Dokumen - Tips Case 821e Service Manual

SERVICE MANUAL
WHEEL LOADER
821E
TIER 3
84299244
(Replaces 87364100)
Revised December 2009

Issued September 2006
SECTION INDEX
GENERAL
Section Title Section Number
Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Copyright © 2006 CNH Ameica LLC.

CASE, LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 5-3090 Issued August, 2006
1001
Section
1001
GENERAL TORQUE SPECIFICATIONS
Copyright © 2004 CNH America LLC.

Racine, WI 53404 U.S.A. Bur 8-71603 Issued April, 2003 Revised July, 2005
1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bur 8-71603 Revised 7-05 Printed in U.S.A.

1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

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

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

1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

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

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

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

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

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

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

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

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

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

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

1002
Section
1002
FLUIDS AND LUBRICANTS

CNH America LLC. All rights reserved.
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bur 5-3100 Issued 8-06 Printed in U.S.A.

1002-3
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ............................................................................................ 21 liters (22 U.S. quarts)
Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4
Engine Cooling System
Capacity...................................................................................................................40.9 liters (10.8 U.S. Gallons)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons)
Type of Fuel............................................................................................. See Diesel fuel specifications on page 5
Hydraulic System
Hydraulic Reservoir Refill Capacity .............................................................................90 liters (23.8 U.S. Gallons)
Total System Capacity............................................................................................... 176 liters (46.5 U.S. Gallons)
Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ............................................................................39.7 litres (10.5 U.S. Gallons)
Type of Oil ................................................................................................................ Case AKCELA No. 1 15W-40
Axles
Capacity
Front...................................................................................................................... 37.4 litres (39.5 U.S. Quarts)
Rear ......................................................................................................................... 23.7 litres (25 U.S. Quarts)
Type of Lubricant .................................................................................................... Case AKCELA Transaxle Fluid
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
Brake System
Type of Fluid (Same as Hydraulic System)................................................................ Case AKCELA Hy-Tran Ultra®

1002-4
ENGINE OIL RECOMMENDATIONS

Case AKCELA No. 1 Engine oil is recommended
for use in your Case engine. Case AKCELA No. 1
Engine Oil will lubricate your engine correctly
under all operating conditions.
If Case AKCELA No. 1 Multi-Viscosity Oil is not
available, use only oil meeting API engine oil service
category CH-4 (preferred) or CG-4.
S e e t h e c h a r t b e l ow fo r
recommended viscosity at
ambient air temperature
ranges.
BD03A102
NOTE: Do not put performance
additives or other oil additive
products in the engine
crankcase. The oil change
RH99K130
intervals given in this manual
are according to tests with Case
AKCELA lubricants.
BC02N250

1002-5
TRANSMISSION TEMPERATURE CHART
BC04F193
DIESEL FUEL SYSTEM

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

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

API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60°C (140°F)
Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above
Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ..................................................................................................... 0.05%

1002-6
MAINTENANCE SCHEDULE
Model 821E
FREQUENCY IN HOURS
Initial Service
LUBRICATE
REPLACE
SERVICE NUMBER
CHANGE
SERVICE POINTS
ADJUST
CHECK
CLEAN
INTERVAL
DRAIN
ITEM
13 Radiator Coolant Level *

14 Tires *
Variable 19 Hydraulic Filter *
Periodic
(*) 22 Alternator, AC, Drive Belt *
29 Air cleaner * *
XX Fire extinguisher *
Every 10 Hours 1 Check Engine Oil Level 10
2 Check Engine Coolant Level 50
3 Check Transmission Oil Level 50
Every 50 Hours 4 Check Hydraulic Oil Level 50
5&6 Grease Bucket Mounting Fittings 50
18 Bleed Fuel Filter of Condensation 50
17 Change Engine Oil and Filters 100
18 & 26 Replace Fuel Filters 100
First 100 Hours
19 Change Hydraulic Filter 100
21 Change Oil in Axles 100
Lubricate The Steering Cylinder Pivots - Rod And
8 100
Closed End (4 Fittings)
Every 100 Hours 9 Grease Front Drive Shaft Support Bearing 100
10 Lubricate Loader Lift & Cylinder Pivots (10) Z-bar 100
11 Lubricate Loader Lift & Cylinder Pivots (18) XT 100
12 & 23 Check Cab Air Filter 250
13 Check Radiator Coolant Level 250
Every 250
14 Check Tire Pressure & Wheel Torque 4 250
Hours
22 Check Drive Belt 250
XX Trans Clutch Calibration (See Section 6002) 250 1000
15 Check Axle Oil Level 500
16 Check Battery Electrolyte Level 500
Every 500 17 Change Engine Oil and Filter 500
Hours 17 Change Crankcase Filter 500
18 Drain Fuel Tank Condensation & Water Separator 500
26 Replace Fuel Filter 500
19 Replace Hydraulic Oil filter 1000
20 Grease Articulation Fittings 1000
21 Change Front & Rear Axle Oil 1000
22 Replace Drive Belt 1000
Every 1000
23 Replace Cab Air Filter 1000
Hours
25 Change Transmission Oil and Filter 1000
XX Check Injector Calibration 1000
XX Check Valve Adjustment (Engine Manual) 1000
XX Trans Clutch Calibration (See Section 6002) 1000
27 Change Hydraulic Oil 2000
Every 2000 28 Change Coolant 2000
Hours 29 Replace Engine Air Cleaner 2000
XX Valve Clearance (Engine Manual) 2000
Every 6000 XX Engine Injectors (Engine Manual) 6000
hours XX Fuel Pump (Engine Manual) 6000 6000

1002-7
MAINTENANCE POINTS
Model 821E
12 23
1 29 17 10 11
26
18
14
21 15 19 25 24 8 21 15 6
10 8 4 13 2 16 22 11
17
6 9 8 20 3 18 17 28 27
BC06F531
See your Operators manual for maintenance of If you operate the machine in severe conditions,
safety related items and for detailed information of lubricate and service the machine more frequently.
the ser vice items on this char t. Operators and
service manuals are available for this machine from
your dealer.

1002-8
NOTES

Section
1003
1003
METRIC CONVERSION CHART

Racine, WI 53404 U.S.A. Bur 7-52590 Issued April, 2003
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

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

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

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

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

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

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

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

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

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

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

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

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

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

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

87519803

Section
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
2000

2000-2
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2000-3
ENGINE
Removal STEP 5
STEP 1
BD02N160
Put a 37 liter (10 gallon) container below radiator

BD03A040
drain. Remove radiator cap. Remove cap and drain
Park machine on a level surface and lower bucket to coolant into container. Install cap after coolant has
ground. Put articulation lock in LOCKED position. drained. Install radiator cap.
STEP 2 STEP 6
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD02N160
Put a 14.2 liter (15 U.S. quarts) container below

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

right batter box. Raise the hood with the hood lift
motor. Put master disconnect switch in OFF position.
Remove both batte r y cove rs and disconn ec t
batteries from the machine.

2000-4
STEP 7 STEP 10
BD03A231 BD06F109
Double up a nylon lifting strap (1) and slide through Tag and disconnect hood wiring harness connector
the exhaust stack (2) on the hood. from rear chassis wiring harness connector.
STEP 8 STEP 11
1
BD03A230 BD03A227
Place a solid steel bar through the strap, raise the

hood and release tension on the lifting motor.
STEP 9
BD03A226
Remove mount bolt (1) and backup alarm wiring

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

2000-5
STEP 12 STEP 15
BD03A232 BD06F110
Carefully raise and remove hood from loader. Lower Loosen clamps on turbocharger and air cleaner,
hood onto suitable platform and disconnect lifting remove the intake hose.
equipment.
STEP 16
STEP 13
BD06F110
BD03A224 Loosen the clamp on the turbocharger for the after

Tag and disconnect engine wiring harness connector cooler inlet hose.
from air filter restriction switch.
STEP 17
STEP 14
BD03A115
BD03A225 Loosen the clamp on the after cooler and remove the
Loosen clamp on air cleaner intake hose and remove after cooler inlet hose from the machine.
the crankcase ventilation hose.

2000-6
STEP 18 STEP 21
BD06F112
BD06F111
Loosen the clamp on the intake manifold for the after Remove the air cleaner and muffler from the bracket.
cooler output hose.
STEP 22
STEP 19
BD06F113
BD03A118
Loosen the clamp on the after cooler and remove the

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

remove the cover.
NOTE: After removing the belt cover remove the
cover mounting brackets from the machine frame.
BD06F110
Loosen the exhaust clamp from the turbocharger.

2000-7
STEP 23 STEP 26
BD06F115 BD06F118
Remove the drive belt from the engine. Tag and disconnect the wiring from the alternator.
STEP 24 STEP 27
BD06F116 BD06F119
Loosen clamps and remove lower cooler hose from Remove bolt securing wiring harness clamp to
the engine. engine.
STEP 25 STEP 28
1
1
2
2
BD06F117 BD06F120
If loader is equipped with air conditioning, identify, Remove bolt securing wiring harness clamp (1) to the
tag, and disconnect the engine wiring harness engine. Remove ground wires (2) from the engine.
connectors from air compressor clutch connector (1).
Remove the thre e m oun tin g b olts (2) for the
compressor and set the compressor on the left
battery cover.

2000-8
STEP 29 STEP 32
2 3
BD06F121 BD06F111
Tag and remove the wires from the starter solenoid Tag and remove the grid heater cable.
(3), remove the ground cable (2), and ground strap
(1) from the starter. STEP 33
NOTE: Move the starter cables away from the
engine, move the wiring harness away from the
engine.
STEP 30
BD03A142
Disconnect the wiring harness from the EDC 7

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

the rear of the engine.
STEP 31
BD06F123
Remove the fuel line from the top of the EDC 7

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

engine, remove the heater hose from the rear of the
engine (2), remove the clamp bolts and clamps (3)
from the bell housing.
2000-9
STEP 35 STEP 38
BD06F127
BD06F124
Tag and disconnect the fuel filter heater wires (1), Remove the lower cover for the drive shaft.
disconnect the fuel line (2) from the fuel filter head,
plug the line and cap the fitting. STEP 39
STEP 36
BD03A172
Remove the drive shaft bolts from the flywheel. Move

BD06F125 the drive shaft clear of the flywheel.
Remove bolt and clamp.
STEP 40
STEP 37 Connect suitable lifting equipment to engine lifting
brackets. Take up all slack in lifting equipment.
Remove the engine mounting bolts and lift the engine
enough to gain access to the drain hose, pull the
drain hose with the engine.
STEP 41
Slowly raise engine from rear chassis. Be sure all
h a r n e s s c o n n e c t i o n s a n d h o s e s h ave b e e n
disconnected and are clear of the engine. Remove
engine from machine.
BD06F126
Connect and turn on vacuum pump to hydraulic

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

2000-10
Installation
1
2 1
3 2
3
1 4
4 5
2
5
3 6
6
7
7
8 4
5
6
7
BS03B035
1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT

2. WASHER 4. INSOLATOR LOWER 6. WASHER 8. REMOTE OIL DRAIN HOSE
STEP 42 STEP 47
If engine rubber isolators require replacement,
remove and discard isolators (3 and 4). Install new
rubber isolator (4), then rubber isolator (3).
STEP 43
Slowly raise engine and move into position over rear
chassis. Be sure all harness connections and hoses
are out of the way then lower engine. Put washer (5)
between front rubber isolator (4) and chassis. Install
washer (2), bolt (1), washer (6), and nut (7) in engine
isolators. Lower engine into position.
BD03A172
STEP 44 At front of engine, position drive shaft on engine

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

2000-11
STEP 48 STEP 51
BD06F127 BD06F124
Install the lower cover for the drive shaft. Remove cap from fitting and plug from the hose,
connect fuel line (2). Connect fuel filter heater wires
STEP 49 (1). Remove and discard tag.
STEP 52
BD06F126
Connect and turn on vacuum pump to the hydraulic

reservoir. Remove caps from fittings and plugs from BD06F123
hoses. Connect hoses to brake pump following tags Remove cap from fitting and plug from the hose,
installed during removal. Remove and discard tags. connect fuel line to EDC 7.
Turn off and disconnect vacuum pump from hydraulic
reservoir. STEP 53
STEP 50
BD03A142
Connect wiring harness to EDC 7 controller.

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

2000-12
STEP 54 STEP 57
2 3
BD06F111 BD06F121
Connect grid heater cable to grid heater. Remove Install the wires to the starter solenoid (3), install the
and discard tag. ground cable (2), and ground strap (1) to the starter.
Remove and discard tags.
STEP 55
STEP 58
3
1
2
2
1
BD06F122
BD06F120
Install the heater hose (2) to the rear of the engine,
mount the clamps (3), install the radiator hose (1). Install bolt securing wiring harness (1) clamp to the
engine. Install ground wires (2) to the engine.
STEP 56
STEP 59
BD06F146
Connect the engine coolant vent hose. BD06F119
Install bolt securing wiring harness clamp to engine.

2000-13
STEP 60 STEP 63
BD06F118 BD06F115
Connect the wiring to the alternator. Remove and Install the drive belt.
discard tags.
STEP 64
STEP 61
BD06F113
BD06F117
If loader is equipped with air conditioning, mount the

compressor using the three mounting bolts (2),
connect the engine wiring harness connectors to air
compressor clutch connector (1). Remove and
discard tags.
STEP 62
BD06F114
Install the cover mounting brackets to the machine

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

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

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

BD06F110
Tighten the clamp on the after cooler.
Install and tighten the exhaust clamp on the
turbocharger, tighten the muffler mounting bolts. STEP 70
STEP 67
BD06F110
Tighten the clamp on the turbocharger for the after

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

2000-15
STEP 71 STEP 74
BD06F110 BD03A232
Install the intake hose and tighten the clamps on Carefully raise and place hood over loader.
turbocharger and air cleaner.
NOTE: Refer to step 7 and 8 of removal for lifting
procedure.
STEP 72
STEP 75
BD03A225
1
Install the crankcase ventilation hose and tighten the
BD03A227
clamp on air cleaner intake hose.
STEP 73
BD03A226
Have another person balance the hood, install the

hood hinge mounting bolts (2) to the cooler frame.
BD03A224 Install mount bolt (1) and backup alarm wiring
Connect engine wiring harness connector to air filter harness clamp to cooler housing.
restriction switch. Remove and discard tag.

2000-16
STEP 76 STEP 78
BD03A221
BD03A228
Install the pin from the top of the lifting motor, lower NOTE: If hood strut is not adjusted properly the
and remove lifting equipment. hood will be damaged.
When a hood is removed and replaced an initial
STEP 77 adjustment on the strut is necessary. Adjust between
the top of the lift motor adjusting jam nut (1) to the top
of the threads (2) to 20 mm (X). With the motor down
to its lowest point take a measurement between the
left hand side hood bumper and the counter weight,
record this measurement (Y). Use the following table
to adjust the strut (X).
Hood Adjustment Table
Y X Y X Y X Y X
(MM) (MM) (MM) (MM) (MM) (MM) (MM) (MM)
1 19 21 14 41 9 61 5
2 19 22 14 42 9 62 5
BD06F109
3 18 23 14 43 9 63 4
Connect hood wiring harness connector to rear
chassis wiring harness connector. Remove and 4 18 24 13 44 9 64 4
discard tag. 5 25 45 65
18 13 9 4
6 18 26 13 46 8 66 4
7 17 27 13 47 8 67 3
8 17 28 12 48 8 68 3
9 17 29 12 49 8 69 3
10 17 30 12 50 7 70 3
11 16 31 12 51 7 71 2
12 16 32 12 52 7 72 2
13 16 33 11 53 7 73 2
14 16 34 11 54 6 74 2
15 16 35 11 55 6 75 2
16 15 36 11 56 6 76 1
17 15 37 10 57 6 77 1
18 15 38 10 58 6 78 1
19 15 39 10 59 5 79 1
20 14 40 10 60 5 80 0

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

2000-18
RADIATOR
Removal STEP 5
STEP 1
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 2
BD06F128
Remove bolt and washer securing LH fender.

Remove LH fender.
STEP 6
BD03A040
Put articulation lock in LOCKED position.
STEP 3
Put master disconnect switch in OFF position.
STEP 4
BD02N160
Put a 37 liter (10 gallon) container below radiator

drain. Remove radiator cap then remove cap and
drain coolant into container. Install cap after coolant
has drained. Install radiator cap.
STEP 7
BD03A120
Have another person raise and hold the side panel

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

core up to gain access to upper radiator hose.

2000-19
STEP 8 STEP 11
2 2
BD03A108 BD03A106
Loosen the upper radiator hose clamps, remove the Remove screws and install lifting eyes (1). Attach
hose. suitable lifting equipment to lifting eyes. Remove four
mounting bolts (2), remove radiator from machine.
STEP 9
BD06F129
Loose and remove the lower radiator hose from the

radiator.
STEP 10
BD03A113
Disconnect overflow hose from radiator. Disconnect

connector from coolant level sender.

2000-20
Installation STEP 15
STEP 12
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.
STEP 13
1
BD06F129
At bottom of radiator, install bottom radiator hose.

2 2
Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
STEP 16
BD03A106
Install four lock washers and bolts (2) to secure

ra d i a t o r t o c o o li n g f ra m e. D i s c o n n e c t l i f t i n g
equipment from lifting eyes. Remove lifting eyes and
install screws (1).
STEP 14
BD03A108
At top of cooling system frame, install hose. Position

hose clamps and tighten to a torque of 10.1 to 11.3
Nm (90 to 100 lb-inch).
STEP 17
BD03A113
Connect connector to coolant level sender, connect

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

fender mounting bolt.

2000-21
STEP 18 STEP 21
BD06F131 BD03A120
Align the whole in the fender on the bolt. Have another person raise and hold the side panel
up into position. Apply Loctite 242 to the threads,
STEP 19 install the two mounting screws for the side panel
and torque to 6.5 ± 3.0 Nm (57.5 ± 26.5
pound-inches).
NOTE: Photo is of the oil cooler side of the machine,
the procedure is the same.
STEP 22
BD06F132
Align the slots in the fender with the tabs on the body
of the machine.
STEP 20
BD02N160
Check that coolant drain cap is tight.
STEP 23
capacity is 36.9 liter (9.75 gallon). Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
DSC00105.TIF
Push the fender towards the front of the machine and

secure it using washer and bolt.

2000-22
STEP 24 WARNING: Hot coolant can spray out if radiator cap
Put master disconnect switch in ON position. is removed. To remove radiator cap: Let system cool,
STEP 25
radiator cap.
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately STEP 26
five minutes to completely mix the Ethylene Glycol
Put articulation lock in OPERATING position.
an d wate r. Wh en the coo lan t is at o pe ra ting
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.

2002
Section
2002
STALL TEST

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

2002-3
SPECIFICATIONS
Low idle ..............................................................................................................................................875 to 925 rpm
Alternate low idle .................................................................................................................................575 to 625 rpm
Cold low idle ....................................................................................................................................1175 to 1225 rpm
In gear low idle when in boost or auto power modes (see note) .....................................................1050 to 1150 rpm
Full throttle (no load)........................................................................................................................2090 to 2225 rpm
Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)
NOTE: This low idle will be held after the engine has accelerated over 1400 rpm while in gear. It will remain at this
accelerated level until the transmission is placed back into neutral for two seconds.
Stall Speeds
Torque converter..............................................................................................................................1750 to 1895 rpm
Hydraulic system .............................................................................................................................1860 to 2175 rpm
Torque converter and hydraulic system together.............................................................................1500 to 1800 rpm
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
INSTRUMENT CLUSTER DISPLAYS

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

down arrow from the driving screen. It displays
engine RPM’s, speed, fuel level, and the voltage
level.
BD06F188
2. From the driving screen push the down arrow, as

shown.

2002-4
BD06F169
6. Press the down button again and the Trip 1

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

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

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

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

2002-6
POWER MODE SELECTION

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

two seconds to arrive at the above ser vice
screen.

2002-7
PERFORMING STALL TESTS
Test No. 1 - Torque Converter and Test No. 2 - Torque Converter Stall
Hydraulic Stall Together 1. Sit in the seat.
1. Sit in the seat.
2. Start the engine and run the engine at low idle.
3. Press the brake pedal, release the park brake,
3. Press the brake pedal, release the park brake, shift into Forward.
shift into Forward.
4. Run the engine at low idle.
4. Run engine at low idle. Push the clutch cutout
5. Push down and hold the brake pedal for the
switch to OFF. Put the transmission in manual
remainder of this test.
mode. Push down and hold the brake pedal for
the remainder of this procedure. 6. Turn the transmission control lever to third gear.
5. Turn the transmission control lever to third gear. 7. Increase the engine speed to full throttle.
6. Increase the engine speed to full throttle. 8. Check the engine speed.
7. Hold the bucket control lever in the ROLLBACK 9. Decrease the engine speed to low idle.
position and raise the lift arms.
10. Place the transmission in neutral and apply the
NOTE: The stall speed must be read while the lift parking brake.
arms are in motion.
11. Stop the engine.
8. Check the engine speed.
9. Release the bucket control lever. Understanding the Results of Test
No. 2
10. Decrease the engine speed to low idle.
1. If the engine speed was as specified, the engine,
11. Lower the bucket to the ground, place the torque converter and transmission are probably
transmission in neutral and apply the parking good.
brake.
2. If the engine speed was more than specified, the
12. Stop the engine. problem can be in the torque converter or the
t r a n s m i s s i o n . S e e S e c t i o n 6 0 0 2 fo r
Understanding the Results of Test troubleshooting information.
No. 1 3. If the engine speed was less than specified, do
1. If the engine speed was as specified, the engine, Test No. 3.
torque converter, transmission and hydraulic
system are probably good.
2. If the engine speed was not as specified, do Test
No. 2 and 3.

