the connector on the Remote communication errors.
Start Tool.
Connect the other end to the connector on the Remote
Connect the Remote Start Tool to the telescopic handler. Start Tool (Service Tool).
Connect the Remote Start Tool (Service Tool) to the
MEL1563 on Page 10-210-1.)
telescopic handler. (See REMOTE START TOOL
(SERVICE TOOL) KIT - 3975015M1 on Page 10-220-1.)
NOTE: Refer to AGCONet for PC requirements and
the latest Service Analyzer software. NOTE: Refer to AGCONet for PC requirements and
the latest Service Analyzer software.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
FUEL LEVEL SENDER Figure 60-160-3
Figure 60-160-1
S38291
1
Fully support the fuel tank using an appropriate lifting

S39066 device [Figure 60-160-3].
Figure 60-160-4
Install a suitable container, large enough to contain all
fuel from the fuel tank, under the drain plug (Item 1)
[Figure 60-160-1].
Remove the drain plug (Item 1) [Figure 60-160-1].

1
2
Remove the operator cab floor mat.
1
Figure 60-160-2
1
1 2
S38086
Remove the four bolts (Items 1 and 2) [Figure 60-160-4].

threads of the bolts. Tighten the two rear bolts (Item 1) to
25 - 30 N•m (18 - 22 ft-lb) torque. Tighten the two front
bolts (Item 2) [Figure 60-160-4] to 5 - 6 N•m (44 - 53 in-
2 S39137
lb) torque.
Remove the bolts (Item 1) and remove the step (Item 2)

[Figure 60-160-2].
NOTE: Support the step while removing the bolts.
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL LEVEL SENDER (CONT'D) Figure 60-160-7
Figure 60-160-5
1 1
S38087
2

S40653
Remove the two screws (Item 1) and filter cover (Item 2) 160-7] to 25 - 30 N•m (18 - 22 ft-lb) torque.
[Figure 60-160-5].
Figure 60-160-8
Figure 60-160-6
1 1
S38088
S40654

160-8] to 25 - 30 N•m (18 - 22 ft-lb) torque.
Lower the fuel tank for approximately 200 mm (8 in).
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL LEVEL SENDER (CONT'D) Figure 60-160-11
Figure 60-160-9
P-85716
Inspect the fuel level sender and replace if worn or

S38090 damaged [Figure 60-160-11].
Disconnect the fuel level sender connector (Item 1)

[Figure 60-160-9].
Figure 60-160-10
S39810
Remove the fuel level sender (Item 1) [Figure 60-160-

10].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
JOYSTICK Figure 60-170-3
1
Figure 60-170-1
1
1
P125385
Lift up the dust cover (Item 1) [Figure 60-170-3]

2
Figure 60-170-4
S39811

(Item 2) [Figure 60-170-1]
1
Figure 60-170-2
P125384
1
Remove the four bolts (Item 1) [Figure 60-170-4] from
each corner of the joystick.
Remove the joystick.
P125383

170-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
LLMI / LLMC SYSTEM Figure 60-180-3
System Components Identification
Figure 60-180-1
1
S39246
The LLMS (Longitudinal Load Moment Sensor) (Item 1)

P125356 [Figure 60-180-3] measures the actual load on the rear
axle.
The LLMI (Longitudinal Load Moment Indicator) (Item 1) The LLMS is equipped with dual electronics, which
[Figure 60-180-1] which is located on the dashboard, independently measure the same load. The first
indicates the stability level of the machine, using a LED measurement is used by the LLMI, while the second
bargraph and a buzzer. measurement is used by the LLMC. The most critical
measurement of both will have priority.
Figure 60-180-2
Figure 60-180-4
S39395
S40793
The LLMC (Longitudinal Load Moment Controller) (Item

1) [Figure 60-180-2] which is located under the The safety valve (Item 1) [Figure 60-180-4] is used as a
dashboard, reduces and stops the boom motions in safety back-up. If machine instability keeps increasing
relation to the machine stability. This controller combines due to a certain failure, the safety valve will stop all boom
with other controllers in the machine. motions.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC SYSTEM (CONT’D) Longitudinal Load Moment Indicator (LLMI)
Description
System Components Identification (Cont’d)
The LLMI warns the operator about inadequate stability
Figure 60-180-5 in the longitudinal plane (forward direction).
The LLMI is intended to warn for tipping over in the case

of:
• The machine is stationary on solid, stable and level

ground
1 • The machine is performing load picking, carrying,
loading and unloading
• The telescopic boom is not fully retracted.
The LLMI is not intended to warn for tipping over in the

case of:
2
• A sudden overload
S39396 • Travelling with a lifted load
• Travelling on rough terrain or on grounds with
The boom angle sensor (5°) (Item 1) [Figure 60-180-5] obstacles and holes
measures the boom angle. If the boom angle is higher • Travelling across a slope or turning on a slope
than five degrees and the machine is in unstable • Turning corners too fast or too sharp.
condition, every boom movement except retract and lift is
reduced. Figure 60-180-7
The boom retracted sensor (Item 2) [Figure 60-180-5] 4

3
detects if the boom is fully retracted. When the boom is
retracted all boom movements will be fully operational at 5
any angle. The internal LLMI buzzer is deactivated with
retracted boom. 2
Figure 60-180-6 6
1
P125420
1 The indicator lights (Items 1, 2 and 3) [Figure 60-180-7]

sequentially illuminate as the machine’s longitudinal
stability decreases. They identify three zones of the
machine's longitudinal stability level:
NOTE: All hydraulic movements are functional if the

P126567 boom is fully retracted, regardless of the
machine's stability level.
The LLMC Override Switch (Item 1) [Figure 60-180-6] NOTE: When the longitudinal stability level reaches a
can be used to override the LLMC. critical level (Critical zone) with the boom not
fully retracted and the boom angle below 5°,
Turned clockwise (unstable position), the switch (Item 1) only hazardous movements are disabled (tilt
[Figure 60-180-6] overrides the LLMC. The switch and boom lowering are reduced in speed). It is
returns to the original position as soon as the switch is still possible to retract and lift the boom.
released and the LLMC becomes active again.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC SYSTEM (CONT’D) Critical zone:
Longitudinal Load Moment Indicator (LLMI) Red indicator light (Item 3) [Figure 60-180-7] (one
Description (Cont’d) light). The machine's longitudinal stability reaches a
critical level. A warning horn is activated along with
Secure zone: the red indicator light.
Green indicator lights (Item 1) [Figure 60-180-7] (four In this zone, the following machine functions are
lights). The operator works in a secure zone. reduced in speed or disabled:
In this zone, the following machine functions are • Boom lowering (disabled with boom angle above 5°,
progressively reduced in speed as the machine's reduced in speed when below 5°).
longitudinal stability decreases: • Boom extend (disabled).
• Tilt (disabled with boom angle above 5°, reduced in
• Boom lowering speed when below 5°).
• Boom extend • Auxiliary hydraulic functions (disabled).
• Tilting of attachment Use the remaining active functions to bring the
• Auxiliary hydraulic functions. machine back to a safe level of stability. If necessary,
activate the LLMC override switch or mode to enable
Warning zone: a disabled function such that the machine can be
Orange indicator lights (Item 2) [Figure 60-180-7] brought back to a safe level of stability. (See
(two lights). The longitudinal stability level gets close Longitudinal Load Moment Controller (LLMC)
to the critical zone. Override Switch on Page 60-180-4.)
NOTE: The LLMC override switch or mode should
In this zone, the following machine functions are only be activated when necessary and is
progressively reduced in speed as the machine's automatically deactivated after a running
longitudinal stability decreases: period of 60 seconds.
• Boom lowering NOTE: The warning horn cannot be deactivated.
• Boom extend
• Tilting of attachment Test Button:
• Auxiliary hydraulic functions.
The test button (Item 4) [Figure 60-180-7] has two
functions:
• Testing the correct functioning of the LLMI and the

LLMC. (See LLMC Calibration Test on Page 60-180-
5.)
• Calibrating the LLMI / LLMC system. (See LLMI /
LLMC Calibration on Page 60-180-7.)
The test indicator light (RED) (Item 5) [Figure 60-180-7]
is used for the test procedure and the LLMI / LLMC
system calibration. The light flashes when the LLMC is in
fault mode.
The control indicator light (ORANGE) (Item 6)

[Figure 60-180-7] indicates that the machine is under
control of the LLMC. The light flashes when the LLMC
override switch is activated. (See Longitudinal Load
Moment Controller (LLMC) Override Switch on Page 60-
180-4.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC SYSTEM (CONT’D) Longitudinal Load Moment Controller (LLMC)
Override Switch
Longitudinal Load Moment Controller (LLMC)
Figure 60-180-8
The LLMC disables or limits the following movements
when the machine stability level is critical:
• lowering of the boom,

• extending the telescopic boom,
• forward tilt of attachment,
• backward tilt of attachment,
• auxiliary hydraulic functions.
P125365
P125420
Turn the LLMC override switch (Item 1) [Figure 60-180-

8] clockwise to override the LLMC.
The control indicator light (ORANGE) (Item 2)

[Figure 60-180-8] flashes when the LLMC override
switch is activated.
The switch returns to the original position as soon as the

switch is released and the LLMC becomes active again.
NOTE: The LLMC override switch should only be

activated when necessary and is
automatically deactivated after a running
period of 60 seconds.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC SYSTEM (CONT’D) Figure 60-180-10
LLMC Calibration Test
The Longitudinal Load Moment Control (LLMC) system

calibration can be tested by performing the following
procedure:
Park the machine on flat level ground and align the front
and rear wheels straight ahead.
NOTE: A load will be needed to topple the machine.
WARNING EM9626
TIPPING CAN CAUSE SERIOUS INJURY OR DEATH

Without attachment and with the attachment carrier fully
Keep the boom low, only raise the load 500 mm (20 tilted up, fully retract and raise the boom [Figure 60-180-
in) when testing or calibrating the LLMI / LLMC 10].
system.
W-2929-1012
Figure 60-180-11
Figure 60-180-9 1
S41197
S39203
1. Push and hold the TEST button (Item 1) [Figure 60-
180-11] during the complete procedure. All the LEDs
Using the LLMC override switch, decrease the rear axle (Item 2 and 3) light up, and the buzzer sounds
load pressure by picking up a load and extending the discontinuously during 3 seconds.
boom until the machine topples over (rear wheels off the
ground) [Figure 60-180-9]. NOTE: Keep holding the test button for default test
result confirmation.
NOTE: Do not move or reposition the machine after
decreasing the rear axle load pressure.
Retract the boom and place the load on the ground.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMC Calibration Test (Cont’d)
Two test results are possible:
Figure 60-180-12 1
1 S41234
• The orange and red LEDs (Item 1) [Figure 60-180-

13] light up, calibration is out of range. Please redo
calibration of the LLMI / LLMC system. (See LLMI /
S41233 LLMC Calibration on Page 60-180-7.)
2. Release the TEST button (Item 1) [Figure 60-180-

• The four green LEDs (Item 1) [Figure 60-180-12] 11].
light up, calibration is OK;
The calibration test is finished.
NOTE: After pressing the TEST button (Item 1)

[Figure 60-180-11 on Page 60-180-5] longer
than 60 seconds, the procedure will
automatically end and the system will return
to normal mode.
NOTE: The system always returns to normal mode

when the TEST button (Item 1) [Figure 60-180-
11 on Page 60-180-5] is released during the
procedure.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC Calibration
Figure 60-180-14
S39203
Using the LLMC override switch, decrease the rear axle

load pressure by picking up a load and extending the
S39205
boom until the machine topples over (rear wheels off the
ground) [Figure 60-180-15].
Before calibration, drive the machine for a while in order
to warm the axles, then check tightening torque of the NOTE: Do not move or reposition the machine after
two bolts (Item 1) of the LLMS (Longitudinal Load decreasing the rear axle load pressure.
Moment Sensor) (Item 2). Torque value should be
65 N•m (48 ft-lb). When torque value is adjusted, drive Retract the boom and place the load on the ground. Then
the machine for a while and check a second time retract the boom and turn off the engine.
tightening torque of the two bolts (Item 1) [Figure 60-
180-14]. Follow the procedure below to calibrate the LLMI / LLMC
system:
Park the machine on flat level ground and align the front NOTE: Calibration must be performed within a time
and rear wheels straight ahead. span of 5 minutes. If longer, the LLMI / LLMC
system will return to its original settings.
NOTE: A load will be needed to topple the machine.
NOTE: During the procedure below, the buzzer will
be activated whenever the TEST button is
pushed.
WARNING
Keep the boom low, only raise the load 500 mm (20
in) when testing or calibrating the LLMI / LLMC
system.
W-2929-1012
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC Calibration (Cont’d)
Figure 60-180-16
EM9626
3. Without attachment and with the attachment carrier

S41197 fully tilted up, fully retract and raise the boom
[Figure 60-180-18].
Figure 60-180-17
4. Press and release the TEST button (Item 1)
[Figure 60-180-16] to record the first calibration
point.
5. The orange and red LEDs (Item 3) [Figure 60-180-

16] light up to indicate the system is ready to record
the second calibration point.
WARNING
S0007 Keep the boom low, only raise the load 500 mm (20
in) when testing or calibrating the LLMI / LLMC
1. Push and hold the TEST button (Item 1) [Figure 60- system.
W-2929-1012
180-16] while turning the key switch to START
[Figure 60-180-17] then quickly press the TEST
button (Item 1) [Figure 60-180-16] for 3 times within
the first 4 seconds after the key switch back to RUN /
PREHEAT.
NOTE: To indicate that the system enters calibration

mode, the LED bar (Items 2 and 3) [Figure 60-
180-16] will be blinking and the buzzer sounds
intermittent for 3 seconds.
2. The green LEDs (Item 2) [Figure 60-180-16] light up

to indicate the system is ready to record the first
calibration point.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC SYSTEM (CONT’D)
LLMI / LLMC Calibration (Cont’d)
Figure 60-180-19
S39203
6. Pick up the load and extend the boom until the

machine topples over (rear wheels off the ground)
[Figure 60-180-19].
7. Press and release the TEST button (Item 1)

[Figure 60-180-16 on Page 60-180-8] to record the
second calibration point.
8. To indicate the calibration has been validated, the

LED bar (Items 2 and 3) [Figure 60-180-16 on Page
60-180-8] lights up for 3 seconds and the buzzer
sounds two times.
NOTE: If the buzzer sounds and LEDs light up in a

particular configuration, a calibration failure
has occurred. (See LLMI / LLMC
Troubleshooting on Page 60-180-10.)
Calibration is finished. The LLMI / LLMC system

automatically returns to normal mode.
Always perform the LLMC calibration test after system

calibration. (See LLMC Calibration Test on Page 60-180-
5.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC Troubleshooting
During the occurrence of one or more of the failures below, the buzzer will sound discontinuous.
ERROR MACHINE
DISPLAY FUNCTION CAUSE SOLUTION
CODE BEHAVIOR
I3018 Sensor No The speed of The LLMI sensor input is Check the harness
Communication the aggravating disconnected. between the sensor and
motions is the LLMI.
decreased The sensor linked to the Replace the LLMS on the
(50%). LLMI has stopped sending rear axle and redo the
CAN frame. calibration.
I3014 Sensor OOR Low No aggravating Sensor shifted toward the Recalibrate the system.
(after 30 seconds) motions stability If the error remains:
possible. Replace the LLMS on the
Shunt is rear axle and redo the
allowed. calibration.
I3015 Sensor OOR High Sensor shifted toward the Recalibrate the system.
(after 1 second) instability If the error remains:
Replace the LLMS on the
rear axle and redo the
calibration.
I3016 Sensor In Error Sensor is out of order Replace the LLMS on the
(after 8 seconds) rear axle and redo the
calibration.
I3017 Sensor Not No motion Sensor has never been Calibrate the system.
Calibrated allowed calibrated.
Or either LLMI, LLMS or
both have been replaced.
I3113 OOR Calibration No aggravating Calibration has been done Redo the calibration
Values motions with out of range values correctly within 5
I3121 Backwards possible. Calibration has been done minutes.
Calibration Values Shunt is backwards.
allowed.
I3122 Calibration Values Calibration has been done
Too Close with points too close.
I3123 Calibration Calibration lasted more
Timeout than 5 minutes.
I3901 Internal Error No impact. LLMI internal memory Replace the LLMI and
I3903 failure. redo the calibration.
I3904
I3905
I3909 Test Membrane Test switch has been on Release the test switch.
Switch Failure. for more than 10s after the If the error remains:
system was started. Replace the LLMI and
redo the calibration.
Test switch has been on Release the test switch.
for more than 60s during If the error remains:
the calibration verification Replace the LLMI and
procedure. redo the calibration.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMI / LLMC Troubleshooting (Cont’d)
ERROR MACHINE
DISPLAY FUNCTION CAUSE SOLUTION
CODE BEHAVIOR
I0314 Battery Voltage No impact. Battery voltage is
OOR Low lower than 9V
I0315 Battery Voltage Battery voltage is
OOR High higher than 16V —
C3018 Sensor No The speed of the The LLMC sensor Check the harness between
Communication aggravating input is disconnected. the sensor and the LLMC.
motions is The sensor linked to Replace the LLMS on the
decreased the LLMC has stopped rear axle and redo the
(50%). sending CAN frame. calibration.
C3014 Sensor OOR Low No aggravating Sensor shifted toward Recalibrate the system.
(after 30 seconds) motions the stability If the error remains:
possible. Replace the LLMS on the
Shunt is rear axle and redo the
allowed. calibration.
C3015 Sensor OOR High Sensor shifted toward Recalibrate the system.
(after 1 second) the instability If the error remains: Replace
the LLMS on the rear axle
and redo the calibration.
C3016 Sensor In Error Sensor is out of order Replace the LLMS on the
(after 8 seconds) rear axle and redo the
calibration.
C3113 OOR Calibration Calibration has been Redo the calibration correctly
Values done with out of range within 5 minutes.
values
C3121 Backwards Calibration has been
Calibration Values done backwards.
C3122 Calibration Values Calibration has been
Too Close done with points too
close.
C3123 Calibration Calibration lasted
Timeout more than 5 minutes.
C0314 Battery Voltage Battery voltage is
OOR Low lower than 9V
—
C0315 Battery Voltage Battery voltage is
OOR High higher than 16V
C3017 Sensor Not No motion Sensor has never Calibrate the system.
Calibrated allowed been calibrated.
Or either LLMC, LLMS
or both have been
replaced.
C3801 Internal Error No motion LLMC internal failure. Replace the LLMC and redo
C3803 allowed the calibration.
C3804
C3805
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMS Removal
1
Raise the boom and install the approved boom stop (See
Installing The Approved Boom Stop on Page 10-150-1.) 2
Figure 60-180-20
1
S39246
Remove the two bolts (Item 1) and remove the LLMS

(Item 2) [Figure 60-180-22]
P125340

located on the cab side below the boom.
Figure 60-180-21
S39144
Remove the electrical harness (Item 1) [Figure 60-180-

21] from the machine.
NOTE: Remove any tie-straps if needed.
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMS Installation
Raise the boom and install the approved boom stop. (See
Installing The Approved Boom Stop on Page 10-150-1.) 1
Figure 60-180-23
S39144
Route the electrical harness (Item 1) [Figure 60-180-25]

into the machine.
Figure 60-180-26
S39355
Clean the axle sensor area (Item 1) [Figure 60-180-23]

to remove rust and / or dirt.
Figure 60-180-24
1
2
1
P125340
Plug the connector (Item 1) [Figure 60-180-26] located

on the cab side below the boom.
Attach the harness with tie-straps.

S39246
To avoid errors caused by position shifts of the LLMS,
perform the following actions:
Position the LLMS (Item 1) and install the two bolts (Item
2) [Figure 60-180-24]. 1. Drive the rear axle over crossties in order to settle the
position of the LLMS on the rear axle.
NOTE: Apply Loctite® #243 to the bolts.
2. Calibrate the LLMS. (See LLMI / LLMC Calibration on
Tighten the two bolts (Item 2) [Figure 60-180-24] in three Page 60-180-7.)
progressive steps:
- 25 N•m (18.4 ft-lb)
- 45 N•m (33.2 ft-lb)
- 65 N•m (47.9 ft-lb).
TH.6534(X) / TH.7035(X) / TH.7038(X)

LLMC Removal And Installation
Remove the dash cover. (See Removal And Installation

on Page 50-120-1.)
Figure 60-180-27
S39353
Disconnect the two connectors (Item 1) [Figure 60-180-

27].
Figure 60-180-28
S39354
Remove the two bolts (Item 1) [Figure 60-180-28].
Remove the LLMC.
Installation: Perform the (above) Removal procedure in

reverse.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE SERVICE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Sensor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-9
ENGINE AND HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Housing Removal And Installation (TH.7035(X)) . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Housing Removal And Installation (TH.6534(X) And TH.7038(X)) . . . . . . . . . . . . . . 70-50-2
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Oil Cooler / Intercooler / Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . 70-60-1
Expansion Tank Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Cooling System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Cooling System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Diesel Exhaust Fluid (DEF) / AdBlue® Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
DeSOX Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
SCR System Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality . . . . . . . . . . . . . . . . . 70-70-6
SCR System Component Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
EGR Impeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption . . . . . . . . . . . . . . . . . . . 70-70-7
Dosing Module Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11
DIESEL OXIDATION CATALYST (DOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
TH.6534(X) / TH.7035(X) / TH.7038(X)

DIESEL EXHAUST FLUID (DEF) TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
DEF Tank Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Coolant Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-3
Dosing Control Unit (DCU) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Supply Module Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-5
Supply Module Filter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-5
FUEL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE
Description
Figure 70-10-1
P125156
The telescopic handler is equipped with a Bobcat direct

injected D34P turbo charged and intercooled diesel
engine with a displacement of 3,4 L (208 in3). The engine
is rated at an SAE J gross 74 kW (100 hp) @ 2400 rpm
or at an SAE J gross 97 kW (130 hp) @ 2400 rpm
[Figure 70-10-1] and has a closed breather system.
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with an air intake heater and electronic timer with cold
start advance function for assisting in cold starts.
To meet emission regulations it is also equipped with a

Diesel Oxidation Catalyst (DOC) system, Selective
Catalytic Reduction (SCR) system and an Exhaust Gas
Recirculation (EGR) system to reduce Nitrogen Oxide
(NOx).
The engine serial number is stamped on the engine and

is located next to the oil filler cap. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol / water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor, the hydraulic / hydrostatic
fluid temperature sensor, fuel temperature and the HVAC
system.
For more information, see your Engine Operation &

Maintenance Manual.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE (CONT’D)
Sensor Locations
Vehicle Side
Figure 70-10-2
1 5
2
3
NA13168
1. Coolant Temperature Sensor (Item 2) [Figure 70-10-2]
2. Camshaft Position Sensor (Item 3) [Figure 70-10-2]
3. Crankshaft Position Sensor (Item 4) [Figure 70-10-2]
4. EGR Valve Actuator (Item 5) [Figure 70-10-2]
5. Turbo Exhaust Gas Temperature Sensor (Item 6) [Figure 70-10-2]
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE (CONT’D)
Sensor Locations (Cont’d)
Hood (Service) Side
Figure 70-10-3
4
2
2
3
5
NA13170
1. Intake Manifold Pressure Sensor (MAP) (Item 1) [Figure 70-10-3]
2. Knock Sensor (Item 2) [Figure 70-10-3]
3. Oil Pressure / Temperature Sensor (Item 3) [Figure 70-10-3]
4. Intake Manifold Temperature Sensor (Item 4) [Figure 70-10-3]
5. Fuel Temperature Sensor (Item 5) [Figure 70-10-3]
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE (CONT’D) Figure 70-10-6
Figure 70-10-4
P125093
Coolant Temperature Sensor (Item 1) [Figure 70-10-6].

P123944
Figure 70-10-7
Common Rail Pressure Sensor (Item 1) [Figure 70-10-4]
Figure 70-10-5
1
2
1
P125094
Camshaft Position Sensor (Item 1) [Figure 70-10-7].

P125092
Mass Air Flow Sensor (MAF) (Item 1) [Figure 70-10-5].
Selective Catalytic Reduction (SCR) temperature sensor

(inlet side) (Item 2) [Figure 70-10-5].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-10-8
P125097
Turbo Exhaust Gas Temperature Sensor (Item 1) [Figure

70-10-10].
P125095
Figure 70-10-11
Crankshaft Position Sensor (Item 1) [Figure 70-10-8].
Figure 70-10-9
1
P125098
Intake Manifold Pressure Sensor (MAP) [Figure 70-10-

P125096
11].
EGR Valve Actuator (Item 1) [Figure 70-10-9].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-10-12
P125158
1
Oil Pressure / Temperature Sensor (Item 1) [Figure 70-
10-14].
P125099
Figure 70-10-15
Knock Sensor (Left Side) (Item 1) [Figure 70-10-12].
Figure 70-10-13
P125100
Intake Manifold Temperature Sensor (Item 1) [Figure 70-

P125157
10-15].
Knock Sensor (Right Side) (Item 1) [Figure 70-10-13].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-10-16
1
2
P125102
Water in Fuel Sensor (Item 1) [Figure 70-10-18].

P125101
Figure 70-10-19
Fuel Temperature Sensor (Item 1) [Figure 70-10-16].
Inlet Metering Valve (Item 2) [Figure 70-10-16].

1
Figure 70-10-17 2
P125159
Diesel Oxidation Catalyst (DOC) Temperature Sensor

(Item 1) [Figure 70-10-19].
Diesel Oxidation Catalyst (DOC) Upstream NOx Sensor

P115946
(Item 2) [Figure 70-10-19].
Engine Control Unit (ECU) (Item 1) [Figure 70-10-17].
Atmospheric Pressure Sensor (Item 2) [Figure 70-10-

17].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE (CONT’D)
Figure 70-10-20
P125160
Selective Catalytic Reduction (SCR) Downstream NOx

Sensor (Item 1) [Figure 70-10-20].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE (CONT’D)
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Massey Ferguson Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 53
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14,15, 18, 26, 27, 28
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15,16, 17, 18, 19, 24, 26, 27, 28,53
No power for engine. 8, 9, 10, 11, 12, 13, 15,16, 17, 19, 20, 21, 22, 26, 27, 28
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 20, 21, 23, 24, 25, 27
Too much fuel consumption. 10, 12, 13, 15,16, 18, 19, 20, 22, 23, 24, 26, 27, 28
Black exhaust. 10, 12, 13, 15,16, 18, 19, 20, 22, 23, 24, 26, 27, 28
Blue / white exhaust. 4, 10, 15, 16, 20, 22, 26, 28, 29, 49
Low oil pressure. 4, 30, 31, 32, 33, 34, 36, 37, 38, 51
Engine knocking. 13, 15, 18, 21, 23, 24, 26, 28, 30, 39, 40, 52
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 16, 17, 21, 23, 24, 25, 28, 39, 52
Vibration. 12, 13, 16, 20, 21, 24, 25, 28, 39, 41, 42
High oil pressure warning. 4, 32, 35
Overheating. 10, 12, 13, 15, 19, 20, 39, 43, 44, 45, 46, 47, 50
Too much crankcase pressure. 21, 26, 28, 29, 39, 48
Poor compression. 10, 15, 20, 23, 24, 26, 27, 28, 29, 40, 52
Start and stop. 9, 10, 11
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE (CONT’D)
Troubleshooting (Cont’d)

1. Alternator belt is loose or damaged. 28. Broken or worn piston rings.
2. Bad electrical connections. 29. Worn valve stems or guides.
3. Faulty starter motor. 30. Worn or damaged bearings.
4. Incorrect grade of oil. 31. Not enough oil in the crankcase.
5. Low cranking speed. 32. Switch / sensor is defective.
6. Fuel tank empty. 33. Oil pump worn.
7. Faulty stop control operation. 34. Relief valve is sticking open.
8. Plugged fuel line. 35. Relief valve is sticking closed.
9. Plugged fuel filter. 36. Broken relief valve spring.
10. Restriction in the air cleaner. 37. Faulty suction pipe.
11. Air in the fuel system. 38. Plugged oil filter.
12. Faulty fuel injection pump. 39. Piston seizure.
13. Faulty fuel injectors. 40. Incorrect piston height.
14. Broken injection pump drive. 41. Faulty engine mounting.
15. Incorrect valve timing. 42. Incorrect flywheel alignment.
16. Poor compression. 43. Faulty thermostat.
17. Plugged fuel tank vent. 44. Restriction in water jacket.
18. Incorrect grade of fuel. 45. Loose alternator belt.
19. Exhaust pipe restriction. 46. Plugged radiator.
20. Cylinder head gasket leaking. 47. Faulty water pump.
21. Overheating. 48. Plugged breather pipe.
22. Cold running. 49. Damaged valve stem deflectors.
23. Incorrect tappet adjustment. 50. Coolant level to low.
24. Sticking valves. 51. Plugged oil pump pipe strainer.
25. Incorrect fuel lines. 52. Broken valve spring.
26. Worn cylinder bores. 53. Damaged Battery
27. Worn valve and seats.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE (CONT’D) Loosen the four clamps (Items 1 and 2) and remove the
two hoses (Item 3) [Figure 70-10-21].
Installation: Tighten the clamp (Item 3) [Figure 70-10-
Remove the engine cover. (See Removal And Installation 22] to 3 - 4 N•m (23 - 31 in-lb) torque.
on Page 50-60-1.)
Figure 70-10-22
Disconnect the ground (-) cable from the battery.
(See Removing And Installing The Battery on Page 60-
2
20-3.)
4
Drain the hydraulic reservoir. (See Removing And
1
Remove the refrigerant from the A/C system. (See
Unit on Page 80-40-1.)
3
Remove the expansion tank. (See Expansion Tank
Removal And Installation on Page 70-60-4.)
Remove the DEF tank (if equipped). (See Removal And P125216
Remove the oil cooler / radiator. (See Oil Cooler /
[Figure 70-10-22].
Intercooler / Radiator Removal And Installation on Page
70-60-1.)
22] to 3 - 4 N•m (25 - 35 in-lb) torque.
Remove the exhaust pipe. (See Removal And Installation
on Page 70-40-1.)
[Figure 70-10-22].
Remove the SCR. (See Removal And Installation on
Page 70-70-8.)
Figure 70-10-23
Remove the DOC. (See Removal And Installation on
Page 70-80-1.) 4 3
Remove the hydrostatic pump. (See Removal And

4 3
Figure 70-10-21
3
1
2
P125219
3 Loosen the clamp (Item 1) and remove the hose (Item 2)

2 [Figure 70-10-22].

22] to 3 - 4 N•m (25 - 35 in-lb) torque.
P125215
Loosen the clamps (Item 3) and remove the coolant
hoses (Item 4) [Figure 70-10-22].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-10-24
3
1
2
1
P125217

from the compressor.
P125177
Remove the compressor hoses (Item 2 and 3) [Figure

Loosen the clamp (Item 1) and remove the hose (Item 2) 70-10-26].
[Figure 70-10-24].
Installation: Tighten the hose (Item 2) to 27 - 41 N•m (20
Installation: Tighten the clamp (Item 1) [Figure 70-10- - 30 ft-lb) torque. Tighten the hose (Item 3) [Figure 70-
24] to 3 - 4 N•m (25 - 35 in-lb) torque. 10-26] to 20 - 27 N•m (15 - 20 ft-lb) torque.
Figure 70-10-25 Cap and plug the hoses and fittings with the proper A/C
caps and plugs.
Remove the compressor. (See Removal And Installation

2 on Page 80-50-1.)
Figure 70-10-27
P125220
1
Remove the two bolts (Item 1) and bracket (Item 2)
[Figure 70-10-25].
Installation: Hand tighten the bolts (Item 1) [Figure 70-

10-25]. The bolts are tightened to torque during S41496
installation of the DOC. (See Removal And Installation on
Page 70-80-1.) Remove the bolts (Item 1) and reposition the fuel filter
(Item 2) [Figure 70-10-27].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-10-28
1 2
1
P125225
Remove the nuts (Item 1) and the wire harness (Item 2)

[Figure 70-10-30].
P125223
NOTE: Mark the leads of the wire harness for correct

Remove the bolt and clamp (Item 1) [Figure 70-10-28] installation.
from the engine basket.
Installation: Tighten the nuts (Item 1) [Figure 70-10-30]
Figure 70-10-29 to 4 - 6 N•m (35 - 53 in-lb) torque.
Figure 70-10-31
1
P125224
Remove the bolt and clamp (Item 1) [Figure 70-10-29] P125226

from the engine.
Remove the bolt and clamp (Item 1) and remove the air
wire harness (Item 2) [Figure 70-10-31] from the engine.
TH.6534(X) / TH.7035(X) / TH.7038(X)


2
Figure 70-10-32
1
1
2
P125201
4
Remove the two nuts (Items 1 and 2) [Figure 70-10-33]
and remove the connector and charge cable from the
P125227
back of the alternator.
Remove the bolt (Item 1) and the ground wires (Item 2) Installation: Tighten nut (Item 1) to 3 - 4 N•m (24 - 34 in-
[Figure 70-10-32]. lb) torque and nut (Item 2) [Figure 70-10-33] to 7 - 8 N•m
(66 - 71 in-lb) torque.
Remove the tie strap (Item 3) and fuel hose (Item 4)
[Figure 70-10-32]. Figure 70-10-35
Figure 70-10-33
2
3 2
1
1
P125229
P125228
Remove the two bolts (Item 1) and bracket (Item 2) from
the engine. Reposition the coolant hoses (Item 3)
Remove the tie strap (Item 1) and wire harness (Item 2) [Figure 70-10-35].
[Figure 70-10-33] from the engine.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-10-36
P125232

39] from the fuel pump.
P125230
Figure 70-10-39
Remove the tie strap (Item 1) and coolant hoses (Item 2)
[Figure 70-10-36] from the engine.
Figure 70-10-37
1
2
1
P125232
1
Disconnect the connector from the starter signal terminal
(Item 1) [Figure 70-10-39].
P125286
Remove the cap (Item 2) [Figure 70-10-39] and

Disconnect the fuel lines (Item 1) [Figure 70-10-37] from disconnect the two wires from the starter battery (+)
the fuel pump. terminal.
Installation: Tighten the nut (Item 1) to 3 - 4 N•m (26 -

35 in-lb) torque. Tighten the nut (Item 2) [Figure 70-10-
39] to 15 - 17 N•m (11 - 12 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-10-40
1
1
1
P126288
Install a hoist and chain to the lift eyes (Item 1) [Figure

70-10-42].
S41508
Figure 70-10-43
Remove the bolt, nut and clamp (Item 1) [Figure 70-10-
40] from the engine basket frame underneath the oil pan.
1
Installation: Tighten the bolt (Item 1) [Figure 70-10-40]
to 12 N•m (9 ft-lb) torque.
Figure 70-10-41
1 1
1
S42128
Remove the four plastic caps (Item 1) [Figure 70-10-43].
P125285
Remove the bolt, nut and clamp (Item 1) [Figure 70-10-

41] from the engine basket frame underneath the oil pan.

to 12 N•m (9 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-10-44
P126288
Lift and remove the engine [Figure 70-10-46].

P125287 P125288
Remove the front engine mount bolts (Item 1) [Figure

70-10-44].
Installation: Tighten the engine mount bolts to 250 -

271 N•m (185 - 200 ft-lb) torque.
Figure 70-10-45
1
1
P125289 P125290
Remove the rear engine mount bolts (Item 1) [Figure 70-

10-45].
Installation: Tighten the engine mount bolts to 250 -

271 N•m (185 - 200 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
ENGINE AND HYDROSTAT ASSEMBLY Figure 70-20-2
The Approved Boom Stop on Page 10-150-1.) 1
1
Remove the engine cover. (See Removal And Installation
on Page 50-60-1.)