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

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

Section
2003
2003
AFTER COOLER

Racine, WI 53404 U.S.A. Bur 6-49850 Issued February, 2004
2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2003-3
TROUBLESHOOTING AFTER COOLER

STEP 1
Park machine on level ground, lower the bucket. Put
transmission in neutral, apply the parking brake. Turn
off engine.
STEP 2
Raise hood. Install ‘T’ fitting in waste gate valve hose.
Attach pressure gauge. Install another pressure
gauge into the intake manifold port.
STEP 3
Have assistant start engine and run at 2000 r/min BD03A118
(rpm). Record pressure readings for both gauges. If Inspect the after cooler outlet flex hose for leaks or
the pressure difference is greater than 60 mBar holes and insure that the clamps are tight.
(0.87 psi), inspect cooler components for damaged
or missing parts.
STEP 6
STEP 4
BD03A119
Inspect the intake manifold flex hose for leaks or

BD03A116
holes and insure that the clamps are tight.
Inspect the turbocharger flex hose for leaks or holes
and insure that the clamps are tight.
STEP 7
STEP 5
BD03A109
Visually inspect top of after cooler for damage or

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

2003-4
AFTERCOOLER REMOVAL
Removal STEP 4
STEP 1
BD03A118
Loosen clamps and remove air cooler outlet hose.

BD03A116
Loosen clamps and remove turbocharger outlet STEP 5

components.
STEP 2
BD03112
Raise air conditioning/air cooler cover. Support cover

with appropriate lifting device. Remove cover support
BD03A115 latch.
Loosen clamps and remove air cooler inlet hose.
STEP 6
STEP 3
BD03A111
BD03A119 Remove three cover mounting bolts and lift cover off.
Loosen clamps and remove Intake hose.

2003-5
STEP 7 STEP 10
BD03A109 BD03A113
Unlatch air conditioning condenser clamp. Remove two bolts, one from each side of the after
cooler mounting frame.
STEP 8
STEP 11
L i f t a i r c o o l e r a n d f ra m e f r o m m a c h i n e w i t h
appropriate lifting devise.
STEP 12
BD03A107
Rotate air conditioning condenser up and remove the

two retaining bolts, one on each side. Move the air
conditioning condenser back away from the air cooler
STEP 9 BD03A111
Remove four bolts that mount air cooler in the air

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

mounting frame.

2003-6
Leak Test Installation

STEP 1
BD03A111
BS03B028 Install after cooler in its frame. Install four mounting

Check the core for leaks by closing off the outlet tube bolts. Support after cooler with appropriate lifting
and attaching regulated air pressure 550kPa (80psi) device. Install the after cooler and frame in the
to the inlet tube. Submerge the cooler in water and machine.
watch for air leakage.
STEP 2
NOTE: If leakage is detected replace the after
cooler.
BD03A113
Install two side mounting bolts
STEP 3
BD03A117
Install two bolts at the rear of the after cooler

mounting frame.

2003-7
STEP 4 STEP 7
BD03A107 BD03A116
Position air conditioner condenser and install Install air cooler inlet hose. Tighten clamps at
mounting bolts. Rotate the condenser down and turbocharger outlet.
latch.
STEP 8
STEP 5
BD03A115
BD03112 Tighten clamps at air cooler inlet.

Support cover with appropriate lifting device. Raise
air conditioning/air cooler cover over machine. Install STEP 9
cover support latch.
STEP 6
BD03A119
Install air cooler outlet hose and tighten clamps at

engine intake.
BD03A111
Install three cover mounting bolts.

2003-8
STEP 10 STEP 11
Install ‘T’ fitting in waste gate valve hose. Attach
pressure gauge. Install another pressure gauge into
the intake manifold port.
STEP 12
Have assistant start engine and run at 2000 r/min
(rpm). Record pressure readings for both gauges.
confirm that the pressure difference is less than 60
mBar (0.87 psi).
BD03A118
Tighten clamps at air cooler outlet.

SECTION INDEX
FUEL SYSTEM
FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL

87519803

4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND

ALTERNATOR

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

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

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

Place the master disconnect switch in the OFF
position.
STEP 3
BD06F134
Place identification tags on the positive cables and

remove the positive cables from the starter.

4001-4
Installation STEP 7
STEP 5
1
BD06F134
2 Install and tighten the wires on the starter solenoid.
STEP 8
Place the master disconnect switch in the ON
BC05G047
1. STUDS position. Lower the engine compartment with lifting
2. NUTS motor.
Apply Loctite 747 primer to studs and holes, apply 2
drops of Loctite 271 to each hole and stud.
Immediately install and torque studs to 19 to 29 Nm
(14 to 21 pound-feet). Allow adhesive to cure for 20
minutes before installing starter.
STEP 6
BD06F135
Position the star ter on the machine, attach the

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

4001-5
ALTERNATOR
Removal STEP 4
STEP 1
ground.
STEP 2
BD06F137
BD06F133
Raise the engine compartment with lifting motor.

position.
STEP 3 BD06F138
Remove four belt cover mounting bolts, remove

cover.
STEP 5
BD06F136
Disconnect wires from the alternator.
BD06F139
Use a wrench to move the belt tensioner to loosen

the tension on the belt. Remove the belt.

4001-6
STEP 6 Installation
STEP 7
BD06F140
Remove mounting bolts for alternator, remove

alternator. BD06F140
Place alternator onto engine, install mounting bolts

for alternator and tighten.
STEP 8
BD06F139
Use a wrench to move the belt tensioner, install the

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

4001-7
STEP 9 STEP 10
BD06F137 BD06F136
Connect wires to the alternator, place rubber boot

over positive post.
STEP 11
BD06F138
Install belt cover, install four belt cover mounting

bolts and tighten.
BD06F133

position. Lower the engine compartment with lifting
motor.

4001-8
BELT INSTALLATION
BC05G045
WITH OUT AIR CONDITIONING
BC05G046
WITH AIR CONDITIONING

4002
Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING

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

4002-4
Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Power Relay Module E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4002-5
Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Air Recirculation Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
HOOD RAISE AND LOWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4002-6
NOTES

4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage................................................................................................................................................24 volts
Batteries
Group Size ..........................................................................................................................................................31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17° C (0° F) for 60 Seconds At 6.0 Volts................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Alternator ..................................................................................................................................... 24 volt, 65 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20° C (68° F) (Nominal)................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20° C (68° F) (Nominal) ........... 305 ohms
Fuel Level Sender............................................................................................................................... 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20° C (68° F) ......................................... 3521 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Set point ............................................................................................................................ 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig)
A/C Trinary Pressure Switch (Closed With Normal System Pressure)
Opens With Pressure ............................................................................ Above 28.5 ± 2.5 bar (413.3 ± 36,25 psi)
Below 2.5 ± 0.25 bar (36.25 ± 3.6 psi)
Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi)
Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi)
Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Set point........................ 5 to 6 bar increasing (75 to 85 psi)
Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi)
Fuel Filters Heater Resistance At 20° C (68° F) (Nominal) .......................................................................... 1.9 ohms
Parking Brake Solenoid DC Resistance At 20° C (68° F) (Nominal) .......................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20° C (68° F) (Nominal) .......................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20° C (68° F) (Nominal) ..................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20° C (68° F) (Nominal)............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20° C (68° F) (Nominal) .............................................................. 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20° C (68° F) (Nominal).......................................................... 39.3 ohms
Fan PWM Solenoid DC Resistance At 20° C (68° F) (Nominal) ..................................................................xx.x ohms
Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi)
Fuel Temperature Sensor At 20° C (68° F) (Nominal) ............................................................................... 2500 ohms
Grid Heater .................................................................................................................................................. 500 ohms
Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)
Analog Throttle ..................................................................................Idle Validation Switch Closes At 0.775V ± 0.1V
Throttle Position Potentiometer.................................................................................................. 5V Reference ± 0.2V
Low Idle Position .............................................................................................................................. 0.4V ± 0.025V
High Idle Position ................................................................................................................................. 4.0V ± 0.1V

4002-8
ELECTRICAL WIRE IDENTIFICATION
Wire Identification Codes

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

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

Color, Size,
Wire Circuit Connector Cavity Connector Cavity
and Material
14 Alternator D+ Lg 1.0 SXL AD, Alternator D+ 1 ENG, Engine Cab 26
42 Work Lights Switched Fused Pwr R2.0 GXL SPL-WL, Ultrasonic A ECC, Work Lights 23
44 Brake Lt Control Power T 1.0 SXL FRONT, Cab Front Chassis 23 PBL, Brake Light Press Switch 2
49 Back Lt Power DU1.0 GXL D-OR, Diode OR C SPL-BCK-LGT, Spl Back Lgt Pwr A
52 Fan Reverse LSD W 0.8 TXL AIC-1, Adv Instr Clust 1 23 ECB, Electrical Center B B8
56 Fan Control PWM W 0.8 TXL CAB-E, Cab Engine 23 AIC-1, Adv Instr Clust 1 26
57 Pin Engage Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 20 YPE, Pin Engage Option A
58 Ride Control Sol Pwr W 1.0 SXL PRBF, Rollback Press Sw A YRC, Ride Control Option 1
64 Horn Power Or 1.0 SXL FRONT, Cab Front Chassis 13 HN1, Horn Power 1
SPL-BCK-LT-GD2, Spl Back Lgt

0 29 RTT/Float Ground Bk 0.8 GXL SFL, Return To Travel Sw 4 K
Gnd
0 AA Proximity Switch Grnd Bk 1.0 SXL PXH, Height Control RTT B SPL-A2, Ultrasonic A
0 AB Proximity Switch Grnd Bk 1.0 SXL SPL-A2, Ultrasonic A GND-FC, Ground A 1
0 AC Proximity Switch Grnd Bk 1.0 SXL PXF, RTD B SPL-A2, Ultrasonic A
0 AD Ride Control Ground Bk 1.0 SXL YRC, Ride Control Option 2 SPL-A1, Ultrasonic A
0 AE Pin Engage Ground Bk 1.0 SXL SPL-A1, Ultrasonic A YPE, Pin Engage Option B
0 AF Horn Ground Bk 1.0 SXL HN2, Horn Ground 1 SPL-A1, Ultrasonic A
0 AG Front Chassis Ground Bk 2.0 SXL SPL-A1, Ultrasonic A GND-FC, Ground A 1
0 AH RH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LRF, Lights RH 1
0 AJ LH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LLF, Lights LH 1
0 AK Park Brake/Warning Ground Bk 1.0 SXL SPL-A4, Ultrasonic A GND-FC, Ground A 1
0 AL Brake Warning Press Sw Gnd Bk 1.0 SXL PBW, Brake Warn Press Sw 2 SPL-A4, Ultrasonic A
0 AM RTD Grnd Bk 1.0 SXL PXM, RTD B PXT, RTD B
0 AN Park Brake Solenoid Ground Bk 1.0 SXL YPB, Park Brake Solenoid 2 SPL-A4, Ultrasonic A
0 AP Front To Rear Chassis Ground Bk 5.0 SXL GND-S1, Ground A 1 GND-S2, Ground A 1
0 AQ Comfort Steering Solenoid Gnd Bk 1.0 SXL YCS, Comfort Steer Solenoid B SPL-A4, Ultrasonic A
0 AR Front Axle Temp Sensor Ground Bk 1.0 SXL FRONT, Cab Front Chassis 9 HOT-FA, Front Axle Oil Temp 2
0B Front Washer Ground Bk 1.0 SXL FWW, Front Washer 2 SPL-ENG-GRD, Gnd Spl 6 Pck E
SPL-PED-BL-GD, Spl Bk Lgt

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

4002-9

21C Bk - 1.0


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

4002-10

21C Bk - 1.0


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

0 B24 Back Light Ground Bk 0.8 GXL SHZ, Hazard Switch 7 C
6 Pck
SPL-HOOD-GRND, Hood
0 B25 Hood Up Control Ground Bk 1.0 GXL D ECC, Work Lights B2
Gnd 6 Pck
0 B26 Buzzer/Switch Pad Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A 6
Grnd
0 B27 Buzzer Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A BUZ, AIC Buzzer 2
0 B28 Switch Pad Ground Bk 0.8 TXL SW-PD, Switch Pad 10 SPL-BUZ, Ultrasonic A

0 B29 RTT/Float Ground Bk 0.8 GXL SPB, Parking Brake Switch 7 E
6 Pck
0 B30 Back Light Ground Bk 0.8 GXL SETHR, Ether Switch 7 D
6 Pck
0 BA Pedestal Gnd Strap Bk 5.0 SXL. GND-PDST, Ground A 1 GND-PDST2, Ground A 1
0 BAC EDC7 Ground Bk 2.0 SXL SPL-EDC1, Ultrasonic A GND-ENG2, WIF, EDC 1
0 BAE EDC7 Sender Ground Bk 1.0 SXL RECT, Engine Coolant Temp B GND-ENG7, Tranny, Cool Temp 1
0 BAF Coolant Lever Sender Ground Bk 1.0 SXL CLS, Cool Jump-Cool Sender B GND-ENG7, Tranny, Cool Temp 1
0 BAG Hood Grounds (EURO) Bk 1.0 SXL GND-ENG4, Rear Lighting 1 E-HD, Trans Hood c
0 BAG
Hood Grounds (NA) Bk 1.0 SXL ENG-H, Engine to Hood 1 GND-ENG4, Rear Lighting 1
N
0 BAH QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 29
0 BAI QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 30
0 BAJ QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 39
0 BAK QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 40
0 BAL QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 41
0 BAM Ether Relay Signal Ground Bk 1.0 SXL PRM-C2, PRM signal B GND-ENG2, WIF, EDC 1
GND-ENG3, Spl Pck Washer

0 BAN Ether Start Ground Bk 1.0 SXL ETHR, Ether Solenoid B 1
Motor
0 BAP QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 50
GND-WIF, Gnd WIF Ring

0 BAR WIF Body Ground Bk 1.0 SXL 1 GND-ENG6, Dedicated 1
Term
0 BAS Rear Axle Temp Sensor Ground Bk 1.0 SXL HOT-RA, Rear Axle Oil Temp 2 GND-ENG7, Tranny, Cool Temp 1
0 BB Fan Reverse Solenoid Ground Bk 1.0 SXL YFR, Fan Reverse Sol Opt 2 SPL-FAN, Ultrasonic A
0 BC EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 11
4002-11

21C Bk - 1.0


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

0 BM Engine Splice Grounds Bk 1.0 SXL A 1
Pck Motor
0 BN Filter Heater Control Bk 0.8 GXL PRM-C2, PRM Signal B EDC7, Engine Controller 13
0 BP WIF Sensor Ground Bk 1.0 SXL GND-ENG2, WIF, EDC 1 WIF, Water In Fuel Sensor 2
0 BQ Fan Speed PWM Sol Grd Bk 1.0 SXL YFN, Fan PWM Solenoid B SPL-FAN, Ultrasonic A
0 BR RH Rear Light Ground (EURO) Bk 1.0 SXL LRR-E, RH Rear Comb Lamp 5 GND-ENG4, Rear Lighting 1
0 BR N LH Rear Light Ground (NA) Bk 1.0 SXL LLR-N, LH Rear Comb Lamp D SPL-J1, Ultrasonic A
0 BS Fan Control Ground Bk 1.0 SXL SPL-FAN, Ultrasonic A SPL-ENG-GRD, Grd Spl 6 Pck D
0 BT LH Rear Light Ground (EURO) Bk 1.0 SXL LLR-E, LH Rear Comb Lamp 5 GND-ENG4, Rear Lighting 1
0 BT N RH Rear Light Ground (NA) Bk 1.0 SXL LRR-N, RH Rear Comb Lamp D SPL-J1, Ultrasonic A
0 BU Fuel Level Sender Ground Bk 1.0 SXL RFLG, Fuel Send Ground 1 GND-ENG7, Tranny, Cool Temp 1
0 BV Grid Heater Control Grnd Bk 0.8 TXL GHC, Grid Heater Relay 2 EDC7, Engine Controller 75
GND-ENG1, Start, FFH,
0 BW Water Separator Htr Ground Bk 2.0 SXL 1 WSH, Water Separator Heater A
WSH
0 BX Fuel Filter Heater Ground Bk 2.0 SXL FFH, Fuel Filter Heater B GND-ENG1, Start, FFH, WSH 1
SPL-ENG-GRD, Grd Spl 6

0 BY Air Filter Restriction Sw Grd Bk 1.0 SXL B PAF, Air Filter Restriction Sw 2
Pck
GND-ENG3, SPLC-PK, Washer
0 BZ Sec. Steering Splice Grd Bk 1.0 SXL ENG-T, Engine To Trans 1 1
Motor
0 CA Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 11 SPL-SEC-STR, Sec. Steer 6 Pck B
0 CB Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 12 SPL-SEC-STR, Sec. Steer 6 Pck A
PSS, Sec. Steer Press
0 CC Sec. Steering Press Sw Ground Bk 1.0 SXL B SPL-SEC-STR, Sec. Steer 6 Pck C
Switch
SPL-SEC-STR, Sec. Steer 6
0 CD Sec. Steering Splice Ground Bk 1.0 SXL F SS-TR, SS Mod Trans D
Pck

4002-12

21C Bk - 1.0


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

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

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

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

4002-13

21C Bk - 1.0


Color, Size,
and Material
0 EA Time Delay relay Control Grnd Bk 0.8 GXL B PRM-B2, PRM Signal B
Light Ground
0 EB Ignition Relay Control Ground Bk 0.8 GXL C PRM-A1, PRM Signal B
Light Ground
0 EC ACC Relay Control Ground Bk 0.8 GXL D PRM-D1, PRM Signal B
Light Ground
0 ED HVAC Grounds Bk 3.0 SXL HVAC2, HVAC2 2 GND-CAB4, Ground C 1
GND-CAB-SPL, Cab Grnd

0 EE DIODE Suppression Grounds Bk 0.8 GXL A 140M, DIODE Module C
Spl
0 EF Brake Lights Relay Ctrl Grnd Bk 0.8 GXL M ECC, Work Lights B6
Light Ground
GND-CAB-SPL2, Spl Back Light
0 EG Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 4 L
Ground
GND-CAB-SPL2, Spl Back Light
0 EH Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 3 K
Ground
CNV, 24V to 12V Pwr
0 EJ Power Converter Ground Bk 1.0 GXL 3 GND-CAB4, Ground C 1
Convert
0 EK AUX Power Outlet 1 Grnd Bk 1.0 GXL PO1, Power Outlet C GND-CAB5, Ground C 1
0 EL AUX Power Outlet 2 Grnd Bk 1.0 GXL PO2, Power Outlet C GND-CAB5, Ground C 1
0 EM Radio Ground Bk 0.8 GXL CAB-RF, Cab to Roof Conn. M GND-CAB-SPL, Cab Grnd Spl B
0 EN Radio Ground Bk 0.8 GXL ROOF, Roof to Cab Conn. M RAD, Radio Power 8
0 EP Horn Switch Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl C SRHSTLK, RH Stalk Switch 31
Splice Pack GND-CAB-SPL2 GND-CAB-SPL2, Spl Back GND-CAB6, Start, FFH, Water
0 EQ Bk 0.8 GXL H 1
Grnd Light Ground Sep Htr
0 ER Power Converter Grnd Bk 1.0 GXL CNV, 24V to 12V Pwr Conv 6 GND-CAB4, Ground C 1
GND-GH1, STRT, FFH, Water
0 ES Grid Heater Ground Bk 19.0 SXL GH-1, Grid Heater 1 1
Sep Htr
GND-ENG1, STRT, FFH, Water
0 GB Starter Relay Control Ground Bk 1.0 SXL SRC-1, Relay 2 1
Sep Htr
SPL-TRN-GND, Spl Trans
0 HC Trans Splice Grounds Bk 1.0 SXL A TRAN-E, Trans to Engine 2
Ground
0 HD Speed Sensor Grounds Bk 1.0 SXL TRANS, Cab Transmission 11 SPL-H2, Ultrasonic A
0 HE Output Speed Sensor Grnd Bk 1.0 SXL TRANS, Cab Transmission 28 OSS, Out Speed Sensor 1
Bk 0.8 GXL
0 HF Engine Speed Sensor Grnd ESS, Engine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist

4002-14

21C Bk - 1.0


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

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

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

4002-15

21C Bk - 1.0


Color, Size,
and Material
0 PA Left Speaker Grnd Bk 0.8 GXL LSPK, Left Speaker 2 SPK, Speaker 8
0 PB Right Speaker Grnd Bk 0.8 GXL RSPK, Right Speaker 2 SPK, Speaker 2
12ACC Ignition Switch ACC Power W 0.8 GXL S-KEY, Ignition Switch 4 SPL-ACC, Ultrasonic A
12ACC
ACC PRM control Power W 0.8 GXL SPL-ACC, Ultrasonic A PRM-D1, PRM Signal A
B
12ACC Power Converter PRM Control
W 0.8 GXL SPL-ACC, Ultrasonic A PRM-E2, PRM Signal A
C Power
12V 12V Pwr To Outlet 1 Or 1.0 GXL PO1, Power Outlet A ECD, Elect Center D AA4
12V A 12V Pwr To Outlet 2 Or 1.0 GXL PO2, Power Outlet A ECD, Elect Center D AA5
12V B 12V Fused Pwr to Radio Or 1.0 GXL CAB-RF, Cab to Roof Conn. N ECD, Elect Center D AA6
12V C 12V Switched Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 5 SPL-12V, Ultrasonic A
12V D Plug 1 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A4
12V E Plug 2 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A5
12V F Radio 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A6
12V G 2 Way Radio 12V Switched Pwr Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A7
12V H 12V Fused Power to Radio Or 0.8 GXL ROOF, Roof to Cab Conn. N SPL-RAD, Ultrasonic A
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 7
HA
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 4
HB
13C Fuel Shutoff Fused Power Or 1.0 SXL DC3, Fuel Solenoid Disc 1 DISC, Disconnect Engine A
13C A Fuel Shutoff Fused Power Or 1.0 SXL ENG-D, Disc Harness A ENG, Engine Cab 21
13C B Fuel Shutoff Fused Power Or 1.0 SXL CAB-E, Cab Engine 21 ECA, Elect Center A A9
13D Time Delay Relay Control Pwr Or 1.0 SXL TDM, Time Delay Module 1 PRM-B2, PRM Signal A
13H Time Delay Power Or 3.0 GXL SPL-DLY-RL, Ultrasonic A PRM-B1 PRM Output C
13H B AIC Time Delay Power Or 0.8 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A3
13H C Trans ECM Time Delay Power Or 0.8 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A1
13H D Engine ECM Time Delay Power Or 3.0 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A2
13K Ignition Switch Pwr Or 1.0 GXL S-KEY, Ignition Switch 3 SPL-PK1, Slice 3-4 Way E
13K A Ignition Switch Pwr Or 1.0 GXL TDM, Time Delay Module 5 SPL-PK1, Slice 3-4 Way G
13K B Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way F PRM-A1, PRM Signal A
13K C Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way H ECB, Elect Center B D1