Drain the hydraulic reservoir. (See Removing And 2

S39811
Remove the refrigerant from the A/C system. (See (Item 2) [Figure 70-20-2]
Unit on Page 80-40-1.) Figure 70-20-3

Figure 70-20-1
4 3
2
S38105
2 Remove the four bolts (Item 1) and the two covers (Item
1 2) [Figure 70-20-3].
P125341
Remove the A/C hose (Item 1) from the drier, and the A/C
hose (Item 2) [Figure 70-20-1] from the expansion valve.
NOTE: Plug the A/C hoses and component openings

to prevent contamination. Mark all hoses for
Remove the heater hoses (Items 3 and 4) [Figure 70-20-

1] from the heater.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE AND HYDROSTAT ASSEMBLY (CONT'D) Figure 70-20-6
Figure 70-20-4
4 2
3
1
S38081
5
Loosen the hose clamp (Item 1) [Figure 70-20-6].

P125340
Figure 70-20-7
Remove the tie-strap (Item 1) [Figure 70-20-4]
Loosen the screw and disconnect the electrical connector

(Item 2) [Figure 70-20-4].
Remove the nut and ground wires (Item 3) [Figure 70- 1

20-4].
Disconnect the ignition connector (Item 4) [Figure 70-20-

4] (red / white cable).
Disconnect the engine connectors (Item 5) [Figure 70-

20-4].
NOTE: Mark all electrical connectors for correct

installation. S38080
Figure 70-20-5
hydraulic tank.
NOTE: Mark the hose for correct installation.
IMPORTANT
1 When repairing hydrostatic and hydraulic systems,
P125374
damage the system.
I-2003-0888
Disconnect the two electrical connectors (Item 1) [Figure

70-20-5] from the hydrostatic motor.
NOTE: Mark all connectors for correct installation.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE AND HYDROSTAT ASSEMBLY (CONT'D) Remove the hose (Item 2) [Figure 70-20-9] from the
hydraulic filter.
Figure 70-20-10
IMPORTANT 1
3
damage the system.
I-2003-0888
2
Figure 70-20-8
P125375
Remove the hydraulic hose (Item 1) [Figure 70-20-10]

from the oil cooler.

1 [Figure 70-20-10].
2
10] to 3 - 4 N•m (25 - 35 in-lb) torque.
Figure 70-20-11
3 1
S38107
1
Remove the tie-straps (Item 1) and loosen the collar
2
(Item 2) [Figure 70-20-8].
Disconnect the hose (Item 3) [Figure 70-20-8].
Figure 70-20-9
2 1 P125176
1
Remove the bolts (Item 1) and cover (Item 2) [Figure 70-
20-11].
P125376
Remove the tie-strap (Item 1) [Figure 70-20-9].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE AND HYDROSTAT ASSEMBLY (CONT'D) Loosen the clamp (Item 1) and disconnect the fuel line
(Item 2) [Figure 70-20-13].
Figure 70-20-14
IMPORTANT
damage the system.
I-2003-0888
Figure 70-20-12 1
P125205

back side of the hydrostatic pump.
1 For TH.7035(X) Telescopic Handler:
2 Figure 70-20-15
1
P125207
1
[Figure 70-20-12] from the radiator. 1
Figure 70-20-13
P119752
3 Remove the five hoses (Item 1) [Figure 70-20-15].
1 2
P125291
Remove the cable tie (Item 3) [Figure 70-20-13].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-20-16 1
1 1
1 P125379

P125204 the hydraulic pump.
For All Telescopic Handlers:

the hydraulic pump. Figure 70-20-19
For TH.6534(X) And TH.7038(X) Telescopic Handlers: 1
Figure 70-20-17
1
2
S38084
2
P125378 (Item 2) [Figure 70-20-19] from the front of the operator
cab.
Remove the three hoses (Item 1) [Figure 70-20-17].
Remove the two clamps (Item 2) [Figure 70-20-17] and

remove the two hoses. IMPORTANT
damage the system.
I-2003-0888
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE AND HYDROSTAT ASSEMBLY (CONT'D)
Figure 70-20-20
IMPORTANT
1 damage the system.
I-2003-0888
2 Figure 70-20-22
S38085
Remove the two hoses (Item 1 and 2) [Figure 70-20-20]

1 2
from the steering valve.
Figure 70-20-21
P125292
Remove the clamp (Item 1) by removing the nut (Item 2)

1 [Figure 70-20-22].
Support the engine / hydrostat assembly with a fork lift or

suitable lift jack.
NOTE: Make sure the fork tips of the fork lift only
support the engine / hydrostat assembly and
not the machine frame.
1
1 1
P125377

the valve.
NOTE: Some hoses and connectors were removed in

[Figure 70-20-20] for picture clarity. Mark all
hoses for correct installation.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 70-20-23
1 S38110
Remove the mounting bolt and nut (Item 1) [Figure 70-

P125342 20-25] in the middle of the engine / hydrostat assembly.
Installation: Tighten the mounting bolt to 195 - 225 N•m

Remove the three mounting bolts (Item 1) [Figure 70-20- (144 - 166 ft-lb) torque.
23] at the rear of the engine / hydrostat assembly.
Carefully remove the engine / hydrostat assembly from
Installation: Tighten the mounting bolts (Item 1) [Figure the machine. Guide the hoses and wire harness out of
70-20-23] to 195 - 225 N•m (144 - 166 ft-lb) torque. the frame.
Figure 70-20-24 Pay special attention to route the HVAC hoses out of the
operator cab.
P125411
Remove the three mounting bolts (Item 1) [Figure 70-20-

24] at the front of the engine / hydrostat assembly.
Installation: Tighten the mounting bolts (Item 1) [Figure

70-20-24] to 195 - 225 N•m (144 - 166 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
ENGINE SPEED CONTROL

Figure 70-30-1
1 1
2 1
S38084

cab.
Figure 70-30-2
2
1
S40900
Disconnect the connector (Item 1) [Figure 70-30-2]from

the throttle pedal.
Remove the three nuts (Item 2) [Figure 70-30-2] from the

pedal.
Installation: Tighten the bolts and nuts (Item 2) [Figure

70-30-2] to 12 - 15 N•m (9 - 11 ft-lb) torque.
NOTE: For installation, access the bolts from the

front of the operator cab.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
EXHAUST PIPE Figure 70-40-2

3
WARNING 1
2
HOT SURFACES CAN CAUSE SERIOUS INJURY
• Do not touch.
• Allow to cool before servicing.
W-2533-1012
Open the engine cover. (See Opening And Closing on P125278

Page 10-160-1.)
Figure 70-40-1 Remove the clamp (Item 1 and 2) [Figure 70-40-2] by

removing the two nuts.
1 Installation: Tighten the nuts of the clamps (Item 1 and

2) [Figure 70-40-2] alternately in two times. First make
contact with each nut and then tighten them to 40 N•m
(30 ft-lb) torque.
Remove the exhaust pipe (Item 3) [Figure 70-40-2].

2
3
4
P125333
Remove the clamp (Item 1) [Figure 70-40-1] by removing

the two nuts.
Loosen the clamp (Item 2) [Figure 70-40-1] by loosening

the two nuts.
Installation: Tighten the nuts of the clamps (Item 1 and

2) [Figure 70-40-1] alternately in two times. First make
contact with each nut and then tighten them to 40 N•m
(30 ft-lb) torque.
Remove the outer section (Item 3) [Figure 70-40-1] of

the exhaust.
Completely remove the clamp (Item 2) [Figure 70-40-1].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
AIR CLEANER Figure 70-50-3
Housing Removal And Installation (TH.7035(X))

Page 10-160-1.)
Figure 70-50-1 1
2
1
P125187

3 3].

P125186 to maximum 25 N•m (18 ft-lb) torque.
Remove the air cleaner housing assembly.

[Figure 70-50-1] from the air cleaner.
NOTE: Cover or plug the air intake hose so no

contamination gets into the engine.

1].
Figure 70-50-2
1
P125324
Remove the two bolts (Item 1) and remove the bracket

(Item 2) [Figure 70-50-3].
TH.6534(X) / TH.7035(X) / TH.7038(X)

AIR CLEANER (CONT’D) Figure 70-50-6
Housing Removal And Installation (TH.6534(X) And

TH.7038(X))
1
Open the engine cover. (See Opening And Closing on 4
Page 10-160-1.)
Figure 70-50-4
2
3 1
1
P125321
Remove the two bolts (Item 1) and remove the bracket

(Item 2) [Figure 70-50-6].

[Figure 70-50-6] from the air cleaner.
P125373
NOTE: Cover or plug the air intake hose so no
contamination gets into the engine.
Remove the air cleaner housing assembly.
to maximum 16 N•m (12 ft-lb) torque.
Figure 70-50-5
P125372

to maximum 16 N•m (12 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM Remove the clamp (Item 2) and radiator hose (Item 3)
[Figure 70-60-2].
Oil Cooler / Intercooler / Radiator Removal And
Installation NOTE: Install caps or plugs on the hydraulic hoses.
Remove the engine cover. (See Removal And Installation For Standard Fan Motor:
on Page 50-60-1.)
Figure 70-60-3
Remove the A/C condenser. (See Removal And

Remove the expansion tank. (See Expansion Tank


Page 70-110-1.)
Figure 70-60-1
P125171
2
from the fan motor.
1 Figure 70-60-4
1
P125203

(Item 2) [Figure 70-60-1].
Figure 70-60-2
P125172
2 Remove the two hydraulic hoses (Item 1) [Figure 70-60-

6] from the fan motor.
1
P125178
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM (CONT'D) For All Models:
Oil Cooler / Intercooler / Radiator Removal And Figure 70-60-7

For Fan Motor With Inversion:

2 1
Figure 70-60-5
1
2
P125173
Loosen the clamp (Item 1), remove the radiator hose and
the isolating foam (Item 2) [Figure 70-60-7].
S41471
Installation: Tighten the clamp (Item 1) to 3 - 4 N•m (25 -
35 in-lb) torque. Install the isolating foam (Item 2) [Figure
Remove the hydraulic hose (Item 1) [Figure 70-60-5] 70-60-7].
from the fan motor.
Figure 70-60-8
Disconnect the wire harness (Item 2) [Figure 70-60-5].
3
Figure 70-60-6 1
1
2
1
3
2
P125174
S41583 Loosen the clamps (Item 1 and 2) and remove the two
radiator hoses (Item 3) [Figure 70-60-8].
Remove the two hydraulic hoses (Item 1) [Figure 70-60- Installation: Tighten the clamp (Item 1) to 1,1 - 1,6 N•m
6] from the fan motor. (10 - 14 in-lb) torque. Tighten the clamp (Item 2) [Figure
70-60-8] to 3- 4 N•m (25 - 35 in-lb) torque.
Disconnect the wire harness (Item 2) [Figure 70-60-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM (CONT'D) Figure 70-60-11
Oil Cooler / Intercooler / Radiator Removal And

Figure 70-60-9
1
1
2
2
P125207
Remove the clamp (Item 1) and radiator hose (Item 2)

2 3 [Figure 70-60-11].
P125175
Figure 70-60-12
Loosen the clamps (Item 1 and 3) [Figure 70-60-9].
Remove the radiator hoses (Item 2) [Figure 70-60-9].

1
Installation: Tighten the clamp (Item 1) to 3 - 4 N•m (25 -
35 in-lb) torque. Tighten the clamp (Item 3) [Figure 70- 1
60-9] to 3 - 4 N•m (25 - 35 in-lb) torque.
Figure 70-60-10
1
P125179
2

12].
1 P125176
Remove the bolts (Item 1) and cover (Item 2) [Figure 70-

60-10].
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM (CONT'D) Expansion Tank Removal And Installation
Oil Cooler / Intercooler / Radiator Removal And Drain the radiator. (See Removing And Replacing The
Installation (Cont’d) Coolant on Page 10-70-3.)
Figure 70-60-13 Figure 70-60-15
1
2
2
2
1
3
1
P125180 P125263
Remove the mounting bolt (Item 1) [Figure 70-60-13], Loosen the clamps and remove the two coolant hoses
washer and nut. (Item 1) [Figure 70-60-15].
With the aid of an assistant, lift and remove the oil cooler Installation: Tighten the clamps (Item 1) [Figure 70-60-
/ radiator assembly from the machine using the lifting 15] to 1,1 - 1,6 N•m (10 - 14 in-lb) torque.
points (Item 2) [Figure 70-60-13] (one hidden from view).
Remove the expansion tank (Item 2) [Figure 70-60-15].
Installation: Make sure the seals and insulating foams
are still in place. NOTE: The bolts (Item 3) [Figure 70-60-15] do not
need to be removed.
Figure 70-60-14
Figure 70-60-16
2
2
1
P125180
P125214
Remove the three bolts (Item 1) and the air intake plate
(Item 2) [Figure 70-60-14]. Remove the three bolts (Item 1) [Figure 70-60-16] from
the back of the engine basket frame and remove the
Remove the fan motor from the oil cooler / radiator support.
assembly. (See Removal And Installation on Page 20-
110-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

ENGINE COOLING SYSTEM (CONT'D) Cooling System Inspection
Cooling System Check This engine has a pressure type cooling system.
A pressure type cooling system gives two advantages:
1. The following conditions indicate that a heat problem
exists. • The pressure type cooling system can operate safely
at a higher temperature than the boiling point of water
• Hot coolant is released through the pressure cap at a range of atmospheric pressures.
during the normal operation of the engine. Hot coolant
can also be released when the engine is stopped. • The pressure type cooling system prevents cavitation
in the water pump.
• Hot coolant is released from the coolant system but
not through the pressure cap during normal operation Cavitation is the sudden generation of low pressure
of the engine. Hot coolant can also be released when bubbles in liquids by mechanical forces. The generation
the engine is stopped. of an air or steam pocket is much more difficult in a
pressure type cooling system.
• Coolant must be added frequently to the cooling
system. The coolant is not released through the Regular inspections of the cooling system should be
pressure cap or through an outside leak. made in order to identify problems before damage can
occur. Visually inspect the cooling system before tests
2. If any of the conditions in step 1 exist, perform the are made with the test equipment.
following procedures:
• Run the engine at medium idle, which is

approximately 1200 rpm, for 3 minutes after the high
idle shuts off. Running the engine at medium idle will
allow the engine to cool before the engine is stopped.
• Inspect the poly V-rib belt for wear or for damage. If

necessary, replace the poly v-belt. (See
ALTERNATOR on Page 60-30-1.)
3. Inspect the radiator and the cooling system for leaks.

(See Cooling System Inspection on Page 70-60-5.)
4. If the coolant does not flow through the radiator and

through other components of the cooling system,
perform the following procedures:
• Test the water temperature regulator. (See Engine

Service Manual for correct procedure).
• Clean the radiator and other components with hot

water or steam at low pressure. Detergent in the
water can also be used. Compressed air can be used
to remove materials from the cooling system. Identify
the cause of the restriction before you choose the
method for cleaning.
• Straighten any fins of the radiator if the fins are bent.
5. Check the high idle of the engine. The engine can

overheat if the high idle rpm is set too high.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM
Description
The engine exhaust system is equipped with a selective catalytic reduction (SCR) system. The SCR is an emissions
reduction system that removes nitrogen oxides from the exhaust gases.
The machine will periodically perform a process to clean sulfur oxides from the SCR. This process is called DeSOX.
The SCR system requires Diesel Exhaust Fluid (DEF) / AdBlue® to function correctly. (See the Operation & Maintenance
Manual for more information.)
NOTE: Diesel exhaust fluid (DEF) and AdBlue® are different names for the same fluid.
Figure 70-70-1
P121002B
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM (CONT’D)
Diesel Exhaust Fluid (DEF) / AdBlue® Level
DEF /
ENGINE ENGINE
FLUID LEVEL ADBLUE® DISPLAY SERVICE
STAGE ALARM TORQUE RPM
LEVEL INDICATOR MALFUNCTION SCREEN CODES
DERATE DERATE
ICON
Four Green
Full
Lights
Three Green
75%
Lights
Two Green
50%
Lights
25% - One Green E00524617
Warning On DEF L [1] Three Beeps
10% Light U00176115
Three Beeps
E00524615
Less Than One Yellow (Additional
Level 1 On DEF L [1] E00524617 25%
10% Light beep every 20
U00176115
minutes)
Three Beeps
E00524615
for each code
Severe Less Than One Red E00524616
On DEF L [2] (Additional 50% 60%
Level 5% Light E00524617
beep every 10
U00176115
minutes)
[1] Pressing the information button on the left panel will return the display to the main menu for 20 minutes.
NOTE: The level indicator, DEF / AdBlue® malfunction icon, and display screen are located on the display panel.
(See the Operation & Maintenance Manual for more information.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

DeSOX Process
There are three DeSOX processes:
• Passive DeSOX (Automatically performed by the machine unless inhibited)
• Forced DeSOX (Machine requested; operator initiated)
• Inhibit DeSOX
—————————————————————————————————————————————————————
Passive DeSOX Process Forced DeSOX Process
Figure 70-70-2 The machine may request a forced DeSOX if a passive

DeSOX was not finished.
Figure 70-70-3
P122912
The DeSOX process will begin automatically every 180

P122911
hours. The upper part of the DeSOX switch will light and
[DESOX] and a progress status from 0 to 100 per cent
progress status from 0 to 100 per centwill alternately The alarm will beep once every hour, the upper part of
appear in the data display [Figure 70-70-2]. the DeSOX switch will blink, and [DESOX] will flash in the
data display [Figure 70-70-3] during ten seconds every
When finished, the display will display [PASS] before hour and at each cycle of the start key or keyless switch.
reverting to the main menu. Press the information button
to return to the main menu immediately. Forced DeSOX is requested when sulfur load hours are
higher than 190 hours. If Forced DeSOX has not been
The DeSOX process can last 15 to 20 minutes. performed at 200 sulfur load hours, the engine control
unit (ECU) will reduce engine torque by 25% at low idle
It is recommended to continue operating the machine and progressively up to 60% at high idle.
under load until the DeSOX process is finished.
Park the machine in a ventilated outdoor area.
The DeSOX process can be stopped by turning off the
machine or by pressing the Inhibit DeSOX switch. The Put the travel direction control in NEUTRAL.
process will resume the next time the machine is started
after acceptable conditions are reached. Release the throttle pedal and make sure the parking
brake is engaged.
The engine coolant temperature must be higher than

40°C (104°F).
TH.6534(X) / TH.7035(X) / TH.7038(X)

DeSOX Process (Cont’d)
Forced DeSOX Process (Cont’d) Inhibit DeSOX Process
2 1
P125355 P125355
Press the top of the DeSOX switch (Item 1) [Figure 70- Press the bottom of the DeSOX switch (Item 1) [Figure
70-4] for about three seconds to start the Forced DeSOX 70-70-5] to prevent the telescopic handler from
process. performing a DeSOX process. The switch will light while
DeSOX is inhibited. The inhibit will reset when the
The forced DeSOX process will last 15 to 20 minutes with machine is turned OFF.
engine speed at maximum idle.
If DeSOX is inhibited, press and release the bottom of the
The Forced DeSOX process can be stopped by pressing DeSOX switch (Item 1) [Figure 70-70-5] to reset and
the bottom of the DeSOX switch (Inhibit) (Item 2) [Figure allow the machine to perform a DeSOX process.
70-70-4], putting the travel direction control out of
NEUTRAL or engaging the throttle. The system will If a DeSOX process has started, pressing and holding
request a Forced DeSOX the next time the machine is the bottom of the DeSOX switch (Item 1) [Figure 70-70-
started. The Forced DeSOX process will resume from the 5] for three seconds will stop the process.
last progress status.
Figure 70-70-6
P122911
The engine malfunction icon will light [Figure 70-70-6]

and the alarm will beep twice if a DeSOX process is
needed while inhibited. Service code [E00008107] will
also be displayed. The engine torque will reduce by 40%
if the operator continues to operate the machine while
inhibited.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SCR System Codes
The following SCR system codes alert the operator of conditions that require attention. Continued operation of the machine
under these conditions will result in reduced machine performance.
Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory EGR Impeded

Quality
Figure 70-70-9
Figure 70-70-7
P122909
P122910
[EGR] will appear in the data display [Figure 70-70-9] to

[DEF Q] will appear in the data display [Figure 70-70-7] alert the operator that the exhaust gas recirculation
to alert the operator that the DEF / AdBlue® quality is (EGR) system is impeded. (See EGR Impeded on Page
unsatisfactory. (See Diesel Exhaust Fluid (DEF) / 70-70-7.)
AdBlue® Unsatisfactory Quality on Page 70-70-6.)
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing
SCR System Component Tampering Interruption
P122908 P122907
[SCR] will appear in the data display [Figure 70-70-8] to [DOSE] will appear in the data display [Figure 70-70-10]
alert the operator that an SCR system component has to alert the operator that there has been an interruption in
been tampered with. (See SCR System Component DEF / AdBlue® dosing. (See Diesel Exhaust Fluid (DEF)
Tampering on Page 70-70-6.) / AdBlue® Dosing Interruption on Page 70-70-7.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality
The machine can detect unsatisfactory quality DEF / AdBlue® and will alert the operator.
ENGINE ENGINE ENGINE

DISPLAY SERVICE
STAGE MALFUNCTION ALARM TORQUE RPM
SCREEN CODES
ICON DERATE DERATE
Three Beeps (Additional

Warning On DEF Q [1] E00524624 [3]
beep every 20 minutes)
Level 1 On DEF Q [1] E00524624 [3] 25%
Severe Level Flashing DEF Q [2] E00524624 [3] 50% 60%
[1] Pressing the information button on the display panel will return the display to the main menu for 20 minutes.
[3] Also code U00351600, U00351601, or U00351631 will be displayed.
NOTE: The engine malfunction icon and display screen are located on the display panel. (See the Operation &
Maintenance Manual for more information.)
NOTE: Level 1 Stage is reached 10 hours after Warning Stage. Severe Level is reached 20 hours after Warning
Stage. If the error repeats within 40 hours following repair, then Severe Level will be reached in 2 hours.
SCR System Component Tampering
The machine can detect tampering with SCR system components and will alert the operator.

DISPLAY SERVICE
SCREEN CODES
ICON DERATE DERATE

Warning On SCR [1] E00524625 [3]
Level 1 On SCR [1] E00524625 [3] 25%
Severe Level Flashing SCR [2] E00524625 [3] 50% 60%
[3] One or more ‘U’ codes could also be displayed.
TH.6534(X) / TH.7035(X) / TH.7038(X)

EGR Impeded
The machine can detect an impeded exhaust gas recirculation (EGR) system and will alert the operator.

DISPLAY SERVICE
SCREEN CODES
ICON DERATE DERATE

Warning On EGR [1] E00524621 [3]
Level 1 On EGR [1] E00524621 [3] 25%
Severe Level Flashing EGR [2] E00524621 [3] 50% 60%
[3] Also code U06522621. Additional ‘E’ codes could also be displayed.
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption
The machine can detect an interruption in DEF / AdBlue® dosing and will alert the operator.

DISPLAY SERVICE
SCREEN CODES
ICON DERATE DERATE

Warning On DOSE [1] E00524622 [3]
Level 1 On DOSE [1] E00524622 [3] 25%
Severe Level Flashing DOSE [2] E00524622 [3] 50% 60%
[3] One or more ‘U’ codes could also be displayed.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-70-12
(CONT’D)
WARNING 1
HOT SURFACES CAN CAUSE SERIOUS INJURY

• Do not touch.
• Allow to cool before servicing.
W-2533-1012
P125213
Page 10-160-1.)
Disconnect the metering valve connector (Item 1)
Remove the exhaust pipe. (See Removal And Installation [Figure 70-70-12].
on Page 70-40-1.)
Figure 70-70-13
Drain the engine coolant from the cooling system. (See
Removing And Replacing The Coolant on Page 10-70-3.)
NOTE: It is recommended that any clamps be

replaced with new if removed during service. 2
1
Always use new gaskets when servicing. 1
Figure 70-70-11
P125209
1
Remove the two coolant lines (Item 1) and remove the
DEF/Adblue® line (Item 2) [Figure 70-70-13].
2
NOTE: Coolant lines must be hooked up correctly.
P115864
Remove the tie straps (Item 1) and disconnect the heat

sensor connector (Item 2) [Figure 70-70-11].
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-70-15
(CONT’D)
Figure 70-70-14
1 3
2
P125211
3
Remove the temperature sensor (Item 3) [Figure 70-70-
15].
P125210
Figure 70-70-16
Remove the NOx sensor (Item 1) [Figure 70-70-13] and

move it aside.
NOTE: When the Downstream and Upstream NOx

sensors are both removed mark the sensors
for correct installation into the SCR or DOC.
Use anti-seize when replacing or reinstalling

temperature and NOx sensors. 1
Installation: Apply Weicon® ASW 040P Anti-Seize and

tighten the NOx sensor (Item 1) [Figure 70-70-13] to 50
N•m (37 ft-lb) torque.
2 P125212
Loosen the nut (Item 2) and remove the clamp (Item 3)
[Figure 70-70-14].
Remove the four nuts and bolts (Item 1) from the SCR
Installation: Tighten the nut to 8 - 10 N•m (71 - 89 in-lb) mount bracket (Item 2) [Figure 70-70-15] and [Figure
torque. 70-70-16] (one bolt hidden).
Remove the SCR from the engine.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM For TH.6534(X) And TH.7038(X) Machines:
(CONT’D)
Figure 70-70-18
If necessary, the SCR can be removed from its mounting

plate. Follow the procedure below to remove the
mounting bracket.
For TH.7035(X) Machines:

1
Figure 70-70-17
2 2
2
P125426
Loosen the nuts (Item 1) and remove the clamps (Item 2)

[Figure 70-70-18].
1
to 19 - 20 N•m (14 - 15 ft-lb) torque.
P125427
Loosen the nuts (Item 1) and remove the clamps (Item 2)

[Figure 70-70-17]. Remove the SCR from the mounting
bracket.

to 19 - 20 N•m (14 - 15 ft-lb) torque.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM
(CONT’D)
Dosing Module Removal And Installation
Figure 70-70-19
1 2
1
P121170
Remove the three bolts (Item 1) and the dosing module

(Item 2) [Figure 70-70-19].
Figure 70-70-20
P121175A
Inspect the dosing module (Item 1) [Figure 70-70-20] for

damage and replace if necessary.
Replace the gasket (Item 2) [Figure 70-70-20].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
DIESEL OXIDATION CATALYST (DOC) Figure 70-80-2

Page 10-160-1.)
2
Page 70-110-1.)
Figure 70-80-1
1
3
P125281
1
4
Loosen the nuts (Item 1) to loosen the clamp (Item 2)
[Figure 70-80-3]. Reposition the clamp.
Installation: Tighten nut (Item 1) [Figure 70-80-3] to 10 -

11 N•m (89 - 97 in-lb) torque.
Figure 70-80-3
2
P125279
Loosen the nut (Item 1) to loosen the clamp (Item 2)

[Figure 70-80-1]. Reposition the clamp. 3

9 - 11 N•m (80 - 97 in-lb) torque.
Remove the two sensors (Item 3 and 4) [Figure 70-80- 1

2
1].
Installation: Apply Weicon® ASW 040P Anti-Seize to

the sensors (Items 3 and 4). Tighten the sensor (Item 3)
to 50 N•m (37 ft-lb) torque and sensor (Item 4) [Figure
P125280
70-80-1] to 45 N•m (33 ft-lb) torque.
Loosen the nuts (Item 1) [Figure 70-80-3].
Installation: Tighten nuts (Item 1) [Figure 70-80-3] to 14

- 15 N•m (10 - 11 ft-lb) torque.
Reposition the clamps (Item 2) [Figure 70-80-3].
Remove the DOC (Item 3) [Figure 70-80-3] and the

gasket.
NOTE: Use new clamps (Item 2) [Figure 70-80-3] for

installation.
Installation: Install a new gasket.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
The Exhaust Gas Recirculation (EGR) system circulates some of the exhaust gas from the engine to the intake side, cools
the gas and then delivers the cooled gas to the engine for re-combustion in order to reduce NOx emission.
To reduce NOx emission from the engine, EGR circulates the exhaust gas of which oxygen concentration is very little to
the intake system. As a result, low temperature combustion occurs in the engine and the NOx emission is reduced.
The EGR cooler is used to reduce NOx emission and enhance engine combustion efficiency by reducing temperature of
high-temperature exhaust gas.
Figure 70-90-1
P125020
The air from the air filter (Item 1) is routed to the compressor side (Item 2) of the turbo charger. The compressed air then
flows through the inter cooler (Item 3) to the intake manifold (Item 6) and combustion chamber. Some of the exhaust gas
(Item 7) flows through the EGR valve (Item 8), through the EGR cooler (Item 5) and mixes with the air from the inter cooler
(Item 3). The remaining exhaust gas flows through the turbine (Item 9) side of the turbo charger, through the muffler (DOC)
(Item 10) and out the muffler tail pipe (Item 11) [Figure 70-90-1].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
TURBOCHARGER
Description
The turbocharger is located between the exhaust and

intake manifolds. It is driven by hot exhaust gases and
supplies air at more than atmospheric pressure to the
intake. Lubrication for the turbocharger is supplied with
pressurized oil from the main engine oil galley. The
location of the turbo is between the engine and the
blower housing.
Figure 70-100-1
P121062
The oil is delivered to the turbocharger through a tubeline

(Item 1) and returns to the engine block through a drain
line (Item 2) [Figure 70-100-1].
The turbocharger internal components are not

serviceable.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
DIESEL EXHAUST FLUID (DEF) TANK Figure 70-110-3

Page 10-160-1.)
Figure 70-110-1 1 1
P125366
Remove the two nuts (one is hidden at the back) (Item 1)

[Figure 70-110-2] and reposition the charge filter
assembly.
1
P125203 Figure 70-110-4
Loosen the two bolts (Item 1) and remove the cover (Item
2) [Figure 70-110-1] from the front side of the engine /
hydrostat assembly. 1
Figure 70-110-2
P125190
Loosen the hose clamp (Item 1) [Figure 70-110-4] and

remove the hose.
NOTE: Cap the hoses to prevent coolant from

1 leaking. Mark the hoses for installation.
P125189

2] from the DEF tank.
TH.6534(X) / TH.7035(X) / TH.7038(X)

DIESEL EXHAUST FLUID (DEF) TANK (CONT’D) DEF Tank Fan Removal And Installation
Removal And Installation (Cont’d) Figure 70-110-7
Figure 70-110-5
2
1 1
3
2
P125269
P125264
Remove the four bolts (Item 1) and remove the grid
(Item 2) [Figure 70-110-7].
Remove the electrical connector (Item 1) [Figure 70-110-
5] from the SCR. Figure 70-110-8
Loosen the clamp and remove the hose (Item 2) [Figure

70-110-5].
Remove the two hoses (Item 3) [Figure 70-110-5]. 1
NOTE: Cap the hoses to prevent coolant from

leaking. Mark the hoses for installation.
Figure 70-110-6
1 P125270
Pull out the DEF tank fan (Item 1) [Figure 70-110-8].
2
2
P125265
Attach a strap to the DEF tank lifting eye (Item 1) [Figure

70-110-6].
Remove the three bolts (Item 1) [Figure 70-110-6] and

remove the DEF tank.
NOTE: Approximate weight of the DEF tank is 40 kg

(88 lb).
TH.6534(X) / TH.7035(X) / TH.7038(X)

DIESEL EXHAUST FLUID (DEF) TANK (CONT’D) Figure 70-110-11
Fan Removal And Installation (Cont’d) 1

Figure 70-110-9
5
3
4
1 2
P125190

P125271 110-11] at the back.
Remove the nut and bolt (Item 2) [Figure 70-110-11] to

Disconnect the electrical connector (Item 1) [Figure 70- loosen the clamp.
110-9].
Remove the DEF tank fan. remove the hose.
Coolant Valve Removal And Installation NOTE: Cap the hose to prevent coolant from leaking.
Mark the hose for installation.
Remove the two bolts (Item 4) [Figure 70-110-11] at the
Figure 70-110-10 bottom.

remove the hose.
NOTE: Cap the hose to prevent coolant from leaking.

Mark the hose for installation.
1 1
Remove the coolant valve.
Installation: Note the flow arrow on the coolant valve for

P125366
Remove the two nuts (one is hidden at the back) (Item 1)

[Figure 70-110-2] and reposition the charge filter
assembly.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Dosing Control Unit (DCU) Removal And Installation

1
Remove the fan. (See DEF Tank Fan Removal And
Figure 70-110-12
3
P125277
Remove the ground wire by removing the bolt (Item 1)

2 [Figure 70-110-14].
1 Figure 70-110-15
P125274
1
Lift the lever (Item 1) and remove the electrical connector

(Item 2) [Figure 70-110-12].

carefully take out the DCU.
Figure 70-110-13
2
1
1
P125275
Remove the two bolts (Item 1) and remove the DCU from
the bracket (Item 2) [Figure 70-110-15].
P125276
Disconnect the five electrical connectors (Item 1) [Figure

70-110-13].
TH.6534(X) / TH.7035(X) / TH.7038(X)

DIESEL EXHAUST FLUID (DEF) TANK (CONT’D) Supply Module Filter Removal And Installation
Supply Module Removal And Installation Figure 70-110-18

2
Page 70-110-1.)
Figure 70-110-16
P121225
Remove the filter cover (Item 1) from the supply module

(Item 2) [Figure 70-110-18].
Installation: Tighten the filter cover (Item 1) [Figure 70-

P125272 110-18] to 20 N•m (15 ft-lb) torque.
Figure 70-110-19
Remove the electrical connector (Item 1) [Figure 70-110-
16] from the back of the supply module.
Figure 70-110-17
2
P121226
2
Remove the equalizer element (Item 1) [Figure 70-110-
P125273 19].
Remove the hoses (Item 1) [Figure 70-110-17].
Remove the three nuts and bolts (Item 1) [Figure 70-

110-17].
Remove the supply module.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Supply Module Filter Removal And Installation

(Cont’d)
Figure 70-110-20
P121228
Rotate the filter removal tool clockwise as shown (Item 1)

[Figure 70-110-22].
P121231
Figure 70-110-23
Use the filter removal tool (7267635) [Figure 70-110-20]

to aid in the removal of the filter.
Figure 70-110-21
1
P121230
P121227 Installation: Install new filter and equalizer element.
Insert the filter removal tool (Item 1) [Figure 70-110-21]

into the filter till it clips on guide.
TH.6534(X) / TH.7035(X) / TH.7038(X)

FUEL COOLER Figure 70-120-2

1
Open the engine cover. (See Opening And Closing on 3
Page 10-160-1.)
2
Figure 70-120-1
1
4
3 2 P126010
Clamp the fuel line (Item 1) [Figure 70-120-2] to prevent

leakage.
Loosen the clamp (Item 2) and disconnect the fuel line

P125291 (Item 1) from the fuel cooler (Item 3) [Figure 70-120-2].