4002-16

21C Bk - 1.0


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

4002-17

21C Bk - 1.0


Color, Size,
and Material
18G F RH Position/Tail Fused Power Or 0.8 GXL CAB-E, Cab Engine 9 SPL-POS-R, Ultrasonic
18G G RH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis A SPL-POS-R, Ultrasonic
18G H RH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 9 SPL-POS, Ultrasonic A
18G
RH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 9 ENG-H, Engine to Hood 5
HN
LRR-E, RH Rear
18G J RH Position/Tail Fused Power Or 1.0 SXL 3 SPL-POS, Ultrasonic A
Combination Light
18G
RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-POS-NA, Ultrasonic A
JN
18G K RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-P9, Ultrasonic A
18G L RH Position/Tail Fused Power Or 1.0 SXL SPL-P9, Ultrasonic A E-HD9, Trans Hood A
LRR-9, RH Rear Combination

18G M RH Position/Tail Fused Power Or 1.0 SXL SPL-P9, Ultrasonic A 3
Light
18J EDC7 Time Delay Fused Power Or 2.0 GXL CAB-E, Cab Engine 18 SPL-D2, Ultrasonic A
18J A EDC7 Time Delay Fused Power Or 2.0 GXL ENG, Engine Cab 18 SPL-EDC2, Ultrasonic A
18J B EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 3
18J C EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 2
18J D EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC4, Ultrasonic A EDC7, Engine Controller 8
18J E EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC4, Ultrasonic A EDC7, Engine Controller 9
18J F EDC7 Time Delay Fused Power Or 2.0 SXL ENG, Engine Cab 14 SPL-EDC4, Ultrasonic A
18J G EDC7 Time Delay Fused Power Or 2.0 GXL CAB-E, Cab Engine 14 SPL-D2, Ultrasonic A
18J H Water In Fuel Sensor Fused Pwr Or 1.0 GXL SPL-EDC4, Ultrasonic A WIF, Water In Fuel Sensor 3
18J K EDC7 Time Delay Fused Power Or 3.0 GXL SPL-D2, Ultrasonic A ECD, Elect Center D AA2
18J L QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 17
18J M QSM11 Time Delay Power Or 0.8 GXL SPL-EDC2, Ultrasonic A QSM11, Engine controller 7
18J N QSM11 Time Delay Power Or 0.8 GXL SPL-EDC2, Ultrasonic A QSM11, Engine controller 8
18J P QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 18
18J Q QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 28
18K A Diagnostic Fused Power Or 0.8 GXL DIA, Diagnostic B ECC, Work Lights A9
18L A Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECA, Elect Center A A2
18L B Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECC, Work Lights D9
18L C Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECC, Work Lights B9

4002-18

21C Bk - 1.0


Color, Size,
and Material
18L D Comfort Steer Fused Power Or 0.8 GXL SCS, Comfort Steer Switch 2 SPL-CSTR, Ultrasonic A
18M AC Relay Fused Power Or 0.8 GXL ECA, Elect Center A C5 ECD, Elect Center D B9
18N Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A ECA, Elect Center A C1
18N A Blower Motor Fused Power Or 0.8 GXL SPL-BLWR, Ultrasonic A HVAC1, HVAC1 2
18N B Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A HVAC2, HVAC2 1
18R Voltmeter Relay Fused Power Or 2.0 SXL ENG, Engine Cab 13 PRM-C1, PRM Output A
18R A Voltmeter Relay Fused Power Or 2.0 GXL CAB-E, Cab Engine 13 ECB, Elect Center B B1
19A Output Speed Sensor Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 29 OSS, Out Speed Sensor 3
19A A Brake Declutch Sw Fused Pwr Or 1.0 SXL FRONT, Cab Front Chassis 27 PBD, Dec. Pressure Switch A
19A B FNR Switched Fused Power Or 0.8 GXL 197M, FNR Main Cab 1 SPL-FNR, Ultrasonic A
19A C FNR Switched Fused Power Or 0.8 GXL 197F, Main Cab FNR 1 SPL-TRNS-PWR, Trans Pwr F
19A D Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 2 SPL-D15, Ultrasonic A
19A E Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 10 SPL-D15, Ultrasonic A
19A F Trans Enable Switch Fused Pwr Or 0.8 GXL SPL-TRNS-PWR, Trans Pwr B SPL-D15, Ultrasonic A
19A G FNR Sw Fused Power Or 0.8 GXL SPL-FNR, Ultrasonic A SFNR, FNR Switch 8
19A H Trans Shifter Fused Power Or 0.8 GXL TS1, Transmission Shifter A SPL-TRNS-PWR, Trans Pwr M
19A J Pilot Control Switched Fused Or 0.8 GXL SPC, Pilot Control Switch 2 SPL-PB1, Ultrasonic A
Pwr
SPL-TRANS-PWR, Trans
19A K TECM Fused Power Or 0.8 TXL J TECM, Trans 45
Pwr
19A L Park Brake Switched Fused Pwr Or 0.8 GXL SPB, Parking Brake Switch 2 SPL-PB1, Ultrasonic A
19A M Output Speed Sensor Fused Pwr Or 0.8 TXL CAB-T, Cab Transmission 29 SPL-TRNS-PWR, Trans Power K
19A N Trans Fused Power Or 1.0 GXL A ECA, Elect Center A A1
Pwr
19A P Backup Alarm Relay Control SPL-TRANS-PWR, Trans

Bk 1.0 GXL G ECD, Elect Center D AA10
Fused Power Pwr
19A Q Trans/Auto Switch Fused Power Or 0.8 GXL STA, Trans Auto Switch 2 SPL-TRANS-PWR, Trans Pwr C
19A R Declutch Switch Fused Power Or 0.8 GXL SDC, Declutch Switch 2 SPL-TRANS-PWR, Trans Pwr H
19A S Trans Fused Power Or 0.8 GXL L SPL-PB1, Ultrasonic A
Pwr
19A T Brake Declutch Switch Fused Or 0.8 GXL CAB-F, Cab Front Chassis 27 SPL-TRANS-PWR, Trans Pwr D
Power

4002-19

21C Bk - 1.0


Color, Size,
and Material
19A U Trans Dick Down Switch Fused Or 0.8 GXL SPL-FNR, Ultrasonic A 20M, Trans Kick Down 1
Power
19A V FNR Switch Fused Power Or 0.8 GXL SFNR, FNR Switch 5 SPL-FNR, Ultrasonic A
19A W Diagnostic Conn. Fused Power Or 0.8 GXL 108F, Diagnostic Connector 1 SPL-TRANS-PWR, Trans Pwr E
19B Turn Signal Fused Power Or 0.8 GXL SRHSTLK, RH Stalk Switch 49a ECA, Elect Center A A8
19C A Pilot Ctrl Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A ECA, Elect Center A A5
19C B Pilot Ctrl Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A ECD, Elect Center D B5
19C C Pilot Ctrl Fused Pwr Or 0.8 GXL SPL-D24, Ultrasonic A ECD, Elect Center D D5
19C D Ride Control Fused Pwr Or 1.0 GXL SRC, Ride Control Switch 2 SPL-D24, Ultrasonic A
19D A Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECA, Elect Center A A6
19D B Parking Brake Relay Fused Pwr Or 0.8 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B D9
19D C Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B B9
19E A AIC Wake Up Ignition Or 0.8 TXL AIC-2, Adv Instr Cluster 2 21 ECA, Elect Center A A3
19H Backup Alarm Relay Fuse Pwr Or 1.0 GXL ECA, Elect Center A C4 ECD, Elect Center D A10
19J Front Wiper Fused Pwr Or 0.8 GXL SPL-PK3, Splice 3-4 Way K ECA, Elect Center A C2
19J A Front Wiper Motor Fused Pwr Or 0.8 GXL SPL-PK3, Splice 3-4 Way M FWM, Front Wiper Motor C
19J B Front Wip Wash Sw Fused Pwr Or 0.8 GXL SFWW, Front Wiper/Washer 5 SPL-PK3, Splice 3-4 Way J
19J C Front Wiper Relay Fused Power Or 0.8 GXL SPL-PK3, Splice 3-4 Way L SPL-FW, Ultrasonic A
19J D Front Wiper Relay HS Control Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D D1
Fused Power
19J E Front Wiper Relay Fused Power Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D B1
Front Wiper Relay LS Control A D3

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

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

4002-20

21C Bk - 1.0


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

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

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

19U C Dome Lt Fused Pwr Or 0.8 GXL D LDM1, Dome Light B+ 1
Connection

4002-21

21C Bk - 1.0


Color, Size,
and Material
CAB-RF, Cab to Roof
19U D Dome Lt Fused Pwr Or 0.8 GXL D SPL-LT, Ultrasonic A
Connection
19U E Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Work Lights D7
ROOF, Roof to Cab

19U F Door Sw Fused Power Bk 0.8 GXL S DS, Door Switch A
Connection
CAB-RF, Cab to Roof
19U G Door Sw Fused Power Or 0.8 GXL S SPL-LT, Ultrasonic A
Connection
19U H Beacon Switch Fused Power Or 1.0 GXL SBE, Beacon Switch 2 SPL-LT, Ultrasonic A
19W Cigar Lighter Pwr Or 3.0 GXL CL, Cigar Lighter 1 ECC, Work Lights A8
19Y Hood control Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights A7
19Y A Hood Up Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights D2
19Y B Hood Down Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights D4
19Y C Hood Switch Fused Power Or 1.0 GXL CAB-E, Cab Engine 35 SPL-HOOD, Ultrasonic A
19Y D Hood Switch Fused Power Or 1.0 GXL ENG, Engine Cab 35 HD, Hood Switch B
19Z Driving Lights Sw Fused Power Or 1.0 GXL SPL-PK2, Splice 3-4 Way G ECC, Work Lights A3
19Z A Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 2 SPL-PK2, Splice 3-4 Way E
19Z B Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 5 SPL-PK2, Splice 3-4 Way F
19Z C High Beam Flash Fused Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56d SPL-PK2, Splice 3-4 Way H
1A Ign Switch Fused Power R 1.0 GXL S-KEY, Ignition Switch 1 SPL-DLY, Ultrasonic A
1CB Cab CB Protected Power R 19.0 SXL CB1A, Circuit Breaker 1 CBPW, Cab Power 1
1CB A Cab CB Protected Power R 19.0 SXL P-A3, B+ Power 1 CAB-PW, Cab Power 1
1DM Time Delay/Ign Sw Fused Pwr R 1.0 GXL SPL-DLY, Ultrasonic A ECC, Work Lights A5
1DN Time Delay Fused Power R 1.0 GXL TDM, Time Delay Module 2 SPL-DLY, Ultrasonic A
1NC Cab CB PRM Power R 19.0 SXL B1, Starter Power Stud 1 CB2B, Cab B+ CB 1
1 AA Brake Lt Sw Pwr R 1.0 SXL FRONT, Cab Front Chassis 22 PBL, Brake Light Press Switch 1
1 B9 PRM C Power R 8.0 SXL CB3B, Cab B+ CB 1 P-C5, B+ Power from PRMC 1
1 BA Alternator B+ R 13.0 SXL AB+, Alternator B+ 1 B2 Starter Power 1
1 BB Starter Solenoid Pwr R 8.0 SXL 193 Starter Relay 1 194 Starter Signal 1
1 BC Cab CB Power R 19.0 SXL P-C3, B+ Power From PRMC 1 CB1B, Cab B+ CB 1
1 BE Grid Htr Pwr R 19.0 SXL 115 Grid Htr Pwr 1 GH, Grid Htr 1
1C ECC Bat Power R 8.0 GXL P-A1, B+ Power 1 L1-ECC, ECC Battery Power cs01
1 DR Brake Light Switch Power R 1.0 GXL CAB-F, Cab Front Chassis 22 SPL-FLSHR-PWR, Ultrasonic A

4002-22

21C Bk - 1.0


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

4002-23

21C Bk - 1.0


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

4002-24

21C Bk - 1.0


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

4002-25

21C Bk - 1.0


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

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

4002-26

21C Bk - 1.0


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

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

4002-27

21C Bk - 1.0


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

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

4002-28

21C Bk - 1.0


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

4002-29

21C Bk - 1.0


Color, Size,
and Material
43 B Dome Light Auto Mode DU 0.8 GXL ROOF, Roof to Cab Conn. A LDM2, Dome Light Auto 1
44A A Brake Light Relay Out T 0.8 GXL SPL-BRK, Ultrasonic A ECC, Work Lights D6
44A B Brake Light Relay Out T 0.8 TXL SPL-BRK, Ultrasonic A AIC-1, Adv Instrument Cluster 1 15
44A C Brake Light Relay Out T 0.8 GXL CAB-E, Cab Engine 8 SPL-BRK, Ultrasonic A
44A D Brake Light Relay Out T 1.0 SXL ENG, Engine Cab 8 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL ENG, Engine Cab 8 ENG-H, Engine to Hood 2
DN
44A E Brake Light Relay Out T 1.0 SXL LLR-E, LH Rear Comb Light 1 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL HD-N, Hood to Engine 2 SPL-J2-N, Ultrasonic A
EN
44A F Brake Light Relay Out T 1.0 SXL LRR-E, RH Rear Comb Light 1 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL LLR-N, LH Rear Comb Light A SPL-J2-N, Ultrasonic A
FN
44A
Brake Light Relay Out T 1.0 SXL LRR-N, RH Rear Comb Light A SPL-J2-N, Ultrasonic A
GN
44A J Brake Light Power T 1.0 SXL SPL-L1, Ultrasonic A HD-9, Hood to Engine 2
44A K Brake Light Power T 1.0 SXL SPL-L1, Ultrasonic A LRR-9, RH Rear Comb Light 1
44A L Brake Light Power T 1.0 SXL LLR-9, LH Rear Comb Light 1 SPL-L1, Ultrasonic A
44 A Brake Light Control Power T 0.8 GXL CAB-F, Cab Front Chassis 23 ECC, Work Lights D5
45A A Left Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 9 SRHSTLK, RH Stalk Switch L
45B A Right Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 10 SRHSTLK, RH Stalk Switch R
45H Hazard Switch Power N 0.8 GXL FLSHR, Flasher Module 11 SHZ, Hazard Switch 3
45L Left Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 1 LLF, Lights LH 5
45L 9 Left Turn Signal N 1.0 SXL HD-9, Hood to Engine 3 LLR-9, LH Rear Comb Light 2
45L A Left Turn Signal N 1.0 SXL ENG, Engine Cab 10 LLR-E, LH Rear Comb Light 2
45L AN Left Turn Signal N 1.0 SXL ENG, Engine Cab 10 ENG-H, Engine to Hood 3
45L B Left Turn Signal N 0.8 GXL CAB-E, Cab Engine 10 SPL-PK3, Splice 3-4 Way D
45L BN Left Turn Signal N 1.0 SXL HD-N, Hood to Engine 3 LLR-N, LH Rear Comb Light C
45L C Left Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 1 SPL-PK3, Splice 3-4 Way C
45L D Left Turn Signal N 0.8 GXL FLSHR, Flasher Module 8 SPL-PK3, Splice 3-4 Way B
45L E Left Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way A AIC-2, Adv Instrument Cluster 2 9
45N A Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 2 64F, Flasher Connector 1

4002-30

21C Bk - 1.0


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

49U Back Light Power S 0.8 GXL SETHR, Ether Switch 8 D
Pck
49 A Back Light Power S 0.8 GXL SWL, Work Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr M
49 B Back Light Power S 0.8 GXL SBE, Beacon Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr L
49 C Back Light Power S 0.8 GXL SRWP, Rear Wiper Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr C
49 D Back Light Power S 0.8 GXL SHZ, Hazard SWitch 8 C
Pck
SPL-BCK-LGT2, Spl Back
49 E Back Light Power S 0.8 GXL A SPL-BCK-LGT, Spl Back Lgt Pwr K
Lgt Pwr
SPL-BCK-LGT2, Spl Back Lgt
49 F Back Light Power S 0.8 GXL SPE, Pin Engage Switch 10 F
Pwr
49 G Back Light Power S 0.8 GXL SRC, Ride control Switch 8 K
Pwr
49 H Back Light Power S 0.8 GXL STE, Trans Enable Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr D

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

4002-31

21C Bk - 1.0


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

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

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

49 S Back Light Power S 0.8 GXL F M
Pwr 6 Pck Pwr
49 T Back Light Power S 0.8 GXL SFWW, Front Wiper/Washer 8 H
Pwr
49 U Back Light Power S 0.8 GXL SCS, Comfort Steer Switch 8 A
Pck
49 V Back Light Power S 0.8 GXL SPB, Parking Brake Switch 8 E
Pck
51B A Comfort Steer Solenoid Power W 0.8 GXL SCS, Comfort Steer Switch 6 SPL-CSS, Ultrasonic A
51B B Comfort Steer Solenoid Power W 0.8 GXL SPL-CSS, Ultrasonic A ECC, Work Lights D10
51B C Comfort Steer Solenoid Power W 0.8 GXL SPL-CSS, Ultrasonic A CAB-F, Cab Front Chassis 2
51B D Comfort Steer Solenoid Power W 1.0 SXL FRONT, Cab Front Chassis 2 YCS, Comfort Steer Solenoid A
AIC-1, Adv Instrument

51C Comfort Steer control W 0.8 TXL 21 ECC, Work Lights B10
Cluster 1
51CS Comfort Steer Switch W 0.8 TXL SCS, Comfort Steer Switch 3 AIC-1, Adv Instrument Cluster 1 17
51P A Sec. Str High Press W 1.0 SXL SSM, Sec. Steer Module 9 PSS, Sec. Steer Pressure Switch A
51S Standard Steering Signal W 0.8 TXL SCS, Comfort Steer Switch 1 AIC-1, Adv Instrument Cluster 1 16
51 A Sec. Str Motor Control W 1.0 SXL SSM, Sec. Steer Module 2 SPL-SS, Ultrasonic A
51 B Sec. Str Motor Control W 1.0 SXL SPL-SS, Ultrasonic A SSS, SS Mag Switch 1
51 C Sec. Strg Sol Control W 1.0 SXL SPL-SS, Ultrasonic A YSS, Sec. Steering Solenoid 1
52AU Fan Reverse Auto W 0.8 TXL SFC, Fan Control Switch 3 AIC-2, Adv Instrument Cluster 2 8
52A A Fan Reverse Relay Out W 1.0 GXL CAB-E, Cab Engine 22 ECB, Elect Center B D8
52A B Fan Reverse Relay Out W 1.0 SXL ENG, Engine Cab 22 YFR, Fan Rev Solenoid Option 1

4002-32

21C Bk - 1.0


Color, Size,
and Material
52C Parking Brake Solenoid LSD W 0.8 TXL 14 ECB, Elect Center B B10
Cluster 1
52J Fan Control Switch Jumper W 0.8 GXL SFC, Fan Control Switch 4 SFC, Fan Control Switch 2
52M Fan Reverse Manual W 0.8 TXL SFC, Fan Control Switch 6 AIC-2, Adv Instrument Cluster 2 7
52P Parking Brk Relay Out W 1.0 SXL FRONT, Cab Front Chassis 24 YPB, Park Brake Solenoid 1
52P A Parking Brk Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 24 SPL-PB, Ultrasonic A
52P B Parking Brk Relay Out W 0.8 GXL SPL-PB, Ultrasonic A ECB, Elect Center B D10
52P C Parking Brk Relay Out W 0.8 TXL SPL-PB, Ultrasonic A TECM, Trans 21
53A RTD Switch Power W 0.8 GXL SRTD, Detent Switch 3 EM, RTD Height Control RTT 3
53B RTD Signal W 1.0 SXL FRONT, Cab Front Chassis 12 PXF, RTD C
53B A RTD Signal W 1.0 SXL PXM, RTD A PXT, RTD A
53B B RTD Signal W 0.8 GXL EM, RTD Height Control RTT 4 CAB-F, Cab Front Chassis 12

53C A Pilot Control Solenoid LSD W 0.8 TXL 20 ECD, Elect Center D B6
Cluster 1
53P A Pilot Control Relay Out W 0.8 GXL SPL-D25, Ultrasonic A YPP, Pilot Pressure Solenoid A
53P B Pilot Control Relay Out W 0.8 GXL SFL, Return to Travel Switch 2 SPL-D25, Ultrasonic A
53P C Pilot Control Relay Out W 1.0 GXL SPL-D25, Ultrasonic A ECD, Elect Center D D6
53P D Pilot Control Relay Out W 0.8 GXL SHC, Height Control Switch 2 SPL-D25, Ultrasonic A
53P E Pilot Control Relay Out W 0.8 GXL SRTD, Detent Switch 2 SPL-D25, Ultrasonic A
53P F Pilot Control Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 19 SPL-D25, Ultrasonic A
53P G Pilot Control Relay Out W 1.0 SXL FRONT, Cab Front Chassis 19 SPL-A3, Ultrasonic A
53P H Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXF, RTD C
53P I Pilot Control Relay Out W 1.0 SXL PXM, RTD C PXT, RTD C
53P J Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXH, Height Control RTT C
54A Height Control Switch Power W 0.8 GXL SHC, Height Control Switch 6 EM, RTD Height Control RTT 2
54B Height RTT Control Signal W 1.0 SXL FRONT, Cab Front Chassis 11 PXH, Height Control RTT A
54B A Height RTT Control Signal W 0.8 GXL CAB-F, Cab Front Chassis 11 SPL-D1, Ultrasonic A
54B B Height RTT Control Signal W 0.8 GXL EM, RTD Height Control RTT 5 SPL-D1, Ultrasonic A
54B C Height RTT Control Signal W 0.8 GXL SFL, Return to Travel Switch 6 SPL-D1, Ultrasonic A
55A A RTT Float Sw Power W 0.8 GXL EM, RTD Height Control RTT 1 SPL-RTT, Ultrasonic A
55A B RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 1 SPL-RTT, Ultrasonic A