Remove the cable tie (Item 1) [Figure 70-120-1].
Clamp the fuel line (Item 2) [Figure 70-120-1] to prevent to 43 - 47 N•m (32 - 35 ft-lb) torque.
leakage.
Remove the fuel cooler.
Loosen the clamp (Item 3) and disconnect the fuel line
(Item 2) [Figure 70-120-1].
WARNING
WARNING AVOID INJURY OR DEATH
AVOID INJURY OR DEATH sparks or lighted tobacco away from fuel and oil.
Diesel fuel or hydraulic fluid under pressure can Failure to use care around combustibles can cause
penetrate skin or eyes, causing serious injury or explosion or fire.
death. Fluid leaks under pressure may not be visible. W-2103-0508
W-2072-0807
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
HEATING, VENTILATION, AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-5
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Air Conditioning Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-5
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-6
A/C SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1

Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1
The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-5
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-6
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-4
Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-5
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

TH.6534(X) / TH.7035(X) / TH.7038(X)

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

TH.6534(X) / TH.7035(X) / TH.7038(X)

AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-2.).
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the blower fan (Item
6) (See Chart on Page 80-10-2.). Since the refrigerant is colder than the air, it absorbs the heat from the air and produces
cooled air, which is pushed into the cab by the blower fan. The moisture in the air condenses on the evaporator coil and
drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
TH.6534(X) / TH.7035(X) / TH.7038(X)

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
TH.6534(X) / TH.7035(X) / TH.7038(X)

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
Figure 80-10-1
1
P125341
1
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P125308 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C System (compressor) is

recommended to be turned on for at least 5 1
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2
S39158
Pressure Switch: The pressure switch (Item 1)

[Figure 80-10-4] is located on the receiver / drier
assembly (Item 1) [Figure 80-10-3]. It will disengage the
compressor clutch if the pressure readings are too low or
too high, which indicates loss of refrigerant.
P125314
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Components (Cont'd)
Figure 80-10-5
1 3 2
S38151
1. Blower Fan Switch - This is a four position switch

P125381 (Item 1) [Figure 80-10-7]. When the blower fan
switch is in the OFF position the A/C will not engage.
Evaporator Unit: The evaporator unit (Item 1) [Figure 80-
2. Temperature Control - Turn the knob (Item 2)
10-5] is located under the operator seat inside the cab.
[Figure 80-10-7] clockwise to increase cab
The unit delivers the cold air for the A/C into the cab. The
temperature; counterclockwise to decrease.
unit also contains the blower fan, evaporator coil and
thermostat which are not serviceable.
3. Air Conditioning Switch - Press the top of the switch
(Item 3) [Figure 80-10-7] to turn the Air Conditioning
Figure 80-10-6
ON - Press the bottom of the switch to turn the Air
Conditioning OFF.
P125341
Expansion Valve: The expansion valve (Item 1)

[Figure 80-10-6] controls the amount of refrigerant
entering the evaporator coil.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Safety Equipment
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
Figure 80-10-8
P-16398
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -6°C (21.6°F)
DEGREES "INSTANTLY". If it spills on your skin or in
your eyes you should flood the area with cool water and
SEEK MEDICAL ATTENTION FAST! It is a good idea to
P-16398 wear gloves [Figure 80-10-9] to prevent frost bite if you
should get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-10-
8] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gauge set
WARNING
connectors. Safety glasses or a transparent face shield
are practical safety Items and one or the other is HFC R-134a refrigerant can be dangerous if not
absolutely required. properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
WARNING when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
In the event of a leak, wear safety goggles. Escaping even small amounts of R-134a in the air.
refrigerant can cause severe injuries to eyes. In Any servicing work that involves release or addition
contact with a flame, R-134a refrigerant gives a toxic of R-134a to the system must be done by a
gas. competent refrigeration dealer who has the proper
W-2371-0611 equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
REGULAR MAINTENANCE Recirculation Filter
Filters Figure 80-20-3
Fresh Air Filter

2
Figure 80-20-1
1
1
1
S38736
The recirculation filter is located below the operator’s seat

S40653 inside the operator cab. Remove the two screws (Item 1)
and remove the filter cover (Item 2) [Figure 80-20-3].
The fresh air filter is located on the side of the operator Figure 80-20-4
cab. Remove the two screws (Item 1) and filter cover
(Item 2) [Figure 80-20-1].
Figure 80-20-2
1
S38737
Shake the filter (Item 1) [Figure 80-20-4] or use a

S40654 vacuum to clean. This can be done several times before
replacement is required.
Remove the filter (Item 1) [Figure 80-20-2]. Install the filter (Item 1) [Figure 80-20-4] onto the filter
cover (Item 2) [Figure 80-20-3] and install the filter cover
Clean or replace the filter as necessary. with the two screws (Item 1) [Figure 80-20-3].
TH.6534(X) / TH.7035(X) / TH.7038(X)

REGULAR MAINTENANCE (CONT’D) Belt Replacement
Air Conditioning Belt Adjustment Stop the engine and open the engine cover. (See
The air conditioning belt is a special maintenance free
type that is pretensioned over the pulleys. This belt Figure 80-20-5
eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your Massey
Ferguson dealer for replacement parts.
P115128
A belt tool (Item 1) [Figure 80-20-5] is required to install

the new air conditioning belt. See your Massey Ferguson
dealer.
Figure 80-20-6
P125196

80-20-6].
TH.6534(X) / TH.7035(X) / TH.7038(X)

REGULAR MAINTENANCE (CONT’D) Figure 80-20-9
Belt Replacement (Cont’d)
Figure 80-20-7
4
3
1
1
2
P121970
1
Install the belt on the air conditioning compressor pulley

P123728 and position the belt (Item 1) and belt tool (Item 2) on the
bottom side of the crank shaft pulley (Item 3) [Figure 80-
20-9].
Remove the two bolts (Item 1) and belt cover (Item 2)
[Figure 80-20-7]. Rotate the engine clockwise using the large crankshaft
pulley bolt (Item 4) [Figure 80-20-9]. Do NOT use the
Figure 80-20-8 alternator pulley nut, the water pump pulley bolts, or the
smaller crankshaft pulley bolts. Ensure that the belt is
fully installed on both pulleys. Repeat the procedure if
1 necessary.
Remove the belt tool. Install the air conditioning belt

shield and mounting nuts [Figure 80-20-7].
Install cover [Figure 80-20-6].
P126362
Cut the old belt (Item 1) [Figure 80-20-7] and remove the
belt from the pulleys. Inspect the pulleys for wear.
TH.6534(X) / TH.7035(X) / TH.7038(X)

REGULAR MAINTENANCE (CONT’D) Air Conditioning Lubrication
Cleaning The Condenser Run the air conditioning for about 5 minutes every week
to lubricate the internal components.
Figure 80-20-10
P123744
Loosen the bolt (Item 1) [Figure 80-20-10].
Figure 80-20-11
P123745
Raise the condenser (Item 1) and keep in position by

installing the rod (Item 2) [Figure 80-20-11] in the
condenser mount.
Use low air pressure to clean the condenser (Item 1)

[Figure 80-20-11]. Be careful not to damage fins.
Remove the rod (Item 2) [Figure 80-20-11], lower the

condenser and tighten the bolt (Item 1) [Figure 80-20-
10].
TH.6534(X) / TH.7035(X) / TH.7038(X)

REGULAR MAINTENANCE (CONT’D)
Air Conditioning Service Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain services required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
TH.6534(X) / TH.7035(X) / TH.7038(X)

Evaporator / Heater Coil

1
2
Figure 80-20-12 3
2
1
S38206

2
Remove the retainer screws (Item 2) and remove the
1 cover (Item 3) [Figure 80-20-14].
P125381
Figure 80-20-15
Remove the two screws (Item 1) [Figure 80-20-12].

2
1
Figure 80-20-13
3 1
2 S38203
Remove the bolts (Item 1) and ground wire (Item 2)

1 [Figure 80-20-15].
P125371
Disconnect the connector (Item 1) and the tubes (Items

2) [Figure 80-20-13].
Remove the fluid reservoir (Item 3) [Figure 80-20-13] by

sliding it upward.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Evaporator / Heater Coil (Cont’d)

1
Figure 80-20-16
2
1
S39214
1
Use low pressure air or water to remove debris from the
P125382 heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-18]. Be careful not to damage fins.
Remove the four bolts (Item 1) [Figure 80-20-16].
Remove the frame (Item 2) [Figure 80-20-16].
Figure 80-20-17
S39213
Remove the nine cover screws (Item 1) and remove the

TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
A/C SYSTEM TROUBLESHOOTING
Blower Motor Does Not Operate
POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse / wiring. Replace fuse / repair
wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Evaporator /
Blower Unit.
4. Fan Motor switch Check power into and out of the Fan switch. Replace Fan Switch.
malfunction.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and
obstruction clean evaporator fins with
air or water.
2. Defective thermo. Check thermostat using a circuit tester. Replace Evaporator /
switch (frozen Blower unit.
evaporator).
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on The high side pressure will be low and bubbles can be present Repair any leaks and
refrigerant. in sight glass on receiver / drier. recharge the refrigerant to
the correct level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic
clutch.
5. Oil on the clutch Clutch slips. Replace or clean the
surface. clutch surface.
6. Open coil. Clutch does not engage and there is no reading when a circuit Replace clutch.
tester is connected between the coil and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and connections. Repair.
ground.
8. Wiring harness Test the conductance of the pressure switch, thermostat, relay, Check operation.
components. etc.
TH.6534(X) / TH.7035(X) / TH.7038(X)

A/C SYSTEM TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 2000 rpm are:
High pressure side pressure: 1,45 - 1,83 MPa (14.47 - 18,27 bar) (210 - 265 psi)
Low pressure side pressure: 0,10 - 0,23 MPa (1,03 - 2,27 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve opens Frost is present on the suction hose. Replace expansion valve
too far.
2.Defective compressor The high and low pressure side gauge pressures Replace compressor.
equalize when the magnetic clutch is disengaged.
Low pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles can be Repair any leaks and recharge
present in sight glass on receiver / drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve's inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other contaminants can be the cause. valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion negative low pressure reading can be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Replace Evaporator / Blower unit.
tion.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fan not Clean fins, and / or repair the fan.
formance. operating.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the correct
refrigerant level.
3. Excessive oil charge The high pressure side will be high. Evacuate system. Remove oil
from condenser and compressor.
Measure oil from compressor
and add correct oil charge back
into compressor. Flush system
with nitrogen. Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high will be low. replacing defective parts.
pressure line.
TH.6534(X) / TH.7035(X) / TH.7038(X)

A/C SYSTEM TROUBLESHOOTING (CONT’D)
Gauge Pressure Related Troubleshooting (Cont’d)

High pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles can be Repair any leaks and recharge
present in sight glass on receiver / drier. the refrigerant to the correct
level.
System pressures Equal
1. Clutch not operating See magnetic clutch related topics above.
2.Compressor not pump- Equal high and low pressures. Replace compressor.
ing.
TH.6534(X) / TH.7035(X) / TH.7038(X)

A/C SYSTEM TROUBLESHOOTING (CONT’D)
Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP °C (°F) PSIG TEMP °C (°F) PSIG
-8,9 (16) 15.69 33,9 (93) 110.20
-7,8 (18) 17.04 34,4 (94) 112.10
-6,7 (20) 18.43 35 (95) 114.10
-5,6 (22) 19.87 37,8 (100) 124.30
-4,4 (24) 21.35 38,9 (102) 128.50
-3,3 (26) 22.88 40 (104) 132.90
-2,2 (28) 24.47 41,1 (106) 137.30
-1,1 (30) 26.10 42,2 (108) 141.90
0 (32) 27.79 43,3 (110) 146.50
1,1 (34) 29.52 44,4 (112) 151.30
2,2 (36) 31.32 45,6 (114) 156.10
3,3 (38) 33.17 46,7 (116) 161.10
4,4 (40) 35.07 47,8 (118) 166.10
5,6 (42) 37.03 48,9 (120) 171.30
6,7 (44) 39.05 50 (122) 176.60
7,2 (45) 40.09 51,1 (124) 182.00
10 (50) 45.48 52,2 (126) 187.50
12,8 (55) 51.27 53,3 (128) 193.10
15,6 (60) 57.47 54,4 (130) 198.90
18,3 (65) 64.10 57,2 (135) 213.70
21,1 (70) 71.19 60 (140) 229.40
23,9 (75) 78.75 62,8 (145) 245.80
26,7 (80) 86.80 65,6 (150) 263.00
29,4 (85) 95.40 68,3 (155) 281.10
32,2 (90) 104.40 71,1 (160) 300.10
32,8 (91) 106.30 73,9 (165) 320.10
33,3 (92) 108.20 76,7 (170) 340.80
Evaporator
Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add 12,2 - 13,3°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40°F to the ambient temperature to get
the condensing temperature and then see the pressure chart to see appropriate pressure for ambient temperature.
Example: Ambient Temperature = 32,2°C (90°F)

32,2°C (90°F)
+ 4,4°C (40°F)
54,4°C (130°F) condenser temperature = 200 psig.
Conditions and pressures will vary from system to system.
TH.6534(X) / TH.7035(X) / TH.7038(X)

A/C SYSTEM TROUBLESHOOTING (CONT’D) Inspect the A/C condenser for dirt or mud, and clean if
necessary. (See Cleaning The Condenser on Page 80-
Poor A/C Performance 20-4.)
Start the telescopic handler, engage the parking brake. Inspect the sight glass (Item 2) [Figure 80-30-3] located
Engage the A/C system with the Blower Fan on high. Run on the receiver / drier for air bubbles.
the telescopic handler at full rpm for approximately 15
minutes, with the cab door closed. HVAC Repair And Leaks
1
2
1
P126565 P125341
Figure 80-30-2 Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /
drier (Item 1) [Figure 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.
P-27746
Check the temperature at the louvers (Item 1)

[Figure 80-30-1] with a thermometer [Figure 80-30-2].
The louver temperature should be between 2,2 - 11,6°C

(36 - 53°F) depending on the amount of humidity in the
air.
If the louver temperature is too high. (See A/C SYSTEM

TROUBLESHOOTING on Page 80-30-1.)
Inspect the Blower Fan for proper operation or noise, and

replace if necessary. (See EVAPORATOR / HEATER
UNIT on Page 80-90-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

A/C SYSTEM TROUBLESHOOTING (CONT'D) Figure 80-30-6
Electrical System
Figure 80-30-4 1
S38028
If the compressor clutch does not engage, inspect the

P123728 fuse (Item 1) [Figure 80-30-6]. Replace the fuse if
needed.
Check to see if the compressor clutch (Item 1) is
Figure 80-30-7
engaging. The clutch is located inside the pulley which is
protected by the cover (Item 2) [Figure 80-30-4].
Turn the Ignition key switch to the RUN position without

starting the machine.
Figure 80-30-5
2
1
P125307
Disconnect the connector (Item 1) [Figure 80-30-7] from

the compressor.
S38151
Press the top of the switch (Item 1) [Figure 80-30-5] to

activate the air conditioning.
Turn the Blower Fan switch (Item 2) [Figure 80-30-5] to

the first ON - position. The compressor clutch should
make a click sound, which indicates the clutch is
engaging.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Electrical System (Cont'd)
Figure 80-30-8
1
2
1
P125341
Disconnect the machine harness (Item 1) [Figure 80-30-

P125309 10] from the pressure switch.
Using a multimeter, check the terminals (Item 1)

With a multimeter check the resistance to the compressor [Figure 80-30-10] for voltage.
clutch connector (Item 1) [Figure 80-30-8].
NOTE: The Key switch must still be in the run
If there is no resistance value replace the compressor position (engine off) and the Blower Fan
clutch. (See Clutch Disassembly And Assembly on Page switch to the first ON position.
80-50-5.)
The voltage should be around 12 volt.
Figure 80-30-9
If there is no voltage at the wiring harness, inspect the
harness for broken wires.
1 If there is voltage at the harness, inspect the resistance

at the pressure switch (Item 2) [Figure 80-30-10].
If there is no resistance value, check for a low refrigerant

level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-40-1.)
If a resistance value is seen, the pressure switch is good.
Connect the machine harness to the pressure switch.
P125309
With a multimeter, check the voltage (12V) to the

compressor clutch at the main harness (Item 1)
[Figure 80-30-9].
If there is no power at the clutch, check the wiring

If there is power at the clutch, connect the wiring harness

to the compressor clutch.

TH.6534(X) / TH.7035(X) / TH.7038(X)


1
Figure 80-30-11
P125341
Disconnect the blower wiring connector (Item 1)

P125341 [Figure 80-30-12] from the machine harness.
Figure 80-30-13
Disconnect the thermostat wiring connector (Item 1)
[Figure 80-30-11] from the machine harness.
1
Check the machine harness (Item 1) [Figure 80-30-11]
for voltage. The voltage should be 12 volt.

If there is voltage at the wiring harness, check the

thermostat wire (Item 2) [Figure 80-30-11] for resistance.
The resistance value should be 10 ohm at 20°C (68°F).
If there is no resistance value, replace the thermostat. S42166

(See Removal And Installation on Page 80-100-2.)
Check the machine harness (Item 1) [Figure 80-30-13]

for voltage (between two outer terminals). The voltage
should be 12 volt.

If there is voltage at the wiring harness, check the

resistance to the blower at the blower wiring connector
(Item 1) [Figure 80-30-12].
If there is no resistance value replace the blower.
If there is a resistance value check the climate controls at

the control panel inside the loader cab.
TH.6534(X) / TH.7035(X) / TH.7038(X)


1
Figure 80-30-14
S36342
1 1
Check the main harness (Item 1) [Figure 80-30-16] for
2 voltage. The voltage should be 12 volt, if there is no
voltage inspect the harness for broken wires.
S38151
Figure 80-30-17
Remove the four screws (Item 1) [Figure 80-30-14].

H C
Installation: Tighten screws (Item 1) [Figure 80-30-14]
to 2 N•m (18 in-lb) torque.
Remove the panel (Item 2) [Figure 80-30-14]. B

M
Figure 80-30-15
L
1
N-22288
If there is voltage at the main harness check the Blower

Fan switch [Figure 80-30-17] for resistance.
With the switch in the OFF position, there should be zero

resistance between all terminals.
With the switch in the 1 position, there should be

resistance between C terminal and the B terminal. And
S36341 also between the C terminal and the L terminal frame
[Figure 80-30-17].
Disconnect the main wire harness connector (Item 1) With the switch in the 2 position, there should be
[Figure 80-30-15] from the switch. resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-17].
With the switch in the 3 position, there should be

resistance between C terminal and the B terminal. And
also between the C terminal and the H terminal frame
[Figure 80-30-17].
If any of the above resistance tests fail, replace the

Blower Fan switch.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
SYSTEM CHARGING AND RECLAMATION Figure 80-40-2

Unit
1
Page 10-160-1.)
Figure 80-40-1
N-23024
1
2 NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the refrigerant that
is in the A/C system and if it is pure enough to
use. The tool MEL1592, Refrigerant Identifier
(Item 1) [Figure 80-40-2] will determine, the
P125257 kind of refrigerant and any possible harmful
or dangerous substances that can be present
in the system. Thus preventing mixing of
Locate the low pressure port (Item 1) and high pressure dangerous material with your reclaimed R-
port (Item 2) [Figure 80-40-1] on the back side of the 134a in your reclaimer, and further
compressor. contamination to other A/C systems that are
reclaimed and charged from your MEL 1581
Recovery / Recycling / Recharging Machine.
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
NOTE: This procedure is run with the engine off, and

the A/C switch in the OFF position.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SYSTEM CHARGING AND RECLAMATION (CONT'D)

Unit (Cont'd)
WARNING
Figure 80-40-3 In the event of a leak, wear safety goggles. Escaping
gas.
W-2371-0611
WARNING
1
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
P125257 • Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
Remove the protective cap and connect the refrigerant substances.
identifier to the low pressure hose (Item 1) [Figure 80- • NEVER SMOKE when there is the possibility of
40-3]. even small amounts of R-134a in the air.
Any servicing work that involves release or addition
Connect the refrigerant identifier to its power source. of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
Follow the steps displayed on the refrigerant identifier equipment, knowledge, and experience to service
screen [Figure 80-40-2]. refrigeration equipment.
W-2373-0611
Allow 2 minutes for the refrigerant identifier to display the

type of refrigerant and air content. An alarm will sound if Figure 80-40-4
potentially flammable hydrocarbons are present and will
also indicate on the visual display.
Disconnect the refrigerant identifier from the telescopic

handler A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safely disposed of.
If R-134a is found, evacuate the system.
IMPORTANT: Only A/C trained technicians should

perform the reclaiming and recharging
procedure. N-22291
Use an approved recovery / charging unit [Figure 80-40-

4] to evacuate the system.
Connect the reclaimer to the A/C charge ports.
TH.6534(X) / TH.7035(X) / TH.7038(X)

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-7

Unit (Cont'd)
Figure 80-40-5
2 1
N-22381
NOTE: The reclaimer unit, has a complete step by

step set of instructions [Figure 80-40-7] to
P125258 follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they can vary
Connect the Red hose (Item 1) [Figure 80-40-5] to the slightly depending on the model and brand of
high pressure port and open the valve. reclaimer used.
Connect the Blue hose (Item 2) [Figure 80-40-5] to the

low pressure port and open the valve.
Figure 80-40-6
N-22292
Turn the reclaimer unit to the ON position and follow the

on screen instructions [Figure 80-40-6].
NOTE: The A/C system holds 1,13 kg (2 lb) of

refrigerant R-134a.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
COMPRESSOR Figure 80-50-3
Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 80-40-1.)

1
Figure 80-50-1
2
P125307
Disconnect the connector (Item 1) [Figure 80-50-3] from

the compressor.
1
Figure 80-50-4
P125308
Remove the two bolts (Item 1) and belt cover (Item 2)

[Figure 80-50-1].
Figure 80-50-2
P125309
2 Remove the compressor hoses (Item 1) [Figure 80-50-

4].
1 NOTE: Cap and plug the hoses and fittings with the
proper A/C caps and plugs.
Installation: Tighten the hoses (Item 1) [Figure 80-50-4]

P125196
to 20 - 27 N•m (15 - 20 ft-lb) torque.

80-50-2].
TH.6534(X) / TH.7035(X) / TH.7038(X)

COMPRESSOR (CONT'D) Figure 80-50-7

1 2
Figure 80-50-5
1 3
P125312
Remove the top front compressor mounting bolt and nut

P125312 (Item 1) [Figure 80-50-7].
Tilt the compressor (Item 2) until the air conditioning belt

Loosen the bottom front mounting bolt and nut (Item 1) (Item 3) [Figure 80-50-7] can be removed. Remove the
[Figure 80-50-5] from the compressor. air conditioning belt.
Figure 80-50-6 Remove the bottom front mounting bolt (Item 1) [Figure
80-50-5] and the bottom rear mounting bolt (Item 1)
[Figure 80-50-6]. Remove the compressor.
Figure 80-50-8
P125310
Loosen the bottom rear mounting bolt (Item 1) [Figure

80-50-6].
P125311
Installation: Install the bottom front mounting bolt

(Item 1) [Figure 80-50-8] and bottom rear mounting bolt
(Item 1) [Figure 80-50-6]. Do not tighten yet.
TH.6534(X) / TH.7035(X) / TH.7038(X)

COMPRESSOR (CONT'D) Oil
Removal And Installation (Cont’d) Figure 80-50-10
Figure 80-50-9
S39173
P123742
The compressor (Item 1) [Figure 80-50-10] is factory

Installation: Use a prybar (Item 1) on the compressor to filled with 150 - 170 cm3 (9.15 - 10.37 in3) of PAG oil
tension the air conditioning belt until the top front (Poly Alkelene Glycol).
mounting bolt (Item 2) [Figure 80-50-9] and nut can be
installed and tightened. Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
1. When the evaporator, condenser or receiver / drier is

replaced.
2. When refrigerant has leaked from the system.
3. When refrigerant is suddenly released from the

cooling cycle.
4. When any related problems occur in the cooling cycle.
When one of the components (the evaporator, condenser

or receiver / drier) is replaced, 30 cc (1 U.S. fl oz) of PAG
oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

and R-134a oils.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Oil Check
The compressor oil should be checked as follows when 1

oil is being added to an in service machine.
There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run-in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND S39175
RECLAMATION on Page 80-40-1.)
Open the cab door and windows. Remove the oil drain plug (Item 1) [Figure 80-50-11] and
drain the oil through the connectors (Item 1) [Figure 80-
Run the blower fan at maximum speed. 50-12] and the oil drain hole (Item 1) [Figure 80-50-11].
Run the compressor for at least 20 minutes at 800 - 1200 Installation: Tighten the oil drain plug to 13 - 15 N•m (9 -
rpm. 11 ft-lb) torque.
Remove the compressor from the machine. (See Figure 80-50-13

Figure 80-50-11
1
S39176
NOTE: After draining the oil through the drain hole

S39174
and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
13] several times by hand.
Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
TH.6534(X) / TH.7035(X) / TH.7038(X)

COMPRESSOR (CONT'D) Clutch Disassembly And Assembly
Oil Check (Cont'd) Figure 80-50-15
Figure 80-50-14
1
P-27519
S39175
Remove the center armature nut (Item 1) [Figure 80-50-
15].
Add new compressor oil through the suction side
connector (Item 1) [Figure 80-50-14]. Assembly: Tighten the armature nut to 12 N•m (8 ft-lb)
torque.
Installation: Add 150 - 170 cm3 (9.15 - 10.37 in3) of PAG
oil. Figure 80-50-16
NOTE: The suction port on the compressor is marked

with an S and is the large port on the
compressor. 1
P-27520
To remove the armature plate (Item 1) [Figure 80-50-16]

from the clutch face you must make an armature plate
puller.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-17
8 mm 8 mm (1.25”)
(1.25”)
P-27521
1
8 mm
(1.25”) Attach a slide hammer puller to the armature puller tool
P-27524 [Figure 80-50-19].
Figure 80-50-20
The armature plate puller (Item 1) [Figure 80-50-17] can
be constructed by drilling three 8 mm (0.315 in) holes in a
flat circular plate, located 31,75 mm (1.25 in) apart.
Figure 80-50-18
2 1
P-27523
2
Remove the armature plate (Item 1) [Figure 80-50-20]
from the compressor clutch.
P-27522
Remove the shims (Item 2) [Figure 80-50-20] from the
armature shaft or armature plate.
Attach the armature puller plate (Item 1) to the armature
plate using the three bolts (Item 2) [Figure 80-50-18]. Assembly: Insure that the clutch has the correct
clearance by adding the shims (Item 2) [Figure 80-50-
20].
The specified clearance for the clutch is 0,3 - 0,6 mm

(0.01 - 0.02 in) adjusting shims are available in the
following thicknesses.
0,1 mm (0.0039 in)

0,3 mm (0.0118 in)
0,5 mm (0.0197 in)
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 80-50-21
P-27527
The pulley assembly and bearing [Figure 80-50-23] must

P-27525 be replaced as a complete unit.
Figure 80-50-24
the pulley assembly.
Figure 80-50-22
1
2
P-27528
Remove the lock (Item 1) and connector (Item 2) [Figure

P-27526 80-50-24] from the compressor harness.
Remove the pulley from the compressor [Figure 80-50-

22].
TH.6534(X) / TH.7035(X) / TH.7038(X)

Figure 80-50-25
P-27531
Remove the coil from the compressor [Figure 80-50-27].

P-27529
Figure 80-50-28
Remove the harness retainer screw assembly (Item 1)

[Figure 80-50-25].
Figure 80-50-26
P-27527
1
The compressor [Figure 80-50-28] must be replaced as
a complete unit.
P-27530

the coil.
TH.6534(X) / TH.7035(X) / TH.7038(X)

CONDENSER Figure 80-60-2

Unit on Page 80-40-1.) 1 1
WARNING
P125266
gas.
W-2371-0611
Remove the two bolts and nuts (Item 1) [Figure 80-60-2]

Figure 80-60-1 from each side of the condenser.
Figure 80-60-3
1 1
2
1
P125267
P125268
Remove the two hose (Item 1) [Figure 80-60-1] from the
condenser.
Loosen the bolt (Item 1) [Figure 80-60-3].
NOTE: Install caps and plugs on all fittings.
Remove the condenser (Item 2) [Figure 80-60-3].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
RECEIVER / DRIER Figure 80-70-2

Page 10-160-1.)
Remove the refrigerant from the A/C system. (See 1

SYSTEM CHARGING AND RECLAMATION on Page 80-
40-1.) 1

2
P125381
WARNING
Remove the two retainer screws (Item 1) and remove the
In the event of a leak, wear safety goggles. Escaping cover (Item 2) [Figure 80-70-2].
contact with a flame, R-134a refrigerant gives a toxic Figure 80-70-3
gas.
W-2371-0611
2
Figure 80-70-1 3
S39210
Loosen the screws (Item 1) [Figure 80-70-3] on the two

P125341 clamps.
Remove the tubeline (Item 2) [Figure 80-70-3] from the

Disconnect the two connectors (Item 1) [Figure 80-70-1] receiver / drier.
from the pressure switch.
Remove the receiver / drier (Item 3) [Figure 80-70-3].
receiver / drier.
NOTE: Install caps and plugs on all fittings.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
PRESSURE SWITCH

Page 10-160-1.)

40-1.)

WARNING
gas.
W-2371-0611
Figure 80-80-1
2 2
P125341
S38200
Disconnect the two connectors (Item 1) from the

pressure switch (Item 2) [Figure 80-80-1].
Remove the pressure switch (Item 2) [Figure 80-80-1]

from the receiver / drier assembly.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
EVAPORATOR / HEATER UNIT Figure 80-90-2

5
40-1.)
4 3
WARNING
refrigerant can cause severe injuries to eyes. In 2
contact with a flame, R-134a refrigerant gives a toxic 1
gas.
P125341
W-2371-0611
Remove the operator seat. (See OPERATOR SEAT on Remove the A/C hose (Item 1) from the drier, and the A/C
Page 50-20-1.) hose (Item 2) [Figure 80-90-2] from the expansion valve.
Figure 80-90-1 NOTE: Plug the A/C hoses to prevent contamination.
Remove the heater hoses (Items 3 and 4) [Figure 80-90-

2] from the heater.
Disconnect the blower wiring connector (Item 5)

[Figure 80-90-2] from the machine harness.
Figure 80-90-3
1
1
S39211
Disconnect the thermostat wiring connector (Item 1)

[Figure 80-90-1].
2
1
P125381
TH.6534(X) / TH.7035(X) / TH.7038(X)

EVAPORATOR / HEATER UNIT (CONT’D) Figure 80-90-6

2
Figure 80-90-4
1
4
1
3 1
S38203
2
P125371 [Figure 80-90-6].
Figure 80-90-7
Disconnect the connector (Item 1) and the tubes (Items 2
and 3) [Figure 80-90-4].
Remove the fluid reservoir (Item 4) [Figure 80-90-4] by 2

sliding it upward.
Figure 80-90-5 1
1
2
1
3
P125382
Remove the four bolts (Item 1) [Figure 80-90-7].

2
Remove the frame (Item 2) [Figure 80-90-7].
S38206

TH.6534(X) / TH.7035(X) / TH.7038(X)

EVAPORATOR / HEATER UNIT (CONT’D) Figure 80-90-10
Figure 80-90-8 2
1
1
S38212
2 Lift the rubber cover (Item 1) and retract the flexible hose
S38213 (Item 2) [Figure 80-90-10].
Figure 80-90-11
Remove the screws (Item 1) and remove the cover
(Item 2) [Figure 80-90-8].
Figure 80-90-9
2
3
2
1 S38209
S38210
Remove the two bolts (Item 1) [Figure 80-90-11] on the

S38211 left side of the evaporator / blower unit.
Remove the two bolts on the right side of the evaporator /

Remove the screws (Item 1) [Figure 80-90-9]. blower unit (Item 2) [Figure 80-90-11] (Inset).
Loosen the clamp (Item 2) and retract the flexible hose Remove the evaporator / blower unit from the machine.
(Item 3) [Figure 80-90-9].
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
THERMOSTAT The EDT has the following protection built in:
Description 1. Over temperature
The Electronic De-icing Thermostat (EDT) is a micro 2. Overcurrent from clutch output
controller based module that measures evaporator coil
temperature and cycles the compressor clutch to 3. Voltage (Above and below operational limits or
maintain a constant evaporator pressure. Onboard circuit reverse voltage)
protection and diagnostics are also built into the module.
4. Short circuit protection (Output shorted to ground)
NOTE: The EDT has a 6 second delay before start up
to protect the compressor clutch. 5. Temperature sensor open and short detection
The EDT will turn the clutch on when the evaporator coil
DETECTION
temperature is above 2°C (35.6°F). If the EDT does not MALFUNCTION STATUS LED
INTERVAL
detect any malfunction, it will continue to operate and the
status LED will be lit continuously. When the evaporator Temperature Continuous 1x per second
temperature is below -2°C (28.4°F), the EDT will turn off sensor open or
the clutch and status LED. short circuit
Clutch output At A/C start up 2x per second
Figure 80-100-1 open, short circuit
or over-current
Compressor Continuous 3x per second
clutch short to
ground
1
P90576
When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 80-
100-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over-
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.
TH.6534(X) / TH.7035(X) / TH.7038(X)

THERMOSTAT (CONT’D) Figure 80-100-4

1
Remove the operator seat. (See OPERATOR SEAT on
2
Page 50-20-1.)
NOTE: The thermostat can be changed without 3

evacuating the A/C system, or removing the
evaporator / heater unit from the loader.
Figure 80-100-2
2
S38206
1 Remove the bolt (Item 1) [Figure 80-100-4].