4002-33

21C Bk - 1.0


Color, Size,
and Material
55A C RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 3 SPL-RTT, Ultrasonic A
55B RTT Float Switch Control W 0.8 GXL SFL, Return to Travel Switch 5 EM, RTD Height Control RTT 6
56 A Fan Control PWM W 1.0 SXL ENG, Engine Cab 23 YFN, Fan PWM Solenoid A
57 A Pin Engage Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 20 SPL-PINE, Ultrasonic A
57 B Pin Engage Sol Pwr W 0.8 GXL SPE, Pin Engage Switch 1 SPL-PINE, Ultrasonic A
57 C Pin Engage Sol Pwr W 0.8 TXL SPL-PINE, Ultrasonic A AIC-2, Adv Instrument Cluster 2 16
58C Ride Control Switch Jumper W 0.8 GXL SRC, Ride Control Switch 5 SRC, Ride Control Switch 3
58H A Ride Control Sw Pwr VPS2 W 0.8 TXL TECM, Trans 8 ECD, Elect Center D D7
58L Ride Control Relay LSD Bk 0.8 TXL TECM, Trans 57 ECD, Elect Center D B8
58S E Ride Control Sol to Front Cab W 1.0 SXL FRONT, Cab Front Chassis 21 YRC, Ride Control Option 1
58T Ride Control Relay Sw Pwr W 0.8 GXL SRC, Ride Control Switch 4 ECD, Elect Center D B7
58 A Ride Control Sol Pwr W 1.0 SXL 202M, Rollback Jumper A 202M, Rollback Jumper B
58 B Ride Control Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 21 PRBF, Rollback Pressure Switch B
58 C Ride Control Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 21 SPL-D26, Ultrasonic A
58 D Ride Control Sol Pwr W 0.8 GXL 140M, Diode Module D SPL-D26, Ultrasonic A
58 E Ride Control Sol Pwr W 0.8 GXL SPL-D26, Ultrasonic A ECD, Elect Center D D8
58 F Ride Control Sol Pwr W 0.8 GXL SRC, Ride Control Switch 6 SPL-D26, Ultrasonic A
59D Hood Relay Control Down W 1.0 GXL CAB-E, Cab Engine 37 ECC, Work Lights D3
59D A Hood Relay Control Down W 1.0 SXL ENG, Engine Cab 37 HD, Hood Switch A
59U Hood Relay Control Up W 1.0 GXL CAB-E, Cab Engine 39 ECC, Work Lights D1
59U A Hood Relay Control Up W 1.0 SXL ENG, Engine Cab 39 HD, Hood Switch C
60D Hood Down Relay Out W 1.0 GXL CAB-E, Cab Engine 36 ECC, Work Lights B3
60D A Hood Down Relay Out W 1.0 SXL ENG, Engine Cab 36 HDM, Hood Lift Motor 2
60U Hood Up Relay Out W 1.0 GXL CAB-E, Cab Engine 38 ECC, Work Lights B1
60U A Hood Up Relay Out W 1.0 SXL ENG, Engine Cab 38 HDM, Hood Lift Motor 1
61A Trinary Press Sw Input W 1.0 SXL ENG, Engine Cab 30 PR, Trinary Press Sw A
61A B Trinary Press Sw Input W 0.8 GXL CAB-E, Cab Engine 30 HVAC1, HVAC1 1
61C AC Relay Out Or 0.8 GXL CAB-E, Cab Engine 2 ECD, Elect Center D D10
61C A AC Relay Out Or 1.0 SXL ENG, Engine Cab 2 ACT, AC Comp Clutch 1
61C B AC Relay Out Or 1.0 SXL ENG, Engine Cab 2 ACT-9, AC Comp Clutch 1
61R AC Relay Control W 1.0 SXL ENG, Engine Cab 29 PR, Trinary Press Sw B

4002-34

21C Bk - 1.0


Color, Size,
and Material
61R B AC Relay Control W 0.8 GXL CAB-E, Cab Engine 29 ECD, Elect Center D D9
63C Front Wiper Park Control W 0.8 GXL FWM, Front Wiper Motor D ECD, Elect Center D C4
63C2 Front Wiper Park Control W 0.8 GXL ECD, Elect Center D D4 ECD, Elect Center D C2
63C3 Front Wiper Park Control W 0.8 GXL K-WCO, Wiper Cutout 87a ECD, Elect Center D B3
63HC Front Wiper High Speed Rly Ctrl W 0.8 GXL SFWW, Front Wiper/Washer 9 SPL-HC, Ultrasonic A
63HC
Wiper Cutout Relay Control W 0.8 GXL SPL-HC, Ultrasonic A K-WCO, Wiper Cutout 85
A
63HC
Front Wiper High Speed Rly Ctrl W 0.8 GXL SPL-HC, Ultrasonic A ECD, Elect Center D B2
B
63H A Front Wiper High Speed Rly Out W 0.8 GXL FMW, Front Wiper Motor A SPL-WHS, Ultrasonic A
63H B Front Wiper High Speed Rly Out W 0.8 GXL SPL-WHS, Ultrasonic A ECD, Elect Center D D2
63H C Front Wiper High Speed Rly Out W 0.8 GXL 140M, Diode Module A SPL-WHS, Ultrasonic A
63LC Front Wiper Low Speed Rly Ctrl W 0.8 GXL SFWW, Front Wiper/Washer 3 ECD, Elect Center D B4
63L A Front Wiper Low Speed Rly Out W 0.8 GXL FMW, Front Wiper Motor B SPL-WLS, Ultrasonic A
63L B Front Wiper Low Speed Rly Out W 0.8 GXL K-WCO, Wiper Cutout 30 SPL-WLS, Ultrasonic A
63L C Front Wiper Low Speed Rly Out W 0.8 GXL 140M, Diode Module B SPL-WLS, Ultrasonic A
63W Front Washer Pump W 0.8 GXL CAB-E, Cab Engine 25 SFWW, Front Wiper/Washer 7
63W A Front Washer Pump W 1.0 SXL ENG, Engine Cab 25 FWW, Front Washer 1
64C Horn Relay Control Or 0.8 GXL SRHSTLK, RH Stalk Switch 31b ECC, Work Lights B8
64 A Horn Power Or 0.8 GXL CAB-F, Cab Front Chassis 13 ECC, Work Lights D8
65L Left Speaker Or 0.8 GXL LSPK, Left Speaker 1 SPK, Speaker 7
65R Right Speaker Or 0.8 GXL RSPK, Right Speaker 1 SPK, Speaker 1
68C Rear Wiper Park Control Or 1.0 GXL CAB-RF, Cab to Roof Conn. K SRWP, Rear Wiper Switch 1
68C A Rear Wiper Park Control Or 1.0 GXL ROOF, Roof to Cab Conn. K RWM, Rear Wiper Motor D
68L Rear Wiper Switch Power Or 1.0 GXL SRWP, Rear Wiper Switch 2 SPL-3, Ultrasonic A
68L A Rear Wiper Switch Power Or 1.0 GXL ROOF, Roof to Cab Conn. L RWM, Rear Wiper Motor B
68L B Rear Wiper Switch Power Or 1.0 GXL CAB-RF, Cab to Roof Conn. L SPL-3, Ultrasonic A
68L C Rear Wiper Switch Power Or 1.0 GXL 140M, Diode Module F SPL-3, Ultrasonic A
68W Rear Washer Pump W 0.8 GXL CAB-E, Cab Engine 24 SRWP, Rear Wiper Switch 6
68W A Rear Washer Pump W 1.0 SXL ENG, Engine Cab 24 RWW, Rear Washer 1
Y 0.8 TXL
CAN H CAN High CAN2, CAN Bulk Head A EDC7, Engine Controller 35
TWIST

4002-35

21C Bk - 1.0


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

4002-36

21C Bk - 1.0


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

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

4002-37

21C Bk - 1.0


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

4002-38
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Alternator 1
Correct
Check Points 2 Possible Cause of Bad Reading
Reading
3 4
Check the 10 ampere fuse at
Good Bad fuse.
location 3 and 4C in the fuse block.
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter. 5
6
1. This title is the number and component name on the Electrical Schematic.
2. This column shows the location of the check point.
3. This column shows the indication of the check.
4. This column shows the possible cause of a bad test indication.
5. The numbers in the parentheses show the number of the component on the Electrical Schematic.
6. This statement assumes that all other problems are solved at this point in the test.
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS

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

4002-39
STARTING AND CHARGING SYSTEMS
9 3
10
5
1 2 7
4 11
6 12
BS06H241 / BS06H242
1. STARTING RELAY 7. TIME DELAY MODULE

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

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

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

4002-41
4 – Crank Control Relay

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

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

4002-42
7 – Time Delay Module

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

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

ignition switch in the OFF position, Key OFF
Bad time delay module.
check terminal for wire 13D to 0 volt after 30
ground seconds
After 30 seconds of turning ignition

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

Located on right side battery box cover, remove battery box cover to gain access.
Correct
Reading
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.
Between terminals of master Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
NOTE: Put the master disconnect switch in the OFF position.
Between terminals of master Open Circuit If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).

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

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

4002-44
11 – Neutral Start Relay

Correct
Reading
Terminal for wire 0-DE to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 25T to ground 24 volts Check circuit 25T, check FNR switch (55).
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21K-B to ground 24 volts Check circuit 21K-B and ignition switch (10).
Terminal for wire 21C to ground 24 volts Bad neutral start relay.
12 – Voltmeter Relay
Correct
Reading
Terminal for wire 0-DB to ground Continuity Bad ground circuit.
Check circuit 18R to power relay module C in engine

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

4002-45
POWER RELAY MODULES AND COLD STARTING SYSTEMS
15 19 13
20 17
16 14
21
18
BS06H241 / BS06H242
13. POWER RLEAY MODULE A 18. POWER RELAY MODULE D

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

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

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

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

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

Terminal for wire 13D to ground 24 volts
ignition switch (10).
Terminal for wire 13H to ground 24 volts Bad power relay module B.
15 – Power Relay Module C, For Fuel Filter Heater and Water Separator Heater
Correct
Reading
NOTE: Make sure engine temperature is below -0 ° C (32 ° F).
Terminal for wire 0-GA to ground Continuity Bad ground circuit or bad EDC7 (24).
Terminal for wire 1-NC to ground 24 volts Check circuit 1 and circuit to batteries.
Terminal for wire 28F to ground 24 volts Check EDC7 (24).
Terminal for wires 1-GA ground 24 volts Check 40 ampere fuse, bad power relay module.

4002-47
16 – Grid Heater Relay

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

Correct
Reading
Between terminal A and B on circuit Continuity Bad circuit breaker

breaker
19 – Water Separator Heater

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

4002-48
20 – Fuel Filter Heater

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

Correct
Reading
Terminal for wire 0-EC to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Accessory or the ON
position.
Terminal for wire PRM-D BUSS to Check circuit 1CB to 105 Amp circuit breaker in engine
24 volts
Terminal for wire ACC-B to ground 24 volts Check circuit 12ACC, check ignition switch (10).
Terminal for wire J11 BUSS-ECA to 24 volts Bad power relay module D.
ground

4002-49
ENGINE CONTROLLER
24
22
23
BS06H241 / BS06H242
22. WATER IN FUEL SENSOR

23. THROTTLE POTENTIOMETER
24. ENGINE CONTROLLER

4002-50
22 – Water In Fuel Sensor

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

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

4002-51
24 – Electronic Diesel Control

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

ground
Terminal for wire 0-BF pin 6 to Continuity Bad ground circuit.

ground
Terminal for wire 0-BD pin 10 to Continuity Bad ground circuit.
ground
Terminal for wire 0-BC pin 11 to Continuity Bad ground circuit.

ground
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position.
Terminal for wire 18J-C pin 2 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-B pin 3 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-D pin 8 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-E pin 9 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
NOTE: Use diagnostic service tool for additional tests on EDC7.

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

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

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

Correct
Reading
Terminals for wire 0-B3 to ground Continuity Bad ground circuit.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-D to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
NOTE: Turn the height control switch to the ON position.
Terminal for wire 54A to ground. 24 volts Bad height control switch.

4002-54
27 – Electromagnetic Detents
Located under right side console.
Correct
Reading
NOTE: For joystick controller.
74 ohms @
Between pins 3 and 4 Bad electromagnetic detent
20° C (68° F)
74 ohms @
20° C (68° F)
74 ohms @
20° C (68° F)
NOTE: For single axis controller.
328 ohms @
20° C (68° F)
328 ohms @
20° C (68° F)
328 ohms @
20° C (68° F)
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (39) in OFF
position and return to travel/float switch (25) in ON position.
Wiring harness connector EM, pin 1 24 volts Bad return to travel/float switch (25). Also check wires 55A.
to ground
NOTE: Place the height control switch in the ON position.
Wiring harness connector EM, pin 2 24 volts Bad height control switch. Also check wires 54A.
to ground
NOTE: Place the return to dig switch in the ON position.
Wiring harness connector EM, pin 3 24 volts Bad return to dig switch. Also check wires 53A.
to ground
28 – Return-To-Dig Proximity Switch

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

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

4002-55
29 – Pilot Control Relay

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

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

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

Correct
Reading
Terminals for wire 0-B4 to ground Continuity Bad ground circuit.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-E to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
NOTE: Turn the height control switch to the ON position.
Terminal for wire 53A to ground. 24 volts Bad return to dig switch.

4002-56
32 – Pin Engage Switch (Option)

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

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

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

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

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

4002-58
35 – Ride Control Switch

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

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

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

Correct
Reading
Terminal 85 for wire 58L to Continuity Check wire 58L.

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

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

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

4002-59
37 – Fan Reversing Switch (Option)

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

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

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

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

4002-60
39 – Pilot Control Switch

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

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

control solenoid
41 – Rollback Pressure Switch (Option)

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

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

4002-61
42 – Rollback Jumper (Option)

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

switch
43 – Fan PWM Solenoid (Option)

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

YFN to ground
NOTE: In the options menu of the instrument cluster select auto for the fan. Stall the transmission to raise
transmission temperature to high operating range.
Pin 1 of wiring harness connector 24 volts Bad instrument cluster. Also check wire 56.
YFN to ground
44 – Fan Reversing Solenoid (Option)

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

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

YFR to ground
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ON
position (hold rocker in momentary position).
Pin 1 of wiring harness connector 24 volts Bad fan reversing switch. Also check wire 52-A.
YFR to ground

4002-62
TRANSMISSION
46 48
52
55 56 57 60
49 50 45 53 54
51 47 61 58
BS06H241 / BS06H242
45. OUTPUT SPEED SENSOR 54. TRANSMISSION ENABLE SWITCH

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

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

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

4002-64
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE
66
62 63
67 68
69
65 64
BS06H241 / BS06H242
62. INSTRUMENT CLUSTER CONNECTOR 1 66. AIR FILTER RESTRICTION SWITCH

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

4002-65
62 – Instrument Cluster Connector 1

Located on instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-1 from the instrument cluster and SW-PD from the switch pad.
Connector terminal SW-PD 5 to Open Circuit Bad air filter restriction switch (66). Also check circuit 31F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31H-A.
Connector terminal AIC-1 6 and 12 Continuity Bad ground circuit. Check wires 0-DW and 0-DX.
to ground
Connector terminal AIC-1 11to 130 to 9500 Bad engine coolant temperature sender (68). Also check circuit
ground ohms circuit 36C-A and ground circuit at sender.
Connector terminal AIC-1 2 to Bad fuel level sender (65). Also check circuit 36F-A and ground
33 to 240 ohms
ground circuit at sender.
Connector terminal AIC-1 9to 130 to 9500 Bad hydraulic oil temperature sender (73). Also check circuit
ground ohms 36H-A and ground circuit at sender.
Connector terminal AIC-1 25 to

Continuity Bad wire 17P-A.
connector terminal SW-PD 9
Connector terminal AIC-2 4 to Open Circuit Bad redundant brake switche(s) (75). Also check circuit 33R.
ground
Connector terminal AIC-1 4 and

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

SW-PD 7 to terminal 25 on the Continuity Bad circuit CAN-H.
transmission electronic control
module (53)
Connector terminal AIC-1 15 to Check LH and RH stop lamps and circuit 44A-B. Also check
Continuity
ground ground circuit at lamps.
NOTE: Put the parking brake switch in the ON position.
Connector terminal AIC-1 14to Bad parking brake switch. Also check fuse ECA-F6 and circuit
24 volts
ground 19D and 52C.
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

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

4002-66
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECC-F3. Also check circuit 41H-D.
Connector terminal AIC-1 14 to Bad parking brake relay or fuse ECA-F6. Also check circuits
24 volts
ground 52C and 19D.
Connector terminal AIC-1 20 to Bad pilot control relay or fuse ECA-F5. Also check circuits 53C
24 volts
ground and 19C.
63 – Warning Buzzer
Located on steering column under instrument cluster.
Correct
Reading
NOTE: Buzzer sounds for five seconds during self test when ignition switch is turned on.
Terminal for wire 0_B27 to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the ON position
Terminal for wire 35B to ground 24 volts Bad instrument cluster
NOTE: If all readings are good, replace buzzer.
64 – Parking Brake Relay

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (74) is OFF.
Terminal for wire 19D-B and 19D-C 24 volts Bad fuse ECA-F6, also check circuit 19D.
to ground
Terminal for wire 52C to ground 0 volt Bad instrument cluster (62). Also check circuit 52C.
Terminal for wire 52P-B to ground 24 volts Bad parking brake relay.
NOTE: Put the parking brake switch in the ON position.
Terminal for wire 52C to ground 24 volts Bad instrument cluster (62). Also check wire 52C.

4002-67
65 – Fuel Level Sender

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

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

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

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

4002-68
68 – Radiator Coolant Temperature Sender

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

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

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

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

4002-69
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE
77
70 71 74
75
76
72
73
BS06H241 / BS06H242
70. SWITCH PAD 74. PARK BRAKE SWITCH

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

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

4002-71
71 – Instrument Cluster Connector 2

Located on instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-2 from the instrument cluster and SW-PD from the switch pad.
Connector terminal AIC-2 5 to Bad brake warning pressure switch (69). Also check circuit
Continuity
ground 33P-A and ground circuit at brake warning pressure switch.
Connector terminal AIC-2 26 to Bad coolant level sender (77). Also check circuit 31D-A and
Continuity
ground ground circuit at coolant level sender.
Connector terminal AIC-2 11 to Bad secondary steering pressure switch (118). Also check
Continuity
ground circuit 35X and ground circuit at pressure switch.
Connector terminal SW-PD 5 to Open Circuit Bad air filter restriction switch (66). Also check circuit 31F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31H-A.
Connector terminal AIC-2 15 and 22 Continuity Bad ground circuit. Check wires 0-DB and 0-D-A.
to ground.
Connector terminal AIC-2 4 to Open Circuit Bad redundant brake switche(s) (75). Also check circuit 33R.
ground
Connector terminal AIC-2 14 and 20 Bad fuse ECD-F3. Also check circuit 19S-C and 19S-D. Also
24 volts
to ground check power relay module B (14).
Connector terminal AIC-2 21 to Bad fuse ECA-F3. Also check circuit 19E-A. Also check power
24 volts
ground relay module A (13).
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

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

4002-72
]
72 – Hydraulic Filter Restriction Switch

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

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

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

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

4002-73
74 – Parking Brake Switch

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

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

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

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

4002-74
77 – Coolant Level Sender

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

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


4002-76
78 – Back-up Alarm Relay

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

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

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

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

4002-78
80 – Work Lamps Switch

Correct
Reading
Terminal for wire 0-B14 to ground Continuity Bad ground circuit
NOTE: Put master disconnect witch in the ON position.
Terminal for wire 42-A and 42-B to 24 volts Bad fuse ECC-F2.
ground
NOTE: Put the work lamps switch in position 2 for front work lamps.
Terminal for wire 42FS to ground 24 volts Bad work lamps switch.
NOTE: Put the wok lamps switch in position 3 for rear work lamps.
Terminal for wire 42RS to ground 24 volts Bad work lamps switch.
81 – Door Switch
Located above door in cab.
Correct
Reading
Terminal for wire 19U-F to ground 24 volts Bad fuse ECC-F1.
NOTE: Disconnect connector DS at door switch.
Between pins on door switch with Continuity Bad door switch.

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

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

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

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

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

4002-80
86 – Right Hand Front Work Lamp

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

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

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

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

4002-82
LIGHTS - 02
93 94
95
92 91 90
BS06H241 / BS06H242
90. BRAKE LIGHTS SWITCH 93. HAZARD SWITCH

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

4002-83
90 – Brake Lamp Pressure Switch

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

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

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

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

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

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

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

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

4002-86
95 – Driving Lamp Switch

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

4002-87
LIGHTS - 03 AND HORN
96 99
97
98
BS06H241 / BS06H242
96. LEFT HAND FRONT COMBINATION LAMPS 98. HORN RELAY

97. RIGHT HAND FRONT COMBINATION LAMPS 99. HORN

4002-88
96 – Left Hand Front Combination Lamp

Located on the left front of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector LF from LH front combination lamp connector.
Combination lamp connector pin 3 to Continuity Bad high beam lamp bulb.
pin 1
Combination lamp connector pin 4 to Continuity Bad position lamp bulb.

pin 1
Combination lamp connector pin 2 to Continuity Bad low beam lamp bulb.
pin 1
Combination lamp connector pin 5 to Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector LF to LH front combination lamp connector.
Terminal for wire 0-AJ to ground Continuity Bad ground circuit.
Terminal for wire 18F to ground 24 volts
circuit 18F.
NOTE: Put high/low beam lever (94) in HIGH beam position.
Check fuse ECB-F3, high/low beam relay (80), driving lamp

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

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

4002-89
97 – Right Hand Front Combination Lamp

Located on the right front of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector RF from RH front combination lamp connector.
Combination lamp connector pin 3 to Continuity Bad high beam lamp bulb.
pin 1
Combination lamp connector pin 4 to Continuity Bad position lamp bulb.

pin 1
Combination lamp connector pin 2 to Continuity Bad low beam lamp bulb.
pin 1
Combination lamp connector pin 5 to Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector RF to RH front combination lamp connector.
Terminal for wire 0-AH to ground Continuity Bad ground circuit.
Terminal for wire 18G-A to ground 24 volts
circuit 18G and wire 41T-A.
NOTE: Put high/low beam lever (94) in HIGH beam position.