2 Figure 80-100-5
1
2
P125381
1
Figure 80-100-3
S38203
3

[Figure 80-100-5].
2
P125371
Disconnect the connector (Item 1) and the tubes (Item 2)

[Figure 80-100-3].
Remove the fluid reservoir (Item 3) [Figure 80-100-3] by

sliding it upward.
TH.6534(X) / TH.7035(X) / TH.7038(X)

THERMOSTAT (CONT’D) Figure 80-100-8
Figure 80-100-6
1 1 1
1
1
1
2 1
S39211
Remove the thermostat (Item 1) [Figure 80-100-8] from

S38209 the evaporator / heater unit.
Remove the nine screws (Item 1) and remove the cover

(Item 2) [Figure 80-100-6].
Figure 80-100-7
S39241
Remove the thermostat probe (Item 1) [Figure 80-100-7]

from the A/C evaporator coil.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
EXPANSION VALVE Figure 80-110-2

40-1.) 1
WARNING
refrigerant can cause severe injuries to eyes. In 2
gas.
S39212
W-2371-0611
Remove the operator seat. (See OPERATOR SEAT on Remove the two mount bolts (Item 1) from the expansion
Page 50-20-1.) valve (Item 2) [Figure 80-110-2].
Figure 80-110-1 Remove the expansion valve (Item 2) [Figure 80-110-2].
The expansion valve (Item 2) [Figure 80-110-2] is

1 replaced as a complete unit.
1
2
1
1
P125341
S38214
Remove the A/C hoses (Item 1 and Inset) from the

expansion valve (Item 2) [Figure 80-110-1].
NOTE: Plug the A/C hoses to prevent contamination.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
SPECIFICATIONS
(TH.6534(X)) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Visibility Diagrams - 20” Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Visibility Diagrams - 24” Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
(TH.7035(X)) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . .SPEC-10-10

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-10
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-11
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-11
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-12
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-12
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-13
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-13
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-13
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-13
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-14
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-14
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-14
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-14
Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-14
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-15
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-16
Visibility Diagrams - 20” Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-17
TH.6534(X) / TH.7035(X) / TH.7038(X)

SPEC-01 Service Manual
(TH.7038(X)) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . .SPEC-10-19
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-19
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-20
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-20
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-21
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-21
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-22
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-22
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-22
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-22
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-23
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-23
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-23
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-23
Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-23
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-24
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-25
MACHINE TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Drive Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-5
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
TH.6534(X) / TH.7035(X) / TH.7038(X)

SPEC-02 Service Manual
(TH.6534(X)) TELESCOPIC HANDLER SPECIFICATIONS
Dimensions are given for machine equipped with standard tires and can vary with other tire types.
Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Machine Dimensions
(A) Overall length (with forks) 5874 mm (231.3 in)
(B) Overall length (without attachment carrier) 4669 mm (183.8 in)
(C) Overall length (to carrier pin) 4653 mm (183.2 in)
(D) Overall length (to front tires) 4058 mm (159.8 in)
(E) Overall height (with rotating beacon) 2477 mm (97.5 in)
(F) Overall height 2290 mm (90.2 in)
(G) Carriage rotation angle 135°
(H) Height to back of the machine 1668 mm (65.7 in)
(I) Ground clearance 346 mm (13.6 in)
(J) Front axle to front carriage 1156 mm (45.5 in)
(K) Wheelbase 2870 mm (113.0 in)
(L) Rear axle to back of machine 643 mm (25.3 in)
(M) Operator cab outside width 1013 mm (39.9 in)
(N) Track width (front and rear) 1895 mm (74.6 in)
(O) Width over standard tires 2300 mm (90.6 in)
(P) External turning radius (with forks spaced 1040 mm [40.9 in] ext.) 4758 mm (187.3 in)
(Q) External turning radius (at tires) 3714 mm (146.2 in)
(R) Internal turning radius (at cab) 1092 mm (43.0 in)
Operator cab inside width 900 mm (35.4 in)
TH.6534(X) / TH.7035(X) / TH.7038(X)

SPEC-10-1 Service Manual
(TH.6534(X)) TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)
Performance
Crowding force - Tilt (ISO8313) 6200 daN (13938 lbf)

Crowding force - Lift (ISO8313) 3800 daN (8542 lbf)
Drawbar pull 7900 daN (17759 lbf)
Rated load capacity* 3400 kg (7497 lb)
Capacity (at maximum height) 3400 kg (7497 lb)
Capacity (at maximum reach) 1300 kg (2867 lb)
Tipping load (at maximum reach) 1600 kg (3528 lb)
Lifting height (forks) 6331 mm (249.3 in)
Maximum reach (forks, COG 500 mm [19.7 in]) 3369 mm (132.6 in)
Max. reach (forks, COG 500 mm [19.7 in], max. height) 726 mm (28.6 in)
Travel Speed in First / Second Gear (TH.6534)
- Low range 0 - 5 km/h (0 - 3.1 mph) / 0 - 14 km/h (0 - 8.7 mph)
- High range 0 - 10 km/h (0 - 6.2 mph) / 0 - 26 km/h (0 - 16.2 mph)
Travel Speed in First / Second Gear (TH.6534X)
- Low range 0 - 5 km/h (0 - 3.1 mph) / 0 - 16 km/h (0 - 10 mph)
* Static and dynamic tests have been carried out and passed according to EN1459.
Weights
Weight (unladen) 6550 kg (14443 lb)

Front axle weight (unladen) 3100 kg (6836 lb)
Rear axle weight (unladen) 3450 kg (7607 lb)
Weight with pallet frame and forks 6860 kg (15126 lb)
Front axle weight with pallet frame and forks 3540 kg (7806 lb)
Rear axle weight with pallet frame and forks 3320 kg (7321 lb)
Weight with pallet frame, forks and rated load 10260 kg (22623 lb)
Front axle weight with pallet frame, forks and 8890 kg (19602 lb)
rated load
Rear axle weight with pallet frame, forks and 1370 kg (3021 lb)
rated load
TH.6534(X) / TH.7035(X) / TH.7038(X)

Engine
Make / model Bobcat Engine / 3,4 L Bobcat Engine Stage 4

Fuel / cooling Diesel / liquid
Rated power (ISO 14396) 97 kW (130 hp)
Rated speed 2400 rpm
Low idle speed 900 rpm
Maximum torque at 1400 rpm 500 N•m (368 ft-lb)
Number of cylinders 4
Displacement 3,4 L (207.5 in3)
Bore / stroke 98 mm (3.86 in) / 113 mm (4.45 in)
Fuel consumption (average loading) 10,3 L/h (2.7 U.S. gal/h)
Urea consumption (average loading) 0,4 L/h (0.1 U.S. gal/h)
Lubrication Gear pump pressure
Crankshaft ventilation Closed breathing
Air cleaner Dry replaceable cartridge with safety element
Ignition Diesel compression
Cycle type 4 cycles
Air induction Turbocharged
Engine coolant Ethylene Glycol Mix -37°C (-34.6°F)
Starting aid Air intake heater automatically activated as needed in RUN position
Controls
Engine Foot accelerator pedal

Starting Key-type starter switch and shutdown
Front auxiliary Variable thumbwheel on joystick
Hydraulics lift and tilt Electronic joystick
Hydraulics telescope in and telescope out Variable thumbwheel on joystick
Service brake Pedal-activated wet multi-disc on front axle
Secondary brake Passive brake
Parking brake Passive brake
Steering Proportional hydraulic steering via a conventional steering wheel
Speed range and reverse selection Switches for hydrostatic motor and gear ratios, and switch on
joystick or lever for F-N-R
4WD / 2WD / parallel drive selection Three-position switch on the right-hand console
Auxiliary pressure release Massey Ferguson coupler
TH.6534(X) / TH.7035(X) / TH.7038(X)

Drive System
Transmission Hydrostatic with electronic regulation

Main drive Hydrostatic motor and 2-speed gearbox
Transmission oil ELF SF3 / TOTAL DYNATRANS FR
Traction
Standard tires CAMSO 405/70-20 14PR TM R4

(450 kPa [4,5 bar] [65 psi])
Optional tires CAMSO 400/80-24 20PR TM R4
(425 kPa [4,25 bar] [62 psi])
(450 kPa [4,50 bar] [65 psi])
Optional tires DUNLOP 405/70R20 168A2/152J MPT SPT9
(550 kPa [5,50 bar] [80 psi])
(460 kPa [4,6 bar] [67 psi])
Optional tires MICHELIN 400/80-24 162A8 IND TL POWER CL
(425 kPa [4,25 bar] [62 psi])
Optional tires MICHELIN 460/70-24 159A8/159B IND TL XMCL
(340 kPa [3,40 bar] [49 psi])
(290 kPa [2,90 bar] [42 psi])
Optional tires NOKIAN 460/65R24 156A8/151D TRI STEEL TL
(400 kPa [4,00 bar] [58 psi])
Steering
Steering Pump Priority valve on control valve

Steering Mode 2WS / 4WS / CRAB
Brakes
Engine Braking Hydrostatic

Parking and Emergency brake Passive brake
Service Brake Oil immersed discs
TH.6534(X) / TH.7035(X) / TH.7038(X)

Fluid Capacities
Axle front / rear 9,1 L / 9,1 L (2.4 U.S. gal / 2.4 U.S. gal)
Gear box 1,6 L (0.4 U.S. gal)
Cooling system 17 L (4.5 U.S. gal)
Engine oil with oil filter 8,5 L (2.2 U.S. gal)
Fuel tank 138 L (36.4 U.S. gal)
Hydraulic reservoir 59 L (15.6 U.S. gal)
Hydraulic system plus reservoir 105 L (27.7 U.S. gal)
Hydraulic System
Pump type LS piston pump with electric displacement limiter

Pump capacity 190 L/min (50.2 U.S. gpm)
Relief valve pressure setting 25,5 MPa (255 bar) (3699 psi)
Control valve type Closed centre with flow sharing and flow compensators technology
Hydraulic filter specification Full flow filtration
Auxiliary flow 150 L/min (39.6 U.S. gpm)
Hydraulic fluid PETRONAS
Electrical System
Alternator 110 A
Battery 140 Ah
Starter 4,2 kW (5.7 hp)
Temperature Range
Operation and storage -15 - +45°C (+5 - +113°F)
Altitude
Maximum altitude 2000 m (6500 ft)
TH.6534(X) / TH.7035(X) / TH.7038(X)

Instrument Panel
The following functions are monitored by a combination of gauges and warning lights in the operator's line of sight.
The system alerts the operator of monitored malfunctions by way of audible and visual indicators.
Gauges
Rev counter
Total operating hours
Job hours
Boom angle
Machine speed
Fuel gauge
Engine coolant temperature gauge
DEF gauge
Indicators
Front and rear wheel alignment status
Headlight full beam
Headlight low beam
Position lights
Left and right turn
Trailer turn
Parking brake
Longitudinal stability level
Windscreen wipers
Work lights
Flashing warning lights
Hazard warning lights
Gear Speed Choice
Hydraulic function lock
Rear fog lights
Heater fan
Warning lights
Hydraulic fluid over-temperature
Engine coolant over-temperature
Low oil pressure
Battery not charging
Longitudinal stability alarm
Green - less than 61% of load
Amber - 63 to 68% of load`
Red - over 71% of load
DEF warning
TH.6534(X) / TH.7035(X) / TH.7038(X)

Environmental
DECLARED NOISE EMISSION VALUES
Value Uncertainty
Bystander noise Level per Directive 2000/14/EC - LwA 107 dB(A) N/A*
Operator noise level per EN 12053 - LpA 76 dB(A) 4 dB(A)
DECLARED VIBRATION EMISSION VALUES
Value Uncertainty
Whole-body vibration per EN 13059 1,4 m/s² 0,42 m/s²
4.6 ft/s² 1.4 ft/s²
Hand-arm vibration N/A* N/A*
RMS maximum per Directive 1978/764 N/A* N/A*
* N/A - Not applicable for telescopic handler.
TH.6534(X) / TH.7035(X) / TH.7038(X)

Visibility Diagrams - 20” Wheels
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)

Machine Dimensions
(B) Overall length (to forks face) 4869 mm (191.7 in)
TH.6534(X) / TH.7035(X) / TH.7038(X)

Performance
Crowding force - Tilt (ISO 8313) 6200 daN (13938 lbf)

Crowding force - Lift (ISO 8313) 3600 daN (8093 lbf)
Tipping load (at maximum reach) (ISO 14397-1) 1825 kg (4103 lb)
Max. reach (forks, COG 500 mm [19.7 in], at max. height) 1036 mm (40.8 in)
Weights

Weight with pallet frame, forks and 3500 kg 11140 kg (24564 lb)
(7716 lb) load
3500 kg (7716 lb) load
3500 kg (7716 lb) load
TH.6534(X) / TH.7035(X) / TH.7038(X)

Engine

Rated power (ISO 14396) 74,5 kW (100 hp)
Fuel consumption (average loading) 11 L/h (2.9 gal/h)
Urea consumption (average loading) 0,3 L/h (0.1 gal/h)
Cycle type 4 cycles
Controls

TH.6534(X) / TH.7035(X) / TH.7038(X)

Drive System

Traction

(450 kPa [4,5 bar] [65 psi])
(425 kPa [4,25 bar] [62 psi])
(450 kPa [4,50 bar] [65 psi])
(550 kPa [5,50 bar] [80 psi])
(460 kPa [4,6 bar] [67 psi])
(425 kPa [4,25 bar] [62 psi])
(340 kPa [3,40 bar] [49 psi])
(290 kPa [2,90 bar] [42 psi])
(400 kPa [4,00 bar] [58 psi])
Steering

Brakes

TH.6534(X) / TH.7035(X) / TH.7038(X)

Fluid Capacities
Hydraulic System
Pump type Gear pump with LS valve

Control valve type Open centre with flow sharing and flow compensators technology
Electrical System
Alternator 110 A
Battery 140 Ah
Temperature Range
Altitude
TH.6534(X) / TH.7035(X) / TH.7038(X)

Instrument Panel
Gauges
Rev counter
Job hours
Boom angle
Machine speed
Fuel gauge
DEF gauge
Indicators
Headlight full beam
Headlight low beam
Position lights
Left and right turn
Trailer turn
Parking brake
Windscreen wipers
Work lights
Gear Speed Choice
Rear fog lights
Heater fan
Warning lights
Low oil pressure
DEF warning
TH.6534(X) / TH.7035(X) / TH.7038(X)

Environmental
Value Uncertainty
Value Uncertainty
4.6 ft/s² 1.4 ft/s²
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)

Machine Dimensions
A
B
C
D M
E F
H
G I
J K L N
Q O
R
(B) Overall length (to forks face) 4869 mm (191.7 in)
TH.6534(X) / TH.7035(X) / TH.7038(X)

Performance
Crowding force - Tilt (ISO 8313) 6200 daN (13938 lbf)

Crowding force - Lift (ISO 8313) 4100 daN (9217 lbf)
Tipping load (at maximum reach) (ISO 14397-1) 1825 kg (4103 lb)
Max. reach (forks, COG 500 mm [19.7 in], at max. height) 1036 mm (40.8 in)
Weights

Weight with pallet frame, forks and 3500 kg 11550 kg (25468 lb)
(7716 lb) load
3500 kg (7716 lb) load
3500 kg (7716 lb) load
TH.6534(X) / TH.7035(X) / TH.7038(X)

Engine

Rated power (ISO 14396) 97 kW (130 hp)
Fuel consumption (average loading) 10,3 L/h (2.7 gal/h)
Urea consumption (average loading) 0,4 L/h (0.1 gal/h)
Cycle type 4 cycles
Controls

TH.6534(X) / TH.7035(X) / TH.7038(X)

Drive System

Traction

(450 kPa [4,5 bar] [65 psi])
(425 kPa [4,25 bar] [62 psi])
(450 kPa [4,50 bar] [65 psi])
(550 kPa [5,50 bar] [80 psi])
(520 kPa [5,20 bar] [75 psi])
(425 kPa [4,25 bar] [62 psi])
(360 kPa [3,60 bar] [52 psi])
(310 kPa [3,10 bar] [45 psi])
(400 kPa [4,00 bar] [58 psi])
Steering

Brakes

TH.6534(X) / TH.7035(X) / TH.7038(X)

Fluid Capacities
Hydraulic System
Pump type LS piston pump with electric displacement limiter

Control valve type Closed centre with flow sharing and flow compensators technology
Electrical System
Alternator 110 A
Battery 140 Ah
Temperature Range
Altitude
TH.6534(X) / TH.7035(X) / TH.7038(X)

Instrument Panel
Gauges
Rev counter
Job hours
Boom angle
Machine speed
Fuel gauge
DEF gauge
Indicators
Headlight full beam
Headlight low beam
Position lights
Left and right turn
Trailer turn
Parking brake
Windscreen wipers
Work lights
Gear Speed Choice
Rear fog lights
Heater fan
Warning lights
Low oil pressure
DEF warning
TH.6534(X) / TH.7035(X) / TH.7038(X)

Environmental
Value Uncertainty
Value Uncertainty
4.6 ft/s² 1.4 ft/s²
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
MACHINE TORQUE SPECIFICATIONS
Axle
N•M FT-LB
Axle To Frame Mounting Bolts 490 - 550 361 - 405
Brake Housing Hex Bolt 80 59
Brake Housing Spring Bolts 10 7
Brake Housing Stud 120 88
Differential Lock Retainer Bolt 13 10
Fender Mount Bolt 90 - 100 66 - 74
Housing Bolt 320 236
Housing Nut 190 140
Pinion Ring Gear Bolts 13 10
Planetary Cover Bolts 25 18
Planetary Gear Mount Bolts 120 88
Steering Cylinder Bolts 120 88
Tie Rod Jam Nut 250 185
Tie Rod Nut 220 160
Tie Rod Swivel End 406 300
Turn Stop Adjust Jam Nut 150 110
Wheel Nuts 360 266
Boom
N•M FT-LB
Extension Cylinder Base End 640 - 700 472 - 516
Wear Pads Front 43 - 47 32 - 35
Wear Pads Rear 43 - 47 32 - 35
Drive Box
N•M FT-LB
Cover Bolts 60 44
Inner Housing Bolts 120 88
Mounting Flange Bolts 60 44
Drive Motor
N•M FT-LB
End Cap Bolts 115 85
Mounting Bolts 210 155
Mounting Plate Bolts 63 46
TH.6534(X) / TH.7035(X) / TH.7038(X)

MACHINE TORQUE SPECIFICATIONS (CONT’D)
Engine
N•M FT-LB
A/C Compressor Mount Bolts 54 45
Alternator Mount Bolts 54 45
Starter Mount Bolts 54 45
Hydraulic Pump
N•M FT-LB
Filter Head 122 90
Flange Adapter 122 90
Guide Post Bolts 23 17
Mounting Bolts 106 78
Retaining Plate 13 10
Servo End Cap 13 10
Side Cover Bolts 32 24
TH.6534(X) / TH.7035(X) / TH.7038(X)

TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Massey Ferguson Company that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9 - 10 13 - 14
N•m (80 - 90) (110 - 120)
(in-lb) 0.3125 21 - 23 24 - 27
(180 - 200) (215 - 240)
0.375 34 - 38 48 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 82 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 125 - 135
(65 - 70) (90 - 100)
0.5625 125 - 135 170 - 190
(90-100) (125 - 140)
0.625 170 - 190 240 - 190
(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
N•m 0.875 450 - 490 645 - 710
(ft-lb) (330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
Thread Size (Dia. x Material