Terminal for wire 18C to ground 24 volts
beam switch (94). Also check circuit 18C and wire 41H.
NOTE: Put high/low beam lever (94) in LOW beam position.

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

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

4002-91
LIGHTS - 04 AND BACK UP ALARM
101
103
100
102
BS06H241 / BS06H242
100.RIGHT HAND REAR COMBINATION LAMPS 102.LICENSE PLATE LAMP

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

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

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

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

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

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

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

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

Located on the right rear of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector LRR-E from RH rear combination lamp connector.
Combination lamp connector pin 1 to Continuity Bad stop lamp bulb.

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

pin 5
Combination lamp connector pin 3 to Continuity Bad tail lamp bulb.

pin 5
Combination lamp connector pin 4 to Continuity Bad reverse lamp bulb.

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

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

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

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

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

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

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

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

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

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

Correct
Reading
NOTE: Disconnect wiring harness connector LLR-E from LH rear combination lamp connector.
Combination lamp connector pin 1 to Continuity Bad stop lamp bulb.

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

pin 5
Combination lamp connector pin 3 to Continuity Bad tail lamp bulb.

pin 5
Combination lamp connector pin 4 to Continuity Bad reverse lamp bulb.

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

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

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

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

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

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

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

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

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

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

4002-97
CAB WINDOW WASHER AND WIPER SYSTEM
110
109
111
107 108
112
104 106
113
105
BS06H241 / BS06H242
104.FRONT WIPER HIGH SPEED RELAY 109.FRONT WIPER MOTOR

105.WIPER CUT OUT RELAY 110.REAR WIPER MOTOR
106.FRONT WIPER LOW SPEED RELAY 111.REAR WASHER MOTOR
107.REAR WIPER/WASHER SWITCH 112.FRONT WASHER MOTOR
108.FRONT WIPER/WASHER SWITCH 113.DIODES

4002-98
104 – Front Wiper High Speed Relay

Correct
Reading
Terminal for wire 19J-D and 19J-E to Bad fuse ECA-F12, check circuit 19J, also check power relay
24 volts
ground module D (21).
NOTE: Put the front wiper switch in the HIGH position.
Terminals for wire 63HC-B to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63HC-B to ground 24 volts Bad wiper high speed relay.
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C2 to ground 24 volts Bad wiper high speed relay.
105 – Front Wiper Cut Out Relay

Correct
Reading
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-G to ground 24 volts
module D (21).
Terminal for wire 63L-B to ground 24 volts Bad wiper cut out relay.
Terminals for wire 63HC-A to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63L-B to ground 0 volts Bad wiper cut out relay.

4002-99
106 – Front Wiper Low Speed Relay

Correct
Reading
Bad fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-F to ground 24 volts
module D (21).
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C to ground 24 volts Bad wiper low speed relay.
Terminals for wire 63LC to ground Continuity Bad front wiper and washer switch (108).
Bad wiper low speed relay, also check high speed wiper relay
Terminals for wire 63C3 to ground 24 volts
(104).
107 – Rear Wiper and Washer Switch

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

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

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

4002-100
108 – Front Wiper and Washer Switch

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

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

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

4002-101
109 – Front Wiper Motor

Located in front of steering column.
Correct
Reading
NOTE: Make sure the front wiper and washer switch (108) is in the OFF position.
Between terminals B and D for wires Continuity Bad front wiper motor.
63C and 63L
Terminal for wire 19J to ground 24 volts Check fuse ECA-F12, also check circuit 19J.
NOTE: Put the front wiper and washer switch (108) in the LOW position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63L-A to ground 24 volts
and washer switch (108), low speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (108) in the HIGH position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63H-A to ground 24 volts
and washer switch (108), high speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (108).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L to ground 24 volts pulse Bad front wiper and washer switch (108).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (108).
NOTE: If the readings are good, replace the front wiper motor.

4002-102
110 – Rear Wiper Motor

Located in top of rear cab head liner.
Correct
Reading
Terminal for wire 0-MA to ground Continuity Bad ground circuit.
NOTE: Make sure the rear wiper and washer switch (107) is in the OFF position.
Between terminals for wires 68C-A Continuity Bad rear wiper and washer switch (107).
and 68L-A
Terminal for wire 19K-C to ground 24 volts Check fuse ECA-F13, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (107) in the ON position.
Terminal for wire 68C-A to ground 24 volts Bad rear wiper and washer switch (107).
Terminal for wire 68L-A to ground 0 volt Bad rear wiper and washer switch (107).
NOTE: If the readings are good, replace the rear wiper motor.
111 – Rear Washer Pump Motor

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

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

4002-103
113 – Wiper Diodes

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

4002-104
SECONDARY STEERING
114 116 118

115 117
BS06H241 / BS06H242
114.SECONDARY STEERING DIODES 117.SECONDARY STEERING MOTOR

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

4002-105
114 – Secondary Steering Diodes

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

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

steering solenoid
Between pin 2 of connector YSS and Continuity Bad ground circuit.

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

4002-106
116 – Secondary Steering Module (Option)

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

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

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

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

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

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

4002-107
117 – Secondary Steering Motor (Option)

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

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

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

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

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

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

4002-109
119 – CAN Communication Diagnostics Connector

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

4002-110
RADIO AND POWER CONVERTER
125
124 122 123
120
121
BS06H241 / BS06H242
120.POWER RELAY MODULE E 123.RADIO

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

4002-111
120 – Power Relay Module E

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

Correct
Reading
Terminal for wire 0-EJ to ground Continuity Bad ground circuit.
Terminal for wire 19L-B and 19L-A to 24 volts Bad fuse F1 in power relay module E, also check circuit 19L.
ground
Terminal for wire 12V-C to ground 12 volts Bad power converter.
122 – Power Outlet (Option)

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

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

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

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

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

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

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

4002-113
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR
126 130
129
127
128
BS06H241 / BS06H242
126.AIR SEAT 129.HIGH/LOW SWITCH

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

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

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

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

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

Correct
Reading
Terminal for wire 0-DJ to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (149) to HIGH and
thermostat switch to COLD.
Terminal for wire 61R-B to ground 24 volts Check thermostat switch, also check wire 61R-B.
Terminal for wire 61C to ground 24 volts Bad compressor clutch relay.
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector PR from A/C trinary pressure
switch. Connect a jumper wire between pins A and B of connector PR. Put ignition switch in ON position.
Terminal for wire 61R-C to ground 24 volts Check wires 61R-B and 61R.

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

Located on the rear frame in front of the rear axle.
Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (149) to HIGH and
the thermostat switch to COLD.
Terminal B for wire 61A to ground 24 volts Check the thermostat switch, also check circuit 61A.
NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch.
Bad A/C low pressure switch, also check refrigerant charge

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

Located on the left side of the engine.
Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (149) to HIGH and
thermostat switch to COLD.
Check the compressor clutch relay (128), also check circuit

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

4002-116
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL
135 136 137

140 141
137
131
139
132 133 134 138 142
BS06H241 / BS06H242
131.ELECTRONIC PANEL 137.THERMOCOUPLE SENSOR

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

4002-117
131 – Electronic Panel

Correct
Reading
NOTE: No information at time of print.
132 – External Air Temperature Sensor

Correct
Reading
133 – Internal Air Temperature Sensor

Correct
Reading
134 – Sun Sensor

Correct
Reading
135 – Blower Motor Resistor

Correct
Reading
136 – Blower Motors

Correct
Reading
137 – Thermocouple Sensor

Correct
Reading
138 – Mixed Air Sensor

Correct
Reading

4002-118
139 – Compressor Relay

Correct
Reading
140 – Recycling Motor

Correct
Reading
141 – Electronic Water Valve

Correct
Reading
142 – 24 to 12 Volt Converter

Correct
Reading

4002-119
STANDARD CLIMATE CONTROL
143 144 145

146 147 148
137
149 150 151

152 153
BS06H241 / BS06H242
143.AIR RECIRCULATION MOTOR 149.FAN SPEED SWITCH

144.DRIVER 150.AIR CONDITIONING SWITCH
145.ELETRONIC WATER VALVE 151.CONTROL PANEL LIGHTS
146.BLOWER FAN RESISTOR 152.WATER VALVE POTENTIOMETER
147.BLOWER MOTOR 153.AIR RECIRCULATING SWITCH
148.THERMOSTAT

4002-120
143 – Air Recirculation Motor

Correct
Reading
144 – Driver
Correct
Reading
145 – Electronic Water Valve

Correct
Reading
146 – Blower Motor Speed Resistors with Thermal Fuse

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

Bad blower motor resistor.
motor connector x.x ohms


147 – Blower Motor

Correct
Reading
Terminals for wire DNS66 to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (149)
to position 4.
Terminal for wire DNS65 to ground 24 volts Check the blower switch (149).
NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the blower
switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the blower
motor resistor (146).

4002-121
148 – Thermostat
Correct
Reading
149 – Blower Switch

Correct
Reading
Terminal for wire DNS74 to ground 24 volts Check fuse ECA-F11.
NOTE: Turn the blower switch to position 1.
Terminal for wire DNS61 to ground 24 volts Bad blower switch.
150 – Air Conditioning Switch

Correct
Reading
151 – Control Panel Lights

Correct
Reading
152 – Water Valve Potentiometer

Correct
Reading

4002-122
153 – Air Recirculating Switch

Correct
Reading

4002-123
HOOD RAISE AND LOWER SYSTEM
157
156 154
155
BS06H241 / BS06H242
154.HOOD UP RELAY 156.HOOD SWITCH

155.HOOD DOWN RELAY 157.HOOD MOTOR

4002-124
154 – Hood Up Relay

Correct
Reading
NOTE: Turn the master disconnect switch ON.
Terminal for wire 19Y-A 24 volts Check fuse ECC-F7, check circuit 19Y.
NOTE: Hold the hood switch (156) in the raise position.
Terminal for wire 59U 24 volts Bad hood switch (156), check wire 59U.
Terminal for wire 60U 24 volts Bad hood up relay.
155 – Hood Down Relay

Correct
Reading
NOTE: Turn the master disconnect switch ON.
Terminal for wire 19Y-B 24 volts Check fuse ECC-F7, check circuit 19Y.
NOTE: Hold the hood switch (156) in the lower position.
Terminal for wire 59D 24 volts Bad hood switch (156), check wire 59D.
Terminal for wire 60D 24 volts Bad hood down relay.
156 – Hood Switch

Located in the right battery compartment with the master disconnect switch.
Correct
Reading
NOTE: Disconnect connector HD, turn the master disconnect ON.
Terminal for wire 19Y-D to ground 24 volts Check fuse ECC-F7, check circuit 19Y.
Hold the hood switch in the raise Continuity Bad hood switch.
position, between pin C and B
Hold the hood switch in the lower Continuity Bad hood switch.
position, between pin A and B

4002-125
157 – Hood Motor

Located in the left side of the engine compartment.
Correct
Reading
NOTE: Turn the master disconnect switch ON and disconnect connector HDM. Hold the hood switch (156) in the
raise position.
Bad hood up relay (154), bad hood switch (156), and check
Terminal for wire 60U-A 24 volts
fuse ECC-F7.
NOTE: Hold the hood switch (156) in the lower position.
Bad hood down relay (155), bad hood switch (156), and check
Terminal for wire 60D-A 24 volts
fuse ECC-F7.
NOTE: If all readings are good replace the hood motor.

4002-126
CONNECTORS
CONNECTOR 108F - DIAGNOSTIC CONNECTOR CONNECTOR 197F - MAIN CAB FNR
291663A1 225350C1
CAV WIRE IDENT CIRCUIT CAV WIRE IDENT CIRCUIT

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

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

4002-127
CONNECTOR 202M - ROLLBACK JUMPER CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH
245482C1
CAV WIRE IDENT CIRCUIT 225316C1
A 58-A Ride Control Solenoid Power CAV WIRE IDENT CIRCUIT

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

JUMPER CONNECTOR 215F - ALTERNATOR RESISTOR
245481C1 199436A1

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

JUMPER
199436A1
CAV WIRE IDENT CIRCUIT

245480C1
1 19R-D Alternator Resistor Fused Pwr
A 35A-D Backup Alarm Relay Out
B Not Used

4002-128
CONNECTOR 64F - FLASHER CONNECTOR CONNECTOR AIC1 - ADV INSTRUMENT
CLUSTER 1
245481C1

1 45N-A Flasher Optional Side Control
87419488

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

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

4002-129
CONNECTOR AIC2 - ADV INSTRUMENT CONNECTOR BUZ - AIC BUZZER
CLUSTER 2
222136A1
87410948
CAV WIRE IDENT CIRCUIT 1 35B AIC Buzzer HSD
1 Not Used 2 0-B27 Buzzer Ground
2 43S-C Door Open Signal
3 Not Used
4 33R Redundant Brk Accm Press Low
5 33P-A Brake Low Pressure Warning
6 33U Park Brake Switch
7 52M Fan Reverse Manual
8 52AU Fan Reverse Auto
9 45L-E Left Turn Signal
10 45R-C Right Turn Signal
11 35X Sec. Steering Low Press Signal
12 Not Used
13 Not Used
14 19S-D AIC Delay Fused Power
15 0-DB AIC Power Ground Red
16 57-C Pin Engage Solenoid Power
17 21K-A Ignition Switch Start Signal
18 31L Pilot Control Switch High
19 Not Used
20 19S-C AIC Delay Fused Power
21 19E-A AIC Wake Up Ignition
22 0-DA AIC Chassis Ground
23 Not Used
24 Not Used
25 Not Used
26 31D-A Coolant Level Signal

4002-130
CONNECTOR CAB-E - CAB TO ENGINE CAV WIRE IDENT CIRCUIT
37 59D Hood Down Relay Control
38 60U Hood Up Relay Out
39 59U Hood Up Relay Control
40 35A-F Backup Alarm Relay Out
225415C1

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

4002-131
CONNECTOR CAB-F - CAB FRONT CHASSIS CONNECTOR CAB-RF - CAB TO ROOF
CONNECTION
388710A1
291661A1 A 43-A Dome Light Auto Mode
CAV WIRE IDENT CIRCUIT B 42R-C Rear Work Light Fused Power
1 45L-C Left Turn Signal C 42C-A Front Work Lights Fused Power
2 51B-C Comfort Steering Solenoid Pwr D 19U-D Dome Light Fused Power
3 45R-D Right Turn Signal E 46-C Beacon Switch Power
4 Not Used F 0-DR Roof Splice Grounds
5 18G-G Position RH Fused Power G 0-DS Roof Splice Grounds
6 18F-E Position LH Fused Power J 19K-C Rear Wiper Motor Fused Power
7 18B-A High Beam LH Fused Power K 68C Rear Wiper Park Control
8 36B Front Axle Temperature L 68L-B Rear Wiper Switch Power
9 O-DY Front Axle Temperature Ground M 0-EM Radio Ground
10 Not Used N 12V-B 12V Fused Power to Radio
11 54B-A Height-RTT Signal R 43S-A Door Open Signal
12 53B-B RTD Signal S 19U-G Door Switch Fused Power
13 64A Horn Power

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

4002-132
CONNECTOR CAB-T - CAB TO TRANMISSION CONNECTOR CAN - CAN BULK HEAD
380839A1

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

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

4002-133
CONNECTOR CL - CIGAR LIGHTER CONNECTOR D-OR - DIODE OR
245485C1

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

CONNECTOR CLS - COOL JUMP - COOL SEND
194788A1
CAV WIRE IDENT CIRCUIT 310057A1
A 31D Coolant Level Signal CAV WIRE IDENT CIRCUIT

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

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

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

4002-134
CONNECTOR DM - DIODE OR CAV WIRE IDENT CIRCUIT
21 DNS7
23 DNS12
26 DNS19
CONNECTOR DNS-COMPRESSOR-RELAY
245485C1
85 DNS19
A 19RR Sec. Steering Ignition Fused Pwr
86 DNS20
B Not Used
30 DNS16
C 19R Sec. Steering Ignition Fused Pwr
87 DNS14
CONNECTOR DNS-AC-SWITCH
CONNECTOR DNS-EXTERNAL-AIR-TEMP-SNS

1 DNS72
1 DNS2
2 DNS68
2 DNS1
4 DNS71
CONNECTOR DNS-ACTUATOR CONNECTOR DNS-HVAC-CAN1

5 DNS48
6 DNS49
CONNECTOR DNS-BLUE - ATC CONTROL PANEL

225294C1

A DNS9
B DNS8
1 DNS8
3 DNS10
5 DNS11
6 DNS2
7 DNS4
9 DNS3
10 DNS6
14 DNS9
15 DNS31
16 DBS13
17 DNS18

4002-135
CONNECTOR DNS-HVAC1 CONNECTOR DNS-NOT-USED
225326C1

CAV WIRE IDENT CIRCUIT 1 DNS12
A DNS14 2 DNS10
B DNS15 3 DNS11
C DNS13
CONNECTOR DNS-YELLOW - ATC CONTROL

CONNECTOR DNS-HVAC2 PANEL

1 DNS25
2 DNS24
5 DNS47
6 DNS43
225315C1 8 DNS44
1 DNS36 10 DNS23
2 DNS35 14 DNS28
15 DNS26
16 DNS22
CONNECTOR DNS-INTERNAL-AIR-TEMP-SNS
17 DNS27
18 DNS29
21 DNS22
1 DNS4 24 DNS46
2 DNS3
3 DNS17
4 DNS5

4002-136
CONNECTOR DNS-PWM-BLOWER-PIN4 CONNECTOR DNS-VOLTAGE-CONVERTER

1 DNS34
2 DNS33
3 DNS32
4 DNS31
CONNECTOR DNS-ELECT-WATER-VALVE
HIRSCHMANN 772717-001

1 DNS38 CAV WIRE IDENT CIRCUIT
2 DNS47 1 DNS30
3 DNS37 2 DNS29
3 DNS28
4 DNS27
CONNECTOR DNS-PWM-BLOWER-PIN2
6 DNS26
CAV WIRE IDENT CIRCUIT CONNECTOR DNS-RECYCLING-MOTOR

1 DNS41
2 DNS42

1 DNS21
CONNECTOR DNS-PWM-BLOWER
2 DNS22
3 DNS23
5 DNS24
6 DNS25
1 DNS41
2 DNS42
CONNECTOR DNS-SPEED-SELECTOR
CONNECTOR DNS-THERMOCOUPLE-SENSO

1 DNS74
2 DNS61
1 DNS46
3 DNS62
2 DNS40
4 DNS63
5 DNS73
CONNECTOR DNS-MIXED-AIR-SENSOR

1 DNS39
2 DNS45

4002-137
CONNECTOR DNS-CTRL-PANEL-LIGHT CONNECTOR DNS-RESISTOR

1 DNS69 1 DNS61
2 DNS70 2 DNS62
3 DNS63
4 DNS64
CONNECTOR DNS-WATER-VALVE-POT
CONNECTOR DNS-ELECT-WATER-VALVE-S

1 DNS55
2 DNS54
1 DNS60
3 DNS56
CONNECTOR DNS-RECIRCULATING-SWITCH 4 DNS57

5 DNS58
6 DNS59

1 DNS51 CONNECTOR DNS-DRIVER
2 DNS53
CONNECTOR DNS-THERMOSTAT-1
1 DNS67 CAV WIRE IDENT CIRCUIT

2 DNS50
3 DNS52
CONNECTOR DNS-THERMOSTAT-2
4 DNS49
5 DNS48
6 DNS55
7 DNS57
1 DNS68
8 DNS58
9 DNS59
CONNECTOR DNS-ELECTRIC-FAN 11 DNS51
12 DNS53
13 DNS54
14 DNS56
1 DNS65
2 DNS66

4002-138
CONNECTOR DNS-HVAC1-S CONNECTOR DS - DOOR SWITCH
245482C1
225294C1
A 19U-F Door Switch Fused Power
A DNS67
B 43S-B Door Open Signal
B DNS76
C DNS69
CONNECTOR E-HD - TRANSMISSION HOOD
CONNECTOR DNS-HVAC2-S
245485C1

225315C1
A 18G-D Lic Plate Light Fused Power
B 35A-G Backup Alarm Relay Out
1 DNS74
C 0-BAG Hood Ground (EURO)
2 DNS75

4002-139
CONNECTOR ECA - ELECTRICAL CENTER A
87315248
CAV WIRE IDENT CIRCUIT L1 J6 Pltem Dtnts Park Brake Sol
A1 19A-N Transmission Fused Power L1 J7 Park Brake Solenoid Horn
A2 18L-A Comfort Steering Fused Power L1 J8 Fan Reverse/Turn Signal
A3 19E-A AIC Wake Up Ignition L1 J9 Turn Signal Engine Shutdown
Sec. Steering Ignition Fused L2 J11 Blower Motor Power

A4 19RR
Pwr L2 J12 Blower Mtr Front Wiper Washer
A5 19C-A Pilot Control Relay Fused Pwr L2 J13 Front Wiper Rear Wiper Washer
A6 19D-A Park Brake Relay Fused Power L2 J14 Rear Wiper Washer Backup
A7 19P Pin Engage/Fan Fused Power L2 J15 Backup AC
A8 19B Turn Signal Fused Power L2 J16 AC Seat Compressor
A9 13C-B Fuel Shutoff Fused Power Seat Compressor Emergency
L2 J18
C1 18N Blower Motor Fused Power Steering
C2 19J Front Wiper Fused Power

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

4002-140
CONNECTOR ECB - ELECTRICAL CENTER B
87312843
CAV WIRE IDENT CIRCUIT B3 21K-B Ignition Switch Start Signal
A1 42FS Front Work Lights Power B4 0-DE Neutral Start Relay Control Gnd
A2 42RS Rear Work Lights Power B5 21F EDC7 Digital Ground
A3 41H-B High Beam LH Power B6 0-DF Crank Request Relay Ctrl Gnd
A4 41H-C High Beam RH Power B7 19P-E Fan Reverse Relay Fused Pwr
A5 41L-C Low Beam LH Power B8 52 Fan Reverser LSD
A6 41L-B Low Beam RH Power B9 19D-C Park Brake relay Fused Pwr
A7 41T-B Position Lights LH Sw Power B10 52C Park Brake Solenoid LSD
A8 41T-A Position Lights RH Sw Power D1 13K-C Ignition Switch Power
A9 21H Crank Control Relay LSD D2 13V Voltmeter Input ANALOG
A10 21C-B Neutral Start Relay Output D3 25T Neutral Signal
AA1 42C-C Front Work Lights Fused Power D4 21C Neutral Start Relay Output
AA2 42R-C Rear Work Lights Fused Power D5 21C-A Neutral Start Relay Output
AA3 18B-A High Beam LH Fused Power D6 21E Key Switch Crank
AA4 18C-A High Beam RH Fused Power D7 19P-D Fan Reverse Relay Fused Pwr
AA5 18E-A Low Beam RH Fused Power D8 52A-A Fan Reverse Relay Out
AA6 18D-A Low Beam LH Fused Power D9 19D-B Park Brake Relay Fused Pwr
AA7 18F-C Pos Tail Lights LH Fused Power D10 52P-B Park Brake Relay Out
AA8 18G Pos Tail Lights RH Fused Power

AA9 21D-A Starter Relay Signal
AA10 21G EDC7 Crank Control Relay
B1 18R-A Voltmeter Relay Fused Power
B2 0-DD Voltmeter Relay control Ground

4002-141
CONNECTOR ECC - WORK LIGHTS
87315249

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

4002-142
CONNECTOR ECD - ELECTRICAL CENTER D
87312843
CAV WIRE IDENT CIRCUIT B5 19C-B Pilot Control Relay Fused Pwr
A1 13H-C Trans ECM Time Delay Pwr B6 53C-A Pilot Control Solenoid LSD
A2 13H-D Engine ECM Time Delay Pwr B7 58T Ride Control Relay Switch Pwr
A3 13H-B AIC Time Delay Power B8 58L Ride Control Relay LSD
A4 12V-D Plug 1 12V Switched Power B9 18M AC Relay Fused Power
A5 12V-E Plug 2 12V Switched Power B10 0-DJ AC Relay Control Ground
A6 12V-F Radio 12V Switched Power C2 63C2 Front Wiper Park Control
A7 12V-G 2 Way Radio 12V Sw Power C4 63C Front Wiper Park Control
A9 35C Backup Alarm Relay Control Front Wiper Relay HS Ctrl

D1 19J-D
Fused Pwr
A10 19H Backup Alarm Relay Fused Pwr
D2 63H-B Front Wiper HS Relay Out
AA1 19T-A TECM Delay Fused Power
Front Wiper Relay LS Ctrl Fused
AA2 18J-K EDC7 Time Delay Fused Power D3 19J-F
Pwr
AA3 19S-B AIC Delay Fused Power D4 63C2 Front Wiper Park Control
AA4 12V 12V Power to Outlet 1 D5 19C-C Pilot control Relay Fused Pwr
AA5 12V-A 12V Power to Outlet 2 D6 53P-C Pilot Control Relay Out
AA6 12V-B 12V Fused Power to Radio D7 58H-A Ride Ctrl Switched Pwr VPS2
AA9 35A-A Backup Alarm Relay Out D8 58-E Ride Control Solenoid Power
Backup Alarm Relay Ctrl Fused D9 61R-B AC Relay Control
AA10 19A-P
Pwr
D10 61C AC Relay Out
B1 19J-E Front Wiper Relay Fused Power
B2 63HC-B Front Wiper HS Relay Control
B3 63C3 Front Wiper Park Control
B4 63LC Front Wiper LS Relay Control

4002-143
CONNECTOR EDC7 - ENGINE CONTROLLER CAV WIRE IDENT CIRCUIT
42 35W Water In Fuel Indicator
48 24L Low Idle Switch
75 0-BV Grid Heater Control Ground
77 24S Throttle Supply
78 24R Throttle Ground
79 24B Throttle Signal
89 20G-A EDC7 ISO-K Interface
CONNECTOR EM - HEIGHT CONTROL RTD - RTT
225351C1

1 55A-A RTT/Float Switched Power
2 54A Height Control Switched Power
3 53A RTD Switched Power
4 53B-B RTD Control Signal
5 54B-B HC-RTT Control Signal
BOSCH-89-POLE 6 55B RTT Float Switch Control
2 18J-C EDC7 Time Delay Fused Power
3 18J-B EDC7 Time Delay Fused Power
5 0-BE EDC7 Ground
6 0-BF EDC7 Ground
8 18J-D EDC7 Time Delay Fused Power
9 18J-E EDC7 Time Delay Fused Power
10 0-BD EDC7 Ground
11 0-BC EDC7 Ground
12 28G Grid Heater Source DR
13 0-BN Filter Heater Control
17 21H-A Crank Control Relay LSD
29 21F-B EDC7 Digital Ground
32 21E-A Key Switch Crank
34 CAN-L CAN Low
35 CAN-H CAN High
36 28F Fuel Filter Heater Relay Control
37 21GA EDC7 Crank Control Relay
40 13M-A Fuel Shutoff Fused Power

4002-144
CONNECTOR ENG - ENGINE TO CAB CAV WIRE IDENT CIRCUIT
30 61A Trinary Pressure Switch Input
31 20G-A EDC7 ISO-K Interface
32 36A-A Rear Axle Temperature
33 36F Fuel Level ANALOG
34 36C Radiator Coolant Temp Signal
35 19Y-D Hood Switch Fused Power
225414C1 36 60D-A Hood Down Relay Out
CAV WIRE IDENT CIRCUIT 37 59D-A Hood Down Relay Control
1 21C-D Starter Relay signal 38 60U-A Hood Up Relay Out
2 61C-A AC Relay Out 39 59U-A Hood Up Relay Control
2 61C-B AC Relay Out 40 35A-G Backup Alarm Relay Out
3 21GA EDC7 Crank Control Relay 40 35A-GN Backup Alarm Relay Out
4 21H-A Crank Control Relay LSD

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

4002-145
CONNECTOR ENG-H - ENGINE TO HOOD CONNECTOR ESS - ENGINE SPEED SENSOR
291718A1

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

TRANSMISSION
182069A1

A 1-GB Fuel Filter Heater Power
B 0-BX Fuel Filter Heater Ground
225326C1

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

4002-146
CONNECTOR FLSHR - FLASHER MODULE CONNECTOR FRONT - CAB FRONT CHASSIS
225389C1

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

4002-147
CONNECTOR FWM - FRONT WIPER MOTOR CONNECTOR FWW - FRONT WASHER
245715C1 3227856R1

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

GROUND
3227856R1
245480C1
1 28G Grid Heater Source DR
2 0-BV Grid Heater Control Ground
1 0-B8 Front Wiper Ground

4002-148
CONNECTOR GND-CAB-SPL - CAB GROUND CAV WIRE IDENT CIRCUIT
SPLICE
E 0-DD Voltmeter Relay Control Gnd
Crank Request Relay Control
F 0-DF
Gnd
G 0-DE Neutral Start Relay Control Gnd
Splice Pack Gnd Cab SPL2
H 0-EQ
GND
J Not Used
K 0-EH Flasher Module Ground
L 0-EG Flasher Module Ground
M 0-EF Brake Lights Relay Control Gnd
CONNECTOR HD - HOOD SWITCH

87324393

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

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

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

4002-149
CONNECTOR HD-N - HOOD TO ENGINE CONNECTOR HOT - HYDRAULIC OIL
TEMPERATURE SENDER
194788A1

A 36H Hydraulic Oil Temp Signal
B 0-HW Hydraulic Oil Temp Ground
225319C1

1 0-JA-N Hood Grounds (NA) CONNECTOR HVAC1 - HVAC1
2 44A-EN Brake Light relay Out
3 45L-BN Left Turn Signal
4 45R-BN Right Turn Signal
5 18G-JN RH Position/Tail Fused Power
6 18F-BN LH Position/Tail Fused Power
7 35A-HN Backup Alarm Relay Out
225295C1
CONNECTOR HDM - HOOD LIFT MOTOR
1 61A-B Trinary Pressure Switch Input
2 18N-A Blower Motor Fused Power
3 49A Back Light Power
CONNECTOR HVAC2 - HVAC2
225316C1

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

1 0-ED HVAC Grounds
2 18N-B Blower Motor Fused Power

4002-150
CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC CONNECTOR K-WCO - WIPER CUTOUT
245731C1

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

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

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

4002-151
CONNECTOR LLF - LH FRONT LIGHTS CONNECTOR LLR-E - LH REAR COMBINATION
LAMP
225351C1
225351C1
1 0-AJ Lights Ground LH CAV WIRE IDENT CIRCUIT
2 18D Low Beam LH 1 44A-E Brake Light Relay Out
3 18B High Beam LH 2 45L-A Left Turn Signal
4 18F Position LH Fused Power 3 18F-B Left Tail Fused Power
5 45L Left Turn Signal 4 35A-L Reverse Lamp
6 Not Used 5 0-BT LH Ground (EURO)

6 Not Used
CONNECTOR LLFW - LH FRONT WORK LAMP

CONNECTOR LLR-N - LH REAR COMBINATION
LAMP
245483C1

A 42C-H LH Front Work Lamp Power
B 0-MU LH Front Work Lamp Ground 245715C1

A 44A-FN Brake Lamp Relay Out
B 18F-BN LH Tail Lamp Fused Pwr
C 45L-BN Left Turn Signal
D 0-BR-N LH Rear Light Ground (NA)

4002-152
CONNECTOR LLRW- LH REAR WORK LAMP CONNECTOR LRF - RH FRONT COMBINATION
LAMP
245483C1

225351C1
A 42R-H LH Rear Work Lamp Fused Pwr
B 0-ME LH Rear Work Lamp Ground
1 0-AH RH Front Lights Ground
2 18E RH Low Beam Fused Pwr
CONNECTOR LPL - LICENSE PLATE LAMP 3 18C RH High Beam Fused Pwr
4 18G-A RH Position/Tail Fused Pwr
5 45R Right Turn Signal
6 Not Used
CONNECTOR LRFW - RH FRONT WORK LAMP
245482C1

A 18G-E License Plate Lamp Fused Pwr
A 18G-EN License Plate Lamp Fused Pwr
B 0-JC License Plate Lamp Ground
245483C1

A 42C-G RH Front Work Lamp Fused Pwr
B 0-MJ RH Front Work Lamp Ground

4002-153
CONNECTOR LRR-E - RH REAR COMBINATION CONNECTOR LRRW - RH REAR WORK LAMP
LAMP
245483C1

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

LAMP
195552A1

A 65L Left Speaker Signal
B 0-PA Left Speaker Ground
CONNECTOR OSS - OUTPUT SPEED SENSOR
245715C1

A 44A-GN Brake Lamp Relay Out
RH Position/Tail Lamp Fused
B 18G-CN
Pwr
C 45R-BN Right Turn Signal
D 0-BT-N RH Rear Light Ground (NA)
291719A1

1 0-HE Output Speed Ground
2 25D Output Speed Signal
3 19A Output Speed Fused Pwr

4002-154
CONNECTOR PAF - AIR FILTER RESTRICTION CONNECTOR PBL - BRAKE LAMP PRESSURE
SWITCH SWITCH
222136A1
291718A1
1 1-AA Brake Lamp Switch Power
Air Filter Restriction Switch
1 31F 2 44 Brake Lamp Control Power
Signal
Air Filter Restriction Switch
2 0-BY
Grnd
CONNECTOR PBW - BRAKE PRESSURE
WARNING SWITCH
CONNECTOR PBD - BRAKE DECLUTCH
PRESSURE SWITCH
225316C1
CAV WIRE IDENT CIRCUIT 1 33P Low Brake Press Warning
A 19A-A Brake Declutch Sw Fused Pwr 2 0-AL Brake Press Warn Sw Ground
B 25G Brake Declutch Switch Control

4002-155
CONNECTOR PO1 - POWER OUTLET CONNECTOR PR - TRINARY PRESSURE SWITCH
182068A1

12176446
A 61-A Trinary Pressure Switch Input
B 61R AC Relay Control
A 12V 12V Pwr to Outlet 1
B Not Used
C 0-EK Aux Power Outlet 1 Gnd CONNECTOR PRB1 - REDUNDANT BRAKE
SWITCH
CONNECTOR PO2 - POWER OUTLET
245483C1

RDNT Brake Accumulator Press
A 33R-C
Low
B 0-HM Ground
12176446

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

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

4002-156
CONNECTOR PRBF - ROLLBACK PRESSURE CONNECTOR PRM-B2 - PRM SIGNAL
SWITCH
245483C1
A 58 Ride Control Solenoid Power CAV WIRE IDENT CIRCUIT

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

CONNECTOR PRM-C1 - PRM OUTPUT
409084A1
256340A1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT A 18R Voltmeter Relay Fused Pwr
A 13K-B Ignition Switch Power C 28P Ether Solenoid Power
B 0-EB Ignition Relay Control Ground C 1-GA Filter Heater Power
CONNECTOR PRM-B1 - PRM SIGNAL
409084A1

A Not Used
C 13H Time Delay Power

4002-157
CONNECTOR PRM-C2 - PRM SIGNAL ONNECTOR PRM-E1 - PRM SIGNAL
409084A1

256340A1 A Not Used
CAV WIRE IDENT CIRCUIT C 19L Power Converter FSD Power
A 28E Ether Relay Signal
A 28F Fuel Filter Heater Relay Control
CONNECTOR PRM-E2 - PRM SIGNAL
B 0-BAM Ether Relay Signal Ground
B 0-BN Filter Heater Control
CONNECTOR PRM-D1 - PRM SIGNAL
256340A1

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

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

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

4002-158
CONNECTOR PXF - RTD CONNECTOR PXT - RTD
245485C1 245485C1

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

A 54B RTT Signal 292495A1
B 0-AA Proximity Switch Ground CAV WIRE IDENT CIRCUIT
C 53P-J Pilot Control Relay Out 1 Not Used
2 Not Used
CONNECTOR PXM - RTD 3 Not Used

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

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

4002-159
CONNECTOR RAD-J1 - RADIO POWER CONNECTOR RAD-J3 - RADIO JUMPER
411311A1

1 RAD10 Right Speaker Ground
2 RAD8 Not Used
292497A1 3 RAD4 Left Speaker Ground
CAV WIRE IDENT CIRCUIT 4 RAD6 Not Used
1 Not Used 5 RAD1 Radio Ground
2 Not Used 6 Not Used
3 Not Used 7 RAD3 12V Fused Power to Radio
4 RAD3 12V Fused Power to Radio 8 RAD11 Right Speaker
5 Not Used 9 RAD9 Not Used
6 Not Used 10 RAD5 Left Speaker
7 RAD2 12V Fused Power to Radio 11 RAD7 Not Used
8 RAD1 Radio Ground 12 RAD2 12V Fused Power to Radio
13 Not Used
14 Not Used
CONNECTOR RAD-J2 - SPEAKER
CONNECTOR RECT - ENGINE COOLANT

TEMPERATURE
194788A1
292501A1
A 36C Radiator Coolant Temp Signal
1 RAD11 Right Speaker
B 0-BAE EDC7 Sender Ground
2 RAD10 Right Speaker Ground
3 RAD9 Not Used
4 RAD8 Not Used
5 RAD7 Not Used
6 RAD6 Not Used
7 RAD5 Left Speaker
8 RAD4 Left Speaker Ground

4002-160
CONNECTOR ROOF - ROOF TO CAB CONNECTOR RTHP - THROTTLE PEDAL
CONNECTION
388708A1
CAV WIRE IDENT CIRCUIT 225351C1
A 43-B Dome Light Auto Mode CAV WIRE IDENT CIRCUIT

B 42R-F Rear Work Light Fused Power 1 21F-C EDC7 DIGITAL Ground
C 42C-F Front Work Lights Fused Power 2 Not Used
D 19U-C Done Light Fused Power 3 24B Throttle Signal
E 46-D Beacon Switch Power 3 24B-A Throttle Signal
F 0-MN Roof Grounds 4 24R Throttle Position Sensor Ground
G 0-MK Roof Grounds 4 24R-A Throttle Position Sensor Ground
J 19K-D Rear Wiper Motor Fused Power 5 24S Throttle Supply
K 68C-A Rear Wiper Park Control 5 24S-A Throttle Supply
L 68L-A Rear Wiper Switched Power 6 24L Low Idle Switch
M 0-EN Radio Ground
N 12V-H 12V Fused Power to Radio
CONNECTOR RWM - REAR WIPER MOTOR
R 43S-B Door Open Signal
S 19U-F Door Switch Fused Power
CONNECTOR RSPK - RIGHT SPEAKER
245715C1

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

4002-161
CONNECTOR RWMG - REAR WIPER MOTOR CONNECTOR S-KEY - IGNITION SWITCH TO
GROUND PEDESTAL HARNESS
245480C1
225253C1
1 0-MA Rear Wiper Motor Ground
1 1A Ign Sw Fused Power
2 21K Ign Switch Start Signal
CONNECTOR RWW - REAR WASHER 3 13K Ignition Switch Power
4 12ACC Ign Switch Accessory Power
5 Not Used
6 Not Used
CONNECTOR SBE - BEACON SWITCH
3227856R1

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

1 Not Used
2 19U-H Beacon Switch Fused Power
3 46-C Beacon Switched Power
4 Not Used
5 Not Used
6 Not Used
7 0-B15 Back Light Ground
8 49-B Back Light Power
9 Not Used
10 Not Used

4002-162
CONNECTOR SBU - BACKUP ALARM DISABLE CONNECTOR SCS - COMFOR STEER SWITCH
SWITCH
382391A1
382391A1
1 51S Standard Steering Signal
1 35R-C Backup Alarm Switch
2 18L-D Comfort Steering Fused Power
2 35A-B Backup Alarm Disable Switch
3 51CS Comfort Steering Switch
3 Not Used
4 Not Used
4 Not Used
5 Not Used
5 Not Used
6 51B-A Comfort Steering Solenoid Pwr
6 Not Used 7 0-B9 Back Light Ground
7 0-B21 Back Light Ground 8 49-U Back Light Power
8 49-L Back Light Power 9 Not Used
10 Not Used
CONNECTOR SDC - DECLUTCH SWITCH

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

4002-163
CONNECTOR SDR - DRIVING LIGHTS SWITCH CONNECTOR SFC - FAN CONTROL SWITCH
382391A1
382391A1
2 19Z-A Driving lights Switch Fused Pwr 2 52J Fan Control Switch Jumper
3 41T Position Lights Switch Power 3 52-AU Fan Reverse Auto
4 Not Used 4 52J Fan Control Switch Jumper
Driving Lights Switch Fused 5 19P-C Fan Reverse Switch Fused Pwr
5 19Z-B
Power 6 52M Fan Reverse Manual
6 41J Driving Lights Power 7 0-B7 Back Light Ground
7 0-B19 Back Light Ground 8 49-Q Back Light Power
8 49-P Back Light Power 9 Not Used
10 Not Used
CONNECTOR SFL - RETURN-TO-TRAVEL

CONNECTOR SETHR - ETHER SWITCH SWITCH
382391A1
382391A1
1 Not Used 1 55A-B RTT/Float Switch Power
2 28J Ether AIC OK Signal 2 53P-B Pilot Control Relay Out
3 28H Ether Switch Signal 3 55A-C RTT/Float Switch Power
4 Not Used 4 0-29 RTT/Float Ground
5 Not Used 5 55B RTT Float Switch Control
6 Not Used 6 54B-C HC-RTT Control Signal
7 0-B30 Back Light Ground 7 0-B2 Back Light Ground
8 49U Back Light Power 8 49-K Back Light Power

4002-164
CONNECTOR SFNR - FNR SWITCH CONNECTOR SHC - HEIGHT CONTROL SWITCH
382391A1 382391A1

1 26R-A FNR Reverse Signal 1 Not Used
2 26J FNR Switch Jumper 2 53P-D Pilot Control Relay Out
3 26N-A FNR Neutral Signal 3 Not Used
4 26J FNR Switch Jumper 4 Not Used
5 19A-V FNR Switch Fused Power 5 Not Used
6 26F-A FNR Forward Signal 6 54A HC Control Switch Power
7 32J-A Trans Enable Indication 7 0-B3 Back Light Ground
8 19A-G FNR Switch Fused Power 8 49-M Back Light Power
CONNECTOR SFWW - REAR WIPER AND CONNECTOR SHZ - HAZARD SWITCH

WASHER SWITCH
87345132 382391A1

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

INT Wiper/Washer Sw Fused 5 Not Used
5 19J-B
Pwr
6 Not Used
6 Not Used
7 0-b24 Back Light Ground
7 63W Front Washer Pump
8 49-D Back Light Power
8 49-T Back Light Power
9 Not Used
9 63HC Front Wiper HS Relay Control
10 Not Used
10 Not Used

4002-165
CONNECTOR SPB - PARKING BRAKE SWITCH CONNECTOR SPE - PIN ENGAGE SWITCH
382391A1
382391A1
1 Not Used 1 57-B Pin Engage Solenoid Power
2 19A-L Park Brk Switch Fused Power 2 19P-A Pin Engage Sw Fused Power
3 33U Park Brake Switch 3 Not Used
7 0-B29 RTT/Float Ground
7 Not Used
8 49-v Back Light Power
8 Not Used
9 Not Used
10 Not Used
10 49-F Back Light Power
CONNECTOR SPC - PILOT CONTROL SWITCH CONNECTOR SPK - SPEAKER
382391A1
1 Not Used CAV WIRE IDENT CIRCUIT