Pitch) Property Class 8.8 Property Class 10.9
M 4 x 0.7 2,5 - 3,5 N•m 3,8 - 4,2 N•m
(2.0 - 2.5 ft-lb) (2.8 - 3.1 ft-lb)
M 5 x 0.8 5,5 - 6,5 N•m 7,6 - 8,4 N•m
(4.0 - 5.0 ft-lb) (5,6 - 6,2 ft-lb)
M 6 x 1.0 9,5 - 10,5 N•m 12,3 - 13,7 N•m
(7.0 - 7.5 ft-lb) (9.1 - 10.1 ft-lb)
M 7 x 1.0 15 - 17 N•m 20 - 22 N•m
(11.0 - 12.5 ft-lb) (14.7 - 16.2 ft-lb)
M 8 x 1.25 24 - 26 N•m 29,4 - 32,6 N•m
(18 - 19 ft-lb) (21.7 - 24.0 ft-lb)
M 10 x 1.25 43 - 47 N•m 57 - 63 N•m
(32 - 35 ft-lb) (42.0 - 46.5 ft-lb)
M 12 x 1.25 75 - 85 N•m 105 - 115 N•m
(55 - 60 ft-lb) (78 - 85 ft-lb)
M 14 x 1.5 125 - 140 N•m 160 - 180 N•m
(90 - 100 ft-lb) (118 - 133 ft-lb)
M 16 x 1.5 190 - 210 N•m 255 - 285 N•m
(140 - 155 ft-lb) (188 - 210 ft-lb)
M 18 x 1.5 260 - 290 N•m 345 - 385 N•m
(190 - 215 ft-lb) (255 - 285 ft-lb)
M 20 x 1.5 370 - 410 N•m 490 - 550 N•m
(275 - 300 ft-lb) (360 - 405 ft-lb)
M 22 x 1.5 500 - 550 N•m 740 - 760 N•m
(370 - 400 ft-lb) (545 - 560 ft-lb)
M 24 x 2.0 640 - 700 N•m 850 - 950 N•m
(470 - 520 ft-lb) (625 - 700 ft-lb)
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure SPEC-40-2
IMPORTANT Nut Nut
When repairing hydrostatic and hydraulic systems, Washer

clean the work area before disassembly and keep all Washer
parts clean. Always use caps and plugs on hoses, O-ring
O-ring
damage the system.
I-2003-0888
Figure SPEC-40-1
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-40-
2].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
B-07575 Replace hoses which show signs of wear, damage or

weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use petroleum jelly to hold the O-ring in
position until the fittings are assembled [Figure SPEC-
40-1].
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONNECTION SPECIFICATIONS Tighten the nut until it makes contact with the seat. Make
(CONT'D) a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-40-3].
Flare Fitting
Use the chart below to find the correct tightness needed
Use the following procedure to tighten the flare fitting: (Item 2) [Figure SPEC-40-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
Figure SPEC-40-3 damage.
TS-1619
FLARE FITTING TIGHTENING TORQUE
TUBELINE NEW ROTATE RE-ASSEMBLY

TORQUE N•M
WRENCH SIZE OUTSIDE THREAD SIZE NO. OF HEX ROTATE NO. OF
(FT-LB)
DIAMETER FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 23 (17) 2-1/2 1
11/16" 3/8" 9/16" - 18 30 (22) 2 1
7/8" 1/2" 3/4" - 16 54 (40) 2 1
1" 5/8" 7/8" - 14 81 (60) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 114 (84) 1 3/4
1-3/8" 1" 1-5/16" - 12 160 (118) 3/4 3/4
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT'D) fitting.
O-ring Flare Fitting Figure SPEC-40-5
Figure SPEC-40-4 Hex Flat Tightening Method
Primary O-ring Flare

Seal
1
Secondary
TS-1619
Seal
P-13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts
The flare is the primary seal, the O-ring is the secondary of the connection (Item 1) [Figure SPEC-40-5].
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-40-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring. damage.
FLARE FITTING TIGHTENING TORQUE
** ***
TUBELINE *
NEW ROTATE RE-ASSEMBLY
WRENCH SIZE OUTSIDE THREAD SIZE TORQUE N•M
NO. OF HEX ROTATE NO. OF
DIAMETER (FT-LB)
FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 23 (17) 2-1/2 1
11/16" 3/8" 9/16" - 18 30 (22) 2 1
7/8" 1/2" 3/4" - 16 54 (40) 2 1
1" 5/8" 7/8" - 14 81 (60) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 114 (84) 1 3/4
1-3/8" 1" 1-5/16" - 12 160 (118) 3/4 3/4
* If a torque wrench is used to tighten a new fitting to a used hose / tubeline.

If a torque wrench is used to tighten a used fitting to a new hose / tubeline.
If a torque wrench is used to tighten a new fitting to a new hose / tubeline.
** If using the hex flat tightening method to tighten a new fitting to a new hose / tubeline.
If using the hex flat tightening method to tighten a new fitting to a used hose / tubeline.
*** If using the hex flat tightening method to tighten a used fitting to a new hose / tubeline.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-7
(CONT'D)
O-ring Flare Fitting (Cont'd)
NOTE: O-ring flare fittings are not recommended in 2

all applications. Use the standard flare fittings
in these applications.
Do not use a O-ring flare fitting when a copper hood

orifice is used. When tightened the connection at the
hood can distort the flare face and prevent it from sealing.
Figure SPEC-40-6
Copper Hood Orifice 1

P-13573
When a O-ring flare fitting is used as a straight thread

port adapter the O-ring flare face is not used to seal. The
O-ring can come off the fitting and enter the system.
Always remove the O-ring (Item 1) [Figure SPEC-40-7]

from the flare face as shown.
1
An O-ring (Item 2) [Figure SPEC-40-7] is added to the
flat boss of the fitting to seal the connection in this
application.
P-13572
Use a standard flare fitting (Item 1) [Figure SPEC-40-6]

as shown.
TH.6534(X) / TH.7035(X) / TH.7038(X)

HYDRAULIC CONNECTION SPECIFICATIONS Tighten the nut until it just makes metal to metal contact,
(CONT'D) you can feel the resistance.
Port Seal Fitting Tighten the nut with a wrench no more than one hex flat
maximum.
Figure SPEC-40-8
Do not over tighten the port seal fitting.
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.
PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
FITTING NUT TORQUE N•M

Nut Seals THREAD SIZE
WRENCH SIZE (FT-LB)
to Fitting
11/16" 9/16" - 18 30 (22)
15/16" 3/4" - 16 54 (40)
1-1/8" 7/8" - 14 81 (61)
Nut Seals
to Port 1-1/4" 1-1/16" - 12 114 (84)
1-1/2" 1-5/16" - 12 160 (118)
Figure SPEC-40-9
Secondary O-ring Seal
P-13008
2
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-8].
1
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Use the following procedure to tighten the port seal P-13571

fitting:
Port seal and nut, washer and O-ring (O-ring Boss) Do not use port seal fittings when a thread in orifice
fittings use the same tightening torque valve chart. (Item 1) [Figure SPEC-40-9] is used in the port. The
orifice can interfere with the fitting and prevent it from
If a torque wrench cannot be used, use the following sealing.
method.
Use an O-ring boss fitting (Item 2) [Figure SPEC-40-9]
as shown. (See Straight Thread O-ring Fitting on Page
SPEC-40-1.)
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
Use Massey Ferguson Axle / Transmission Oil SAE

85W90 LS / API GL-5 (P/N 6987805) or Massey
Ferguson Axle / Transmission Oil ISO 100 / API GL-4
(TH.7035(X) Telescopic Handler Only) (P/N 6987794), for
WARNING
the transfer case, planetaries and axle housings.
During cold weather (0°C [32°F] and below), do not
Use Massey Ferguson Superior SH Hydraulic / operate machine until the engine has run for at least
Hydrostatic (P/N 6987791) oil. 5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
DO NOT use automatic transmission fluids in the stopping. Do not operate controls during warm-up
machine or permanent damage to the hydraulic / period.
hydrostatic system will result.
When temperatures are below -30°C (-20°F), the
hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
WARNING temperature will be above -18°C (0°F) if possible.
W-2027-0311

W-2072-0807
When temperatures below -18°C (0°F) are common, the

machine must be kept in a warm building. Extra warm-up
time must be used each time the machine is started
during cold temperature conditions. Cold fluid will not flow
easily and it makes action on the hydraulic function
slower. Loss of fluid flow to the hydrostatic pump can
cause damage in less than 60 seconds.
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
TH.6534(X) / TH.7035(X) / TH.7038(X)

TH.6534(X) / TH.7035(X) / TH.7038(X)
ALPHABETICAL INDEX
(TH.6534(X)) TELESCOPIC HANDLER EVAPORATOR / HEATER UNIT . . . . . . . 80-90-1

SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-1 EXHAUST GAS RECIRCULATION (EGR)
(TH.7035(X)) TELESCOPIC HANDLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
SPECIFICATIONS . . . . . . . . . . . . . . SPEC-10-10 EXHAUST PIPE . . . . . . . . . . . . . . . . . . . 70-40-1
(TH.7038(X)) TELESCOPIC HANDLER EXPANSION VALVE . . . . . . . . . . . . . . . 80-110-1
SPECIFICATIONS . . . . . . . . . . . . . . SPEC-10-19
EXTENSION CYLINDER . . . . . . . . . . . . 20-40-1
A/C SYSTEM TROUBLESHOOTING . . . 80-30-1
FAN MOTOR . . . . . . . . . . . . . . . . . . . . . 20-110-1
ACCUMULATORS . . . . . . . . . . . . . . . . . 20-160-1
FAN PUMP (ONLY FOR TH.6534(X) AND
AIR CLEANER SERVICE . . . . . . . . . . . . 10-60-1 TH.7038(X)) . . . . . . . . . . . . . . . . . . . . . 20-170-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . 70-50-1 FENDER . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
AIR CONDITIONING SYSTEM FLOW . . 80-10-1 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . 1-11
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . 60-30-1 FIXED BOOM . . . . . . . . . . . . . . . . . . . . . 50-30-1
APPROVED BOOM STOP . . . . . . . . . . 10-150-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
ATTACHMENT CARRIER (QUICK-TACH) 50-80-1 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . 40-30-1
ATTACHMENT CARRIER . . . . . . . . . . . 10-130-1 FRONT WIPER MOTOR . . . . . . . . . . . . 60-100-1
AXLE AND DIFFERENTIAL (FRONT) . . 40-20-1 FUEL COOLER . . . . . . . . . . . . . . . . . . . 70-120-1
AXLE AND DIFFERENTIAL (REAR) . . . . 40-21-1 FUEL LEVEL SENDER . . . . . . . . . . . . . 60-160-1
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . 40-40-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 10-80-1
AXLES (FRONT AND REAR) . . . . . . . . 10-110-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 GEAR BOX . . . . . . . . . . . . . . . . . . . . . . 40-100-1
BOOM ANGLE SENSOR . . . . . . . . . . . . 60-90-1 GEAR CONTROL CYLINDER . . . . . . . . 20-70-1
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . 20-90-1 GEAR PUMP (FOR TH.7035(X)) . . . . . 20-101-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . 80-50-1 HYDRAULIC / HYDROSTATIC FLUID
CONDENSER . . . . . . . . . . . . . . . . . . . . . 80-60-1 SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-50-1
CONVERSIONS . . . . . . . . . . . . . . . . SPEC-60-1 HYDRAULIC / HYDROSTATIC SYSTEM 10-100-
COUNTERWEIGHT . . . . . . . . . . . . . . . . 50-90-1 1
DASH COVER . . . . . . . . . . . . . . . . . . . . 50-120-1 HYDRAULIC CONNECTION SPECIFICATIONS
SPEC-40-1
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . 1-14
HYDRAULIC CONTROL VALVE . . . . . . 20-140-1
DIESEL EXHAUST FLUID (DEF) TANK 70-110-1
HYDRAULIC FLUID RESERVOIR . . . . 20-120-1
DIESEL OXIDATION CATALYST (DOC) . 70-80-1
HYDRAULIC SYSTEM INFORMATION . 20-10-1
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
HYDROSTATIC DRIVE MOTOR . . . . . . . 30-30-1
DRIVE SYSTEM TROUBLESHOOTING . 40-10-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . 30-40-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . 40-70-1
HYDROSTATIC SYSTEM INFORMATION 30-10-
ELECTRICAL SYSTEM INFORMATION . 60-10-1 1
EMERGENCY EXIT . . . . . . . . . . . . . . . 10-180-1 INCHING SENSOR . . . . . . . . . . . . . . . . 60-140-1
ENGINE COOLING SYSTEM . . . . . . . . . 10-70-1 INNER BOOM . . . . . . . . . . . . . . . . . . . . . 50-40-1
ENGINE COOLING SYSTEM . . . . . . . . . 70-60-1 INSTRUMENT PANELS . . . . . . . . . . . . . 60-80-1
ENGINE COVER . . . . . . . . . . . . . . . . . . 10-160-1 JOYSTICK PANEL . . . . . . . . . . . . . . . . . 50-130-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . 50-60-1 JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
ENGINE LUBRICATION SYSTEM . . . . . 10-90-1 LIFT CYLINDER . . . . . . . . . . . . . . . . . . . 20-20-1
ENGINE SPEED CONTROL . . . . . . . . . . 70-30-1 LIFTING AND BLOCKING THE TELESCOPIC
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1 HANDLER . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
ENGINE AND HYDROSTAT ASSEMBLY 70-20-1 LIFTING THE TELESCOPIC HANDLER 10-200-1
TH.6534(X) / TH.7035(X) / TH.7038(X)

INDEX-01 Service Manual
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 STOPPING THE ENGINE AND LEAVING THE
LLMI / LLMC SYSTEM . . . . . . . . . . . . . . 60-180-1 TELESCOPIC HANDLER . . . . . . . . . . . 10-170-1
LUBRICATING THE TELESCOPIC HANDLER . . SYSTEM CHARGING AND RECLAMATION .80-
10-120-1 40-1
MACHINE TORQUE SPECIFICATIONS . .SPEC- TELESCOPIC HANDLER STORAGE AND
20-1 RETURN TO SERVICE . . . . . . . . . . . . . 10-190-1
MAINTENANCE SAFETY . . . . . . . . . . . . . . . 1-1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . 80-100-1
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 20-80-1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . 20-50-1
MASSEY FERGUSON TELESCOPIC HANDLER TIRE MAINTENANCE . . . . . . . . . . . . . . 10-140-1
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . 1-15 TOP WIPER MOTOR . . . . . . . . . . . . . . . 60-110-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . 30-20-1 TORQUE SPECIFICATIONS FOR BOLTS SPEC-
OPERATOR CAB . . . . . . . . . . . . . . . . . . . 10-20-1 30-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . 50-10-1 TOWING THE TELESCOPIC HANDLER 10-40-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . 50-20-1 TRANSPORTING THE TELESCOPIC HANDLER
ON A TRAILER . . . . . . . . . . . . . . . . . . . . 10-30-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . 40-50-1
TURBOCHARGER . . . . . . . . . . . . . . . . 70-100-1
PEDAL ASSEMBLY . . . . . . . . . . . . . . . . 60-130-1
WEAR PADS (FRONT) . . . . . . . . . . . . . . 50-50-1
PISTON PUMP (FOR TH.6534(X) AND
TH.7038(X)) . . . . . . . . . . . . . . . . . . . . . . 20-100-1 WEAR PADS (REAR) . . . . . . . . . . . . . . . 50-51-1
PORT RELIEF VALVES . . . . . . . . . . . . . 20-150-1
PRESSURE SWITCH . . . . . . . . . . . . . . . 80-80-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
REAR WIPER MOTOR . . . . . . . . . . . . . 60-120-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . 80-70-1
REGULAR MAINTENANCE . . . . . . . . . . 80-20-1
3975015M1 . . . . . . . . . . . . . . . . . . . . . . 10-220-1
MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . 1-9
SELECTIVE CATALYTIC REDUCTION (SCR)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
SELF LEVELING CYLINDER (LOCK VALVE) 20-
31-1
SELF LEVELING CYLINDER . . . . . . . . . 20-30-1
SERIAL NUMBER LOCATION . . . . . . . . . . . 1-13
SERVICE BRAKE . . . . . . . . . . . . . . . . . . 40-80-1
SERVICE PC (LAPTOP COMPUTER) . 60-150-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . 10-50-1
SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . 60-60-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
STEERING ANGLE ADJUSTMENT . . . . 40-60-1
STEERING COLUMN COVER . . . . . . . 50-110-1
STEERING CYLINDER (FRONT / REAR) . 20-60-
1
STEERING VALVE . . . . . . . . . . . . . . . . . 20-130-1
TH.6534(X) / TH.7035(X) / TH.7038(X)

INDEX-02 Service Manual

Manual Taller Telescopica MF

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TH.

6534 - S/N B41R11001 & Above

AGCO Ltd October 2016

TH.6534(X) / TH.7035(X) / TH.7038(X)

Safety Alert Symbol: This symbol with a warning statement,

CORRECT WRONG WRONG

NA5428 NA5432 NA5433

WRONG WRONG WRONG

NA5434 NA5436 B-6589

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

TH.6534(X) / TH.7035(X) / TH.7038(X)

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

MASSEY FERGUSON TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . 1-15

TH.6534(X) / TH.7035(X) / TH.7038(X)

2. Check that ROPS mounting 10. Attachment locking pins must

3. The seat belt must be 11. Safety treads must be in good

4. Check boom support device, 12. Check for correct function of

5. Machine signs must be 13. Check hydraulic fluid level,

7. Check for correct function of 15. Lubricate the telescopic

8. The parking brake must 16. Check the condition of the

TH.6534(X) / TH.7035(X) / TH.7038(X)

19. Inspect for loose or broken 22. Recommend to the owner

TH.6534(X) / TH.7035(X) / TH.7038(X)

WARNING • The operator must know any prohibited uses or work

TH.6534(X) / TH.7035(X) / TH.7038(X)

Avoid Silica Dust

Cutting or drilling concrete containing sand or rock

TH.6534(X) / TH.7035(X) / TH.7038(X)

Check hydraulic tubes, hoses and fittings for damage

Flammable debris (leaves, straw, etc.) must be removed

Check all electrical wiring and connections for damage.

Battery gas can explode and cause serious injury. Use

TH.6534(X) / TH.7035(X) / TH.7038(X)

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing non-metallic parts such as

Know where fire extinguishers and first aid kits are

TH.6534(X) / TH.7035(X) / TH.7038(X)

2. The five digit Production Sequence Number identifies

Telescopic Handler Statutory Plate

The telescopic handler serial number plate is located on

The telescopic handler statutory plate (if equipped) is

TH.6534(X) / TH.7035(X) / TH.7038(X)

Engine Serial Number Figure 4

The delivery report [Figure 4] contains a list of items that

The delivery report must be reviewed and signed by the

The engine serial number can be found on the engine

Other Serial Numbers

Other components can also have serial numbers and an

TH.6534(X) / TH.7035(X) / TH.7038(X)

ITEM DESCRIPTION ITEM DESCRIPTION