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

4002-166
CONNECTOR SPL-BCK-LGT - SPLICE BACK CAV WIRE IDENT CIRCUIT
LIGHT POWER
D 49-M Back Light Power
E 49-K Back Light Power
F 49-F Back Light Power
G 49-Q Back Light Power
H 49-T Back Light Power
J Not Used
K 49-G Back Light Power
L Not Used
M 49-S Back Light Power
CONNECTOR SPL-BCK-LT-GD - SPLICE BACK

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

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

4002-167
CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK CAV WIRE IDENT CIRCUIT
LIGHT GROUND
D 0-BS Fan Control Ground
E 0-B Front Washer Ground
F 0-BL Rear Washer Ground
CONNECTOR SPL-HOOD-GND - HOOD GROUND

6 PACK
87324393

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

6 PACK
87324391

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

4002-168
CONNECTOR SPL-PED-BL - SPL BACK LIGHT CONNECTOR SPL-PIN - SPL BACK LIGHT
POWER 6 PACK POWER 6 PACK
87324391 87324391

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

LIGHT POWER 6 PACK
87324391

A 0-B9 Back Light Ground
C 0-B24 Back Light Ground
D 0-B30 Back Light Ground
E 0-B29 RTT/Float Ground
F 0-B11 Back Light Ground

4002-169
CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY CONNECTOR SPL-PK2 - SPLICE 3 - 4 WAY
87324462 87324462

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

4002-170
CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY CAV WIRE IDENT CIRCUIT
E 0-MF RH Rear Work Light Ground
F 0-MA Rear Wiper Motor Ground
G Not Used
H Not Used
J 0-MJ RH Front Work Light Ground
K Not Used
L 0-MN Roof Grounds
M 0-MK Roof Grounds
CONNECTOR SPL-SEC-STR - SEC STR 6PK

87324462

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

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

4002-171
CONNECTOR SPL-TRN-GRD - SPLICE CAV WIRE IDENT CIRCUIT
TRANSMISSION GROUND
Output Speed Sensor Fused
K 19A-M
Pwr
L 19A-S Trans Fused Pwr
M 19A-H Trans Shifter Fused Pwr
CONNECTOR SRC - RIDE CONTROL SWITCH
87324391

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

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

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

4002-172
CONNECTOR SRHSTLK - RH STALK SWITCH CONNECTOR SRWP - REAR WIPER SWITCH
382391A1

1 68C Rear Wiper Park Control
87318288
2 68L Rear Wiper Switch Power
3 19K-A Rear Wiper Switch Fused Power
31b 64C Horn Relay Control
4 Not Used
49a 19B Turn Signal Fused Power
5 19K-B Rear Wiper Switch Fused Power
56a 41H-A High Beam Power
6 68W Rear Washer Pump
56b 41L-A Low Beam Power
56d 19Z-C High Beam Flash Fused Power
8 49-C Back Light Power
31 0-EP Horn Switch Ground
9 Not Used
56 41J Drive Lights Power
10 Not Used
L 45A-A Left Turn Switch Power
R 45B-A Right Turn Switch Power
CONNECTOR SS-TR - SS-MOD-TRANS
CONNECTOR SRTD - DETENT SWITCH
245489C1

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

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

4002-173
CONNECTOR SSM - SECONDARY STEERING CAV WIRE IDENT CIRCUIT
MODULE
8 49S Back Light Power
9 Not Used
10 Not Used
CONNECTOR STE - TRANSMISSION ENABLE

SWITCH
225389C1

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

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

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

4002-174
CONNECTOR SWL - WORK LIGHTS SWITCH CAV WIRE IDENT CIRCUIT
8 CAN-LF CAN Low
9 17P-A Switch Pad Pwr From AIC Pwr
10 0-B28 Switch Pad Ground
CONNECTOR TCOT - TORQUE CONVERTER

OUTPUT SENDER
382391A1

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

CONNECTOR SW-PD - SWITCH PAD
225351C1

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

4002-175
CONNECTOR TECM - TRANSMISSION CAV WIRE IDENT CIRCUIT
ELECTRONIC CONTROL MODULE
21 52P-C Park Brake Relay Out
22 25Y-A Trans Kick Down Signal
23 19T-A Time Delay Fused Power
25 CAN-HD CAN High
26 CAN-LK CAN Low
27 CAN-LJ CAN Low
29 25H Trans Auto Signal
30 26R-B FNR Reverse Signal
31 26E Trans Enable Signal
32 25M-A Trans Sol Valve Y3
39 36T-A Valve Body Temp Signal
41 25C-A Turb Speed Signal
42 25B-A Int Speed Signal
43 25F Forward Signal
44 26N-B FNR Neutral Signal
45 19A-K TECM Fused Power
46 36R-E Trans Temp/Filter Return
49 36G-A Torque Conv Out Temp Signal
51 25J-A Trans Sol Valve Y6
55 25N-A Trans Sol Valve Y4
56 25K-A Trans Sol Valve Y1
57 58L Ride Control Relay LSD
62 25D-A Output Speed Signal
63 25Z 1st and 4th Gear Signal
64 25R- Reverse Signal
65 25W 3rd and 4th Gear Signal
411398A1
66 25G-C Brake Declutch Switch Control
67 25T-C Neutral Signal
1 0-DP Diag TECM Ground
2 0-DQ Diag TECM Ground
3 0-DM Speed Sensors Ground
4 0-DN Out Speed Sensor Ground
5 32J-D Trans Enable Indicator Lamp
7 35C Backup Alarm Relay Control
8 58H-A Ride Control Sw Power VPS2
9 25P-A Trans Sol Valve Y5
10 25L-A Trans Sol Valve Y2
12 25S-B Output Sw Power VPS1
13 25S-C Output Sw Power VPS1
15 37D-A Diagnostic Signal
17 32F-A Trans Filter Maint Switch
18 37E Diagnostic Signal Switched
19 25A-A Engine Speed Signal
20 26F-B FNR Forward Signal

4002-176
CONNECTOR TR-SS - SEC-STR-MOD-OPT CONNECTOR TRANS - CAB TO TRANSMISSION
380838A1

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

4002-177
CONNECTOR TRC - TRANSMISSION CONTROL CONNECTOR TS1 - TRANSMISSION SHIFTER
245486C1
371566A1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT A 19A-H Trans Shifter Fused Power
1 25K Trans Solenoid Valve Y1 B 25F Forward Signal
1 25L-9 Trans Solenoid Valve Y1 C 25R Reverse Signal
2 25K-9 Trans Solenoid Valve Y2 D 25T-B Neutral Signal
2 25L Trans Solenoid Valve Y2
3 25M Trans Solenoid Valve Y3
CONNECTOR TS2 - TRANSMISSION SHIFTER
4 25N Trans Solenoid Valve Y4
5 25P Trans Solenoid Valve Y5
6 25J Trans Solenoid Valve Y6
7 25S Output Sw Power VPS1
8 36T Valve Body Temp Signal
9 36R-C Valve Body Temp Return
10 Not Used
11 Not Used
12 Not Used
245487C1
13 Not Used
14 Not Used
A Not Used
15 Not Used
B 25W 3rd and 4th Gear Signal
16 Not Used
C 25Z 1st and 4th Gear Signal
D 25Y Transmission Kick Down Signal

4002-178
CONNECTOR TSS - TURBINE SPEED SENSOR CONNECTOR YCS - COMFOR STEERING
SOLENOID
245482C1
291718A1
CAV WIRE IDENT CIRCUIT A 51B-D Comfort Steering Solenoid Pwr
1 25C Turbine Speed Signal B 0-AQ Comfort Steering Solenoid Gnd
2 0-HH Turbine Speed Ground
CONNECTOR YFN - FNA PWM SOLENOID

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

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

HEATER
225316C1

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

4002-179
CONNECTOR YPB - PARKING BRAKE SOLENOID CONNECTOR YRC - RIDE CONTROL OPT
291718A1 291718A1

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

CONNECTOR YSS - SECONDARY STEERING
SOLENOID
245482C1

A 57 Pin Engage Solenoid Power 225316C1
B 0-AE Pin Engage Ground CAV WIRE IDENT CIRCUIT

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

SOLENOID
245482C1

A 5P-A Pilot Control Relay Out
B 0-DU Pilot Pressure Solenoid Gnd

4002-180
NOTES

4002-181
Symbols Cluster, Instrument Connector 1 ...........................65
12 Volt Radio .......................................................112 Cluster, Instrument Connector 2 ...........................71
Compressor Clutch ..............................................115
A Compressor Clutch Relay ...................................114
A/C High/Low Pressure Switch ............................115 Compressor, Seat ...............................................114
Air Filter Restriction Switch ....................................67 Connector 108F ...................................................126
Air Seat Compressor and Switch .........................114 Connector 140M ..................................................126
Alarm Connector 197F ...................................................126
Back-up (Europe Only) ......................................96 Connector 197M ..................................................126
Back-up (North America Only) ..........................96 Connector 202M ..................................................127
Back-up, Disable Switch ...................................76 Connector 209F ...................................................127
Back-up, Relay ..................................................76 Connector 209M ..................................................127
Alternator ...............................................................40 Connector 20M ....................................................127
Connector 215F ...................................................127
B Connector 216F ...................................................127
Back-up Alarm (Europe Only) ................................96 Connector 64F .....................................................128
Back-up Alarm (North America Only) ....................96 Connector 64M ....................................................128
Back-up Alarm Disable Switch ..............................76 Connector 69 .......................................................161
Back-up Alarm Relay .............................................76 Connector ACT ....................................................128
Batteries ................................................................41 Connector AIC1 ...................................................128
Beacon Switch .......................................................79 Connector AIC2 ...................................................129
Beacon, Rotating (Option) .....................................78 Connector CAB_E ...............................................130
Brake Lamp Pressure Switch ................................83 Connector CAB_F ...............................................131
Brake Lamps Relay ...............................................83 Connector CAB_RF .............................................131
Brake Warning Pressure Switch ............................68 Connector CAB_T ...............................................132
Buzzer ...................................................................66 Connector CAN ...................................................132
Connector CAN2 .................................................132
C Connector CL ......................................................133
CAN Communication Diagnostics Connector ......109 Connector CLS ....................................................133
Cigar Lighter ........................................................114 Connector CNV ...................................................133
Circuit Breaker Cab B+ ..........................................47 Connector D_OR .................................................133
Climate Control, Automatic Connector DIA .....................................................133
24 to 12 Volt Converter ...................................118 Connector DISC ..................................................133
Blower Motor Resistor .....................................117 Connector DM .....................................................134
Blower Motors .................................................117 Connector DNS-AC-SWITCH ..............................134
Compressor Relay ..........................................118 Connector DNS-ACTUATOR ..............................134
Electronic Panel ..............................................117 Connector DNS-BLUE .........................................134
Electronic Water Valve ....................................118 Connector DNS-COMPRESSOR-RELAY ...........134
External Air Temperature Sensor ....................117 Connector DNS-CTRL-PANEL-LIGHT ................137
Internal Air Temperature Sensor .....................117 Connector DNS-DRIVER ....................................137
Mixed Air Sensor .............................................117 Connector DNS-ELECTRIC-FAN ........................137
Recycling Motor ..............................................118 Connector DNS-ELECT-WATER-VALVE ...........136
Sun Sensor .....................................................117 Connector DNS-ELECT-WATER-VALVE-S ........137
Thermocouple Sensor .....................................117 Connector DNS-EXTERNAL-AIR-TEMP-SNS ....134
Climate Control, Standard Connector DNS-HVAC1 ......................................135
Air Conditioning Switch ...................................121 Connector DNS-HVAC1-S ..................................138
Air Recirculation Motor ....................................120 Connector DNS-HVAC2 ......................................135
Air Recirculation Switch ..................................122 Connector DNS-HVAC2-S ..................................138
Blower Motor ...................................................120 Connector DNS-HVAC-CAN1 .............................134
Blower Motor Speed Resistors with Thermal Fuse Connector DNS-INTERNAL-AIR-TEMP-SNS .....135
120 Connector DNS-MISED-SIR-SENSOR ...............136
Blower Switch ..................................................121 Connector DNS-NOT-USED ...............................135
Control Panel Lights ........................................121 Connector DNS-PWM-BLOWER ........................136
Driver ...............................................................120 Connector DNS-PWM-BLOWER-PIN2 ...............136
Electronic Water Valve ....................................120 Connector DNS-PWM-BLOWER-PIN4 ...............136
Thermostat ......................................................121 Connector DNS-RECIRCULATING-SWITCH .....137
Water Valve Potentiometer .............................121 Connector DNS-RECYCLING-MOTOR ..............136

4002-182
Connector DNS-RESISTOR ................................137 Connector PBL ....................................................154
Connector DNS-SPEED-SELECTOR .................136 Connector PBW ...................................................154
Connector DNS-THERMOCOUPLE-SENSO ......136 Connector PO1 ....................................................155
Connector DNS-THERMOSTAT-1 ......................137 Connector PO2 ....................................................155
Connector DNS-THERMOSTAT-2 ......................137 Connector PR ......................................................155
Connector DNS-VOLTAGE-CONVERTER .........136 Connector PRB1 .................................................155
Connector DNS-WATER-VALVE-POT ................137 Connector PRB2 .................................................155
Connector DNS-YELLOW ...................................135 Connector PRBF .................................................156
Connector DS ......................................................138 Connector PRM_A1 ............................................156
Connector E_HD .................................................138 Connector PRM_B1 ............................................156
Connector ECA ....................................................139 Connector PRM_B2 ............................................156
Connector ECB ....................................................140 Connector PRM_C1 ............................................156
Connector ECC ...................................................141 Connector PRM_C2 ............................................157
Connector ECD ...................................................142 Connector PRM_D1 ............................................157
Connector EDC7 .................................................143 Connector PRM_E1 ............................................157
Connector EM ......................................................143 Connector PRM_E2 ............................................157
Connector ENG ...................................................144 Connector PSS ....................................................157
Connector ENG_D ...............................................144 Connector PXF ....................................................158
Connector ENG_H ...............................................145 Connector PXH ...................................................158
Connector ENG_T ...............................................145 Connector PXM ...................................................158
Connector ESS ....................................................145 Connector PXT ....................................................158
Connector FFH ....................................................145 Connector RAD ...................................................158
Connector FLSHR ...............................................146 Connector RAD_J1 .............................................159
Connector FM ......................................................146 Connector RAD_J2 .............................................159
Connector FRONT ...............................................146 Connector RAD_J3 .............................................159
Connector FWM ..................................................147 Connector RECT .................................................159
Connector FWMG ................................................147 Connector ROOF ................................................160
Connector FWW ..................................................147 Connector RSPK .................................................160
Connector GHC ...................................................147 Connector RTHP .................................................160
Connector GND_CAB_SPL .................................148 Connector RWM ..................................................160
Connector GND_CAB_SPL2 ...............................148 Connector RWMG ...............................................161
Connector HD ......................................................148 Connector RWW .................................................161
Connector HD_E .................................................148 Connector S_KEY ...............................................161
Connector HD_N .................................................149 Connector SBE ....................................................161
Connector HDM ...................................................149 Connector SBU ...................................................162
Connector HOT ...................................................149 Connector SC ......................................................162
Connector HVAC_CAN1 .....................................150 Connector SCS ...................................................162
Connector HVAC1 ...............................................149 Connector SDC ...................................................162
Connector HVAC2 ...............................................149 Connector SDR ...................................................163
Connector ISS .....................................................150 Connector SETHR ...............................................163
Connector K_WCO ..............................................150 Connector SFC ....................................................163
Connector LBEE ..................................................150 Connector SFL ....................................................163
Connector LLF .....................................................151 Connector SFNR .................................................164
Connector LLFW .................................................151 Connector SFWW ...............................................164
Connector LLR_E ................................................151 Connector SHC ...................................................164
Connector LLR_N ................................................151 Connector SHZ ....................................................164
Connector LLRW .................................................152 Connector SPB ....................................................165
Connector LPL .....................................................152 Connector SPC ...................................................165
Connector LRF ....................................................152 Connector SPE ....................................................165
Connector LRFW .................................................152 Connector SPK ....................................................165
Connector LRR_E ...............................................153 Connector SPL_BCK_LGT ..................................166
Connector LRR_N ...............................................153 Connector SPL_BCK_LGT2 ................................166
Connector LRRW ................................................153 Connector SPL_BCK_LT_GD .............................166
Connector LSPK ..................................................153 Connector SPL_BCK_LT_GD2 ...........................167
Connector OSS ...................................................153 Connector SPL_ENG_GND ................................167
Connector PAF ....................................................154 Connector SPL_HOOD_GND .............................167
Connector PBD ....................................................154 Connector SPL_PED_BL ....................................168

4002-183
Connector SPL_PED_BL_GD .............................168 E
Connector SPL_PIN ............................................168 Electrical Wire Identification ....................................8
Connector SPL_PK1 ...........................................169 Electromagnetic Detents .......................................54
Connector SPL_PK2 ...........................................169 Electronic Diesel Control .......................................51
Connector SPL_PK3 ...........................................170 Engine Speed Sensor ...........................................63
Connector SPL_ROOF ........................................170
Connector SPL_SEC_STR ..................................170 F
Connector SPL_TRN_GRD .................................171 Fan PWM Solenoid ...............................................61
Connector SPL_TRNS_PWR ..............................171 Fan Reverse Relay ................................................59
Connector SRC ...................................................171 Fan Reversing Solenoid ........................................61
Connector SRC_1 ...............................................171 Fan Reversing Switch ...........................................59
Connector SRHSTLK ..........................................172 Filter Maintenance Switch .....................................63
Connector SRTD .................................................172 Flasher Module ......................................................84
Connector SRWP ................................................172 FNR Switch for Joystick Controls ..........................63
Connector SS_TR ...............................................172 FNR Switch for Single Axis Controls .....................63
Connector SSM ...................................................173 Front
Connector STA ....................................................173 Left Hand Work Lamp .......................................79
Connector STE ....................................................173 Right Hand Work Lamp .....................................80
Connector SW_PD ..............................................174 Front Left Hand Combination Lamp ......................88
Connector SWL ...................................................174 Front Right Hand Combination Lamp ....................89
Connector TCOT .................................................174 Front Washer Pump Motor ..................................102
Connector TDM ...................................................174 Front Wiper and Washer Switch ..........................100
Connector TECM .................................................175 Front Wiper Cut Out Relay ....................................98
Connector TR_SS ...............................................176 Front Wiper High Speed Relay ..............................98
Connector TRAN_E .............................................176 Front Wiper Low Speed Relay ..............................99
Connector TRANS ...............................................176 Front Wiper Motor ...............................................101
Connector TRC ....................................................177 Fuel Filter Heater ...................................................48
Connector TS1 ....................................................177 Fuel Filter Heater Relay ........................................46
Connector TS2 ....................................................177 Fuel Level Sender .................................................67
Connector TSS ....................................................178
Connector WF .....................................................178 G
Connector WSH ...................................................178 Grid Heater ............................................................47
Connector YCS ....................................................178 Grid Heater Relay ..................................................47
Connector YFN ....................................................178
Connector YFR ....................................................178 H
Connector YPB ....................................................179 Hazard Switch .......................................................85
Connector YPE ....................................................179 Heater
Connector YPP ....................................................179 Fuel Filter ..........................................................48
Connector YRC ...................................................179 Grid ...................................................................47
Connector YSS ....................................................179 Water Separator ................................................47
Connector, Diagnostic ...........................................63 Height Control Switch ............................................53
Coolant Level Sender ............................................74 Height Control/Return-To-Travel Proximity Switch 55
Crank Control Relay ..............................................41 High-Low Beam Switch .........................................85
Crank Request Relay ............................................41 Hood
Down Relay .....................................................124
D Motor ...............................................................125
Declutch Brake Switch ...........................................63 Switch .............................................................124
Declutch Switch .....................................................63 Up Relay .........................................................124
Diagnostic Connector ............................................63 Horn .......................................................................90
Diodes Horn Relay ............................................................90
Lights .................................................................81 Horn Switch ...........................................................85
Secondary Steering .........................................105 Hydraulic Filter Restriction Switch .........................72
Wipers .............................................................103 Hydraulic Oil Temperature Sender ........................72
Dome Lamp ...........................................................79
Door Switch ...........................................................78 I
Driving Lamp Switch ..............................................86 Ignition Switch .......................................................43
Instrument Cluster Connector 1 ............................65
4002-184
Instrument Cluster Connector 2 .............................71 P
Intermediate Speed Sensor ...................................63 Parking Brake Relay .............................................. 66
Parking Brake Solenoid ......................................... 67
L Parking Brake Switch ............................................ 73
Lamp Pilot Control Relay ................................................. 55
Dome .................................................................79 Pilot Control Switch ............................................... 60
High Beam ..................................................88, 89 Pilot Pressure Solenoid ......................................... 56
Left Hand Front Combination ............................88 Pin Engage Solenoid ............................................. 56
Left Hand Front Work ........................................79 Pin Engage Switch ................................................ 56
Left Hand Rear Combination (Europe Only) .....95 Potentiometer
Left Hand Rear Combination (North America Only) Throttle .............................................................. 50
............................................................94 Power Converter (24 volts to 12 volts) ................111
Left Hand Rear Work ........................................80 Power Outlet ........................................................111
License Plate (Europe Only) .............................96 Power Relay Module
License Plate (North America Only) ..................95 A Ignition Power ................................................ 46
Low Beam ...................................................88, 89 B Ignition Power ................................................ 46
Position .......................................................88, 89 C Fuel Filter Heater ........................................... 46
Right Hand Front Combination ..........................89 D Accessory Power ........................................... 48
Right Hand Front Work .....................................80 E Power Converter 24V to 12V .......................111
Right Hand Rear Combination (Europe Only) ...93 Proximity Switch
Right Hand Rear Combination (North America Height Control/Return-To-Travel .......................55
Only) ...................................................92 Return-To-Dig ................................................... 54
Right Hand Rear Work ......................................80
Switch, Driving ..................................................86 R
Turn .............................................................88, 89 Radiator Coolant Temperature Sender ................. 68
Left Hand Front Combination Lamp ......................88 Radio
Left Hand Front Work Lamp ..................................79 12 Volt .............................................................112
Left Hand Rear Combination Lamp (Europe Only) 95 Rear
Left Hand Rear Combination Lamp (North America Left Hand Combination Lamp (Europe Only) .... 95
Only) .........................................................94 Left Hand Combination Lamp (North America
Left Hand Rear Work Lamp ...................................80 Only) .................................................. 94
Left Speaker ........................................................112 Left Hand Work Lamp ....................................... 80
License Plate Lamp .........................................95, 96 Right Hand Combination Lamp (Europe Only) . 93
License Plate Lamp (Europe Only) ........................96 Right Hand Combination Lamp (North America
License Plate Lamp (North America Only) ............95 Only) .................................................. 92
Lights Diodes .........................................................81 Right Hand Work Lamp ..................................... 80
Locating Components on the Schematic Posters ..38 Rear Washer Pump Motor ...................................102
Rear Wiper and Washer Switch ............................ 99
M Rear Wiper Motor ................................................102
Magnetic Detents ...................................................54 Redundant Brake Pressure Switch 1 .................... 73
Master Disconnect Switch .....................................42 Redundant Brake Pressure Switch 2 .................... 73
Module Relay
Flasher ..............................................................84 Backup Alarm ....................................................76
Secondary Steering .........................................106 Brake Lamps ..................................................... 83
Time Delay ........................................................42 Compressor Clutch .........................................114
Transmission Electronic Control .......................63 Crank Control ....................................................41
Motor Crank Request .................................................. 41
Hood ................................................................125 Fan Reverse ..................................................... 59
Starter ...............................................................43 Front Wiper Cut Out .......................................... 98
Front Wiper High Speed ................................... 98
N Front Wiper Low Speed .................................... 99
Neutral Start Relay ................................................44 Fuel Filter Heater .............................................. 46
Grid Heater ....................................................... 47
O Hood Down .....................................................124
Outlet, Power .......................................................111 Hood Up ..........................................................124
Output Speed Sensor ............................................63 Horn .................................................................. 90
Neutral Start ...................................................... 44

4002-185
Parking Brake ....................................................66 Pilot Pressure ....................................................56
Pilot Control .......................................................55 Pin Engage .......................................................56
Power Relay Module A Ignition Power ..............46 Ride Control ......................................................60
Power Relay Module B Ignition Power ..............46 Secondary Steering .........................................105
Power Relay Module C Water Separator Htr ....46 Speaker
Power Relay Module D Accessory Power .........48 Left ..................................................................112
Power Relay Module E Power Converter ........111 Right ................................................................112
Ride Control ......................................................58 Specifications ..........................................................7
Starting ..............................................................40 Speed Resistors
Voltmeter ...........................................................44 Blower Motor ...................................................120
Resistor Starter Motor .........................................................43
Alternator ...........................................................40 Starting Relay ........................................................40
Return to Dig Switch Switch ..................................55 Steering
Return-To-Dig Proximity Switch ............................54 Secondary, Module .........................................106
Return-To-Travel/Float Switch ...............................53 Secondary, Motor ............................................107
Ride Control Relay ................................................58 Secondary, Pressure Switch ...........................107
Ride Control Solenoid ............................................60 Secondary, Solenoid .......................................105
Ride Control Switch ...............................................58 Switch
Right Hand Front Combination Lamp ....................89 A/C High/Low Pressure ...................................115
Right Hand Front Work Lamp ................................80 Air Filter Restriction ...........................................67
Right Hand Rear Combination Lamp (Europe Only) . Back-up Alarm Disable ......................................76
93 Beacon ..............................................................79
Right Hand Rear Combination Lamp (North America Blower .............................................................121
Only) .........................................................92 Brake Lamp Pressure .......................................83
Right Hand Rear Work Lamp ................................80 Brake Warning Pressure ...................................68
Right Speaker ......................................................112 Declutch ............................................................63
Rollback Jumper ....................................................61 Declutch Brake ..................................................63
Rollback Pressure Switch ......................................60 Door ..................................................................78
Rotating Beacon (Option) ......................................78 Driving Lamp .....................................................86
Fan Reversing ...................................................59
S Filter Maintenance .............................................63
Seat Compressor and Switch ..............................114 FNR for Joystick Controls .................................63
Secondary Steering FNR for Single Axis Controls ............................63
Module ............................................................106 Front Wiper and Washer .................................100
Motor ...............................................................107 Hazard ..............................................................85
Pressure Switch ..............................................107 Height Control ...................................................53
Solenoid ..........................................................105 High-Low Beam .................................................85
Secondary Steering Diodes .................................105 Hood ...............................................................124
Sender Horn ..................................................................85
Coolant Level ....................................................74 Hydraulic Filter Restriction ................................72
Fuel Level ..........................................................67 Ignition ..............................................................43
Hydraulic Oil Temperature ................................72 Master Disconnect ............................................42
Radiator Coolant Temperature ..........................68 Pad ....................................................................70
Torque Converter Output Temperature .............63 Parking Brake ....................................................73
Sensor Pilot Control Switch ...........................................60
Engine Speed ....................................................63 Pin Engage .......................................................56
Intermediate Speed ...........................................63 Proximity, Height Control/Return-To-Travel ......55
Output Speed ....................................................63 Proximity, Return-To-Dig ...................................54
Transmission Solenoid Valve and Temperature ... Rear Wiper and Washer ....................................99
63 Redundant Brake Pressure 1 ............................73
Turbine Speed ...................................................63 Redundant Brake Pressure 2 ............................73
Water In Fuel .....................................................50 Return to Dig .....................................................55
Shifter, Transmission .............................................63 Return-To-Travel/Float ......................................53
Solenoid Ride Control ......................................................58
Fan PWM ..........................................................61 Rollback Pressure .............................................60
Fan Reversing ...................................................61 Seat Compressor ............................................114
Parking Brake ....................................................67 Secondary Steering Pressure .........................107

4002-186
Transmission Auto ............................................63
Transmission Enable .........................................63
Transmission Kick-down ...................................63
Turn Signal ........................................................85
Work Lamps ......................................................78
Switch Pad .............................................................70
T
Thermal Fuse
Blower Motor ...................................................120
Throttle Potentiometer ...........................................50
Time Delay Module ................................................42
Torque Converter Output Temperature Sender ....63
Transmission Auto Switch .....................................63
Transmission Electronic Control Module ...............63
Transmission Enable Switch .................................63
Transmission Kick-down Switch ............................63
Transmission Shifter ..............................................63
Transmission Solenoid Valve and Temperature Sen-
sors ...........................................................63
Turbine Speed Sensor ...........................................63
Turn Signal Switch .................................................85
U
Understanding the Troubleshooting Tables ...........38
V
Voltmeter Relay .....................................................44
W
Warning Buzzer .....................................................66
Water In Fuel Sensor .............................................50
Water Separator
Heater ...............................................................47
Heater Relay .....................................................46
Wiper
Front Cut Out Relay ..........................................98
Front Motor ......................................................101
Front Switch ....................................................100
Front Washer Pump Motor ..............................102
Front Washer Switch .......................................100
Front Wiper High Speed Relay .........................98
Front Wiper Low Speed Relay ..........................99
Rear Motor ......................................................102
Rear Switch .......................................................99
Rear Washer Pump Motor ..............................102
Rear Washer Switch .........................................99
Wiper Diodes .......................................................103
Wire Identification ....................................................8
Work Lamp Switch .................................................78

Section
4003
4003
BATTERIES

4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

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

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

4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery

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

4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the 1 2
battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check 1. TEMPERATURE IN F 2. TEMPERATURE IN C

B790863
A hydrometer is used to check the specific gravity SPECIFIC GRAVITY CHART

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

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

ARROW AWAY FROM
BATTERY)

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

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

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

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

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

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

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

4003-8
Charging Guide For Batteries Other Than Maintenance Free

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

Reserve Capacity under Slow Charge Fast Charge
Specifications

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

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


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

1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
spe cific gravity is 1 .25 0 or m ore a nd the
2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
electrolyte. This will per mit the volume of
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
3. Install the caps on the battery.
the cell opening.
4. Connect a battery charger to the battery.

Section
4005
INSTRUMENT CLUSTER
4005

4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hardware Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Software Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4005-3
INSTRUMENT CLUSTER
5
4 6
1 2 3 7 8 9 10
15 11
14 12
13
BD06H039
1. LOW BRAKE PRESSURE INDICATOR 9. LACK OF AUX STEER PRESSURE (OPTIONAL)
2. HIGH BEAM INDICATOR 10. PARKING BRAKE INDICATOR
3. TRANSMISSION OIL TEMPERATURE GAUGE 11. RIGHT TURN INDICATOR
4. CAUTION MASTER INDICATOR 12. FUEL LEVEL GAUGE
5. MULTI FUNCTION LCD DISPLAY 13. FUEL LEVEL AT MINIMUM
6. STOP MASTER INDICATOR 14. ENGINE COOLANT TEMPERATURE GAUGE
7. HYDRAULIC OIL TEMPERATURE GAUGE 15. LEFT TURN INDICATOR
8. WAIT TO START ENGINE PREHEAT
The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:

4005-4
Self-Test Power Circuit Test

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

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

Control Lever is in Neutral. The display will show
Forward, Neutral, or Reverse, depending on
where the Directional Control Lever is
positioned.
NOTE: Forward and Reverse will blink if the
transmission clutches are disconnected.
3. This example shows the maximum gear allowed
when in Automatic mode. If display is blank the
Manual mode has been selected.
4. This example shows the current transmission
mode that has been selected.
A. If the Transmission is operating normally it will
display either
BD06J132
The LCD Multi-Function Display is located at the ● A - Automatic

center of the modular dashboard. On start up the ● M - Manual operation.
cluster will flash the instructional lamps and the LCD B. If the Transmission is not operating normally
Multi-Display will display, CASE, with the machine the display will show
model and current hour reading.
● C - Substitute Clutch.
2 ● L - Limp Home.
1
● S - Transmission Shutdown.
● U - TCU Shutdown.
3 5. This example (not displayed) will show the
5 4 transmission clutches disengaged, if the Park
Brake is OFF.
6. This example shows the Power Boost Status.
● MAX - Maximum Power.
● STD - Normal/Standard mode of Operation.
● AUTO - Switches automatically between
Maximum and Standard Power.
● ECO - Limited Power for fuel efficiency.
6 7 7. This example will show the Time in either 12
hour or 24 hour.
BD06F185
LCD MULTI-FUNCTION DISPLAY
Information will be displayed in different zones on the
LCD, as directed by the operator or machine. In
most situations the operator or technician will be
given specific information to follow if conditions are
not correct.
1. In the example, above, the machine hours are
d i s p laye d . M a c h i n e h o u r s w i l l a l way s b e
displayed briefly, on start up. After, the machine
is started, the display will show engine rpm’s.
After, beginning travel, the machine will display
travel speed, if default settings were not changed
by the operator.

4005-6
Navigating Through The LCD Using The Arrow Keys
Multi-function Display Screens At any time, during operation or with the key switch
on, the operator may scroll through three information
screens and two trip screens by using the arrow
keys. These five screens are in a circular loop and
A C may be reached by pressing the up or down key. The
following sequence is using the down key only.
NOTE: Pressing the escape key will return the LCD
back to the normal driving screen.
B D
BD06F186
Located on the steering column, just to the left of the
Park Switch, is the key pad. Use this key pad to
move from one screen to another, choose various
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
the same basic manner.
A. Escape key: Use this key to exit and return to
BD06F188
the driving screen. Use this key anytime you
would like to start over and begin again, plus From the driving screen push the down arrow, as
use to check active, acknowledge errors. shown.
B. Enter key: Use this key to confirm, yes, this is

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

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

4005-7
BD06F169
Press the down button again and the Trip 1 screen
BD06F027
will display. The LCD provides two trip computers.
Info 2 will be displayed next. The Info 2 screen will These will display since last reset the total time in
display coolant temperature, turbocharger air h o u r s , t h e t o t a l f u e l , a n d t h e a ve r a g e f u e l
temperature, engine oil temperature in either consumption per hour.
Fahrenheit or Celsius, as well as oil pressure PSI.
BD06F170
By continuing to scroll down, the fifth screen will
BD06F184
Push the down button again and the Info 3 screen. display the Trip 2 screen. Trip 1 and Trip 2 screens
This screen displays the temperature in Fahrenheit can be reset independently. The previous screen can
or Celsius of the transmission oil, hydraulic oil, sump be accessed by using the up arrow key.
oil, and radiator coolant temperature.

4005-8
Reset The Trip Information
BD06F172
BD06F170 The trip screen will indicate a reset message. At this

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

4005-9
Entering The Service Screens

After the machine has been started or the key switch has been turned to on the operator or service technican may
use this service menu to adjust machine configurations to working conditions, test components, view faults that
may have occurred, or select preferences.
NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery
disconnect you may loose all of your selections and need to reprogram the LCD Multi-function display.
BD06H038 / BD06F188
Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to
scroll through the menu’s.
Items and selections in this menu are: ● Month
1. Power Mode Menu ● Year
● Max - Maximum power possible 6. Cluster H/W
● Standard - Standard operation ● Part Number
● Auto - Will cycle between Max and Standard ● Serial Number
● Eco - Limited power for economy ● ID
2. Preferences Menu ● Version
● Language - English, Italian, French, Spanish, 7. Cluster S/W
Portuguese, German ● Part Number
● Units - Metric, English or Imperial ● Loader Version
● Clock - 24 or 12 hour ● ID
3. Options Menu ● Version
● Fan Auto - manual or automatic 8. Config Menu
● Idle Auto - manual or automatic ● Change Model *
● Show RPM ● Select Tires (Select tire sizes)
● Show MPH/KPH ● Clutch Calibration (calibrate gear box)*
4. Display Menu ● Gear Limits (choose maximum gear)
● Day Display ● Park Brake (Park brake test)
● Day LED ● Cold Start (choose cold start system)
● Night Display ● FAN Test (sound level)
● Night LED ● Special
5. Clock Menu - Reset Error
● Hour - Factory Set
● Minute
● Day

4005-10
* The tests in the configuration menu should be Software Screen
performed only by a qualified operator or technician,
as some tests require the engine to be running at
high RPM’s.
Select Screen
The select screen will allow you to make time
s e t t i n g s a s w e l l a s g i ve a c c e s s t o m a c h i n e
information. Navigate this screen also by highlighting
your selection and pressing confirm. This will allow
you to change clock settings or view the hardware
and software screens. No operator changes can be
made to the hardware or software screens.
BD06H028
The cluster software selection will display the CNH
part number, serial number, ID number and software
version of the Instrument cluster. This display is a
convenient source of information when ordering parts
or accessories. Press escape to exit from this field
and return to the selection menu or use the up or
down arrow key to toggle to the software information
screen.
Selecting Power Modes
The power mode allows the operator to choose the
BS06F177 most effective machine power for the current job
Hardware Screen conditions. Most commonly auto is chosen, as the
power will automatically increase or decrease
Scroll to the hardware selection and press confirm to between maximum power and standard power while
display machine information. the machine is working. This allows for maximum
power if necessary, but will switch to standard mode
for economy. Maximum power can be chosen for
more severe work conditions. Economy can be
chosen for limited power and fuel efficiency.
Press and hold the confirmation button for two
seconds to arrive at the service screen.
BD106F193
The cluster hardware selection will display the CNH
part number, serial number, ID number and version
of the Instrument cluster. This display is a convenient
source of infor mation when ordering par ts or
accessories. Press escape to exit from this field and
return to the selection menu or use the up or down
arrow key to toggle to the software information BD06H038
screen. At the screen shown above, highlight the power
mode and press the confirmation button to move to
the Power Mode Selection Menu.

4005-11
Preferences
BD06F178
At the Power Mode Menu press the confirmation BD06F179
bu t t o n a g a i n t o a c t i va t e t h e s e l e c t i o n s. T h e Language Screen, Measurement Units,
highlighted section will flash to indicate a new
selection can be made.
and Clock
The LCD screen can be set with language, units, and
Press the up or down button to select the Power
clock preferences. Use the arrow keys to scroll to the
Mode, and then press the confirmation button again.
preferences menu. Press confirm.
This changes the mode and locks it into memory.
Choose the preferences desired, language in
The selected mode will display in zone 3 (bottom) of
(English, Italian, Spanish, Portuguese, German,
the Multi-Function Display when power mode is
French, measurement units in English, Metric, or
correctly selected.
Imperial and clock units in either 12 or 24 hour).
NOTE: Selecting options and navigating through the Highlight the preference you wish to change and
screen menus are the same for all functions. The press the confirm key. The preference will flash and
display will tell the operator if errors have occurred. allow you to scroll through the choices. When the
correct preference is chosen, use the confirm key to
lock in the preference for the display. The escape
key will allow you to leave this application.
BD06F176
S h o u l d a n e r r o r m e s s a g e d i s p l ay, p r e s s t h e
confirmation button to acknowledge and begin again.

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

4005-13
Auto Idle
Idling can be changed from automatic to a fixed rate.
The fixed idle rate is defined as Standard Idle at 900
RPM. Highlight the auto idle selection by using the
arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.
Display Menu
The display menu can be used to change the
background and brightness of the screen. Use the
arrow keys to make your selection from the display
menu and press the confirm key to lock the selection
BD06F174
into memory. The screen display can be changed to
Options Menu suit working conditions for day and night separately.
Use the arrow keys to choose the options menu. RPM
Press the confirm key, and the options sub-menu will
Engine speed in RPM will show on the display if the
appear. The options menu will allow the operator to
engine speed is running up to 550 RPM’s, and will
choose options for the fan, idle.
disappear if the engine speed is lower than 300
Fan Auto RPM.
The fan can be set to run at automatic or the fan will MPH/KPH
run at maximum speed. Automatic is the more
common or preferred setting. It will switch between Vehicle speed will show on the display if it is up to 1.0
high speed, low speed, or reverse as conditions MPH / 1.5 KPH and will disappear if the vehicle
require depending on actual temperature of the speed is less than 0.6 MPH / 1.0 KPH.
coolant, turbocharger air, transmission oil, and
hydraulic oil.
The operator can choose fan speed or reversing
capabilities. Highlight the fan auto selection by using
the arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.

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

1. Press and hold the escape key and up arrow key 1. 1000 to 1999 vehicle errors.
for more than 2 seconds to access the fault
2. 2000 to 2999 not used.
codes.
3. 3000 to 3999 engine errors.
4. 4000 to 4999 transmission errors.
A 5. 5000 to 5999 eltro-hydraulic system errors.

C
6. 6000 to 6999 reserved.
7. 7000 to 7999 reserved.
8. 8000 to 8999 optional equipment IE: GPS.
9. 9000 to 9999 internal AIC errors.
B D
BD06F186
A. Escape key
B. enter key
C. up key
D. down key
2. Yellow Faults, buzzer will beep once every 2
seconds:
A. Operator can acknowledge it by pressing the
enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
D. Yellow lamp will stay ON.
E. Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer will be continuous,
alternating sounds:
A. Operator can acknowledge it by pressing the
enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.

4005-15
VEHICLE FAULT CODES
CODE DEFINITION POSSIBLE STEPS FOR REPAIR
1310 Hydraulic filter blocked Change filter

1311 Engine air filter blocked Change filter
1312 Hydraulic oil temperature above normal 1. Stop machine operations
2. Run engine at 1500 rpm
1313 Hydraulic oil temperature to high 3. Check fan operation
1314 Transmission oil temperature above normal 4. Check cooling core for clogs
1315 Transmission oil temperature to high

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

4005-16
1336 Transmission oil filter blocked Replace filter
NOTE: The following fault codes are for optional climate controlled heating and air conditioning system.
DESCRIPTION AND POSSIBLE

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

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

4005-17
ENGINE FAULT CODES

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

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

Foot throttle sensor signal above range max.
Check wiring or replace accelerator pedal.
3003 Short circuit in wiring or in accelerator pedal.

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

4005-18

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

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

4005-19

CODE DEFINITION
STEPS FOR REPAIR
Cylinder 1 injector cable short-circuit low side Short circuit in wiring with external source.
3061
to battery Check the wiring or replace injector
3062 Cylinder 1 signal low
replace ECU
Defective coil of injector.
3063 Cylinder 1 short-circuit high side to ground
Check the wiring and replace injector
replace ECU
3065
replace ECU.
3067 Defective coil of injector.

Cylinder 5 short-circuit high side to ground
replace ECU
3069
replace ECU.
replace ECU
3073
replace ECU.
replace ECU

4005-20

CODE DEFINITION
STEPS FOR REPAIR
3077
replace ECU.
replace ECU
3081
replace ECU.
3083 Defective coil of injector.

Cylinder 4 short-circuit high side to ground
Signal interrupted do to wiring problem, defective
or incorrectly installed crankshaft speed sensor.
3088 Crankshaft sensor lost synchronization Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)
Check wiring, sensor installation and proper
3089 Crankshaft sensor defective functioning of crankshaft sensor (evaluate raw
signals).
or incorrectly installed camshaft phase sensor.
3090 Camshaft sensor lost phase Check wiring, sensor installation and proper
functioning of camshaft phase sensor (evaluate
raw signals)
Camshaft sensor phase synchronization
3091 functioning of camshaft phase sensor (evaluate
failure
raw signals).
or incorrectly installed camshaft or crankshaft
3093 Offset between camshaft and crankshaft sensor.
outside boundaries Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)
3095 Operating with camshaft sensor only functioning of crankshaft sensor (evaluated raw
signals).
Short circuit of wiring to ground or defective
Rail pressure sensor CP3 signal below range pressure sensor.
3102
min. Check wiring and proper functioning of rail
pressure sensor

4005-21

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

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

4005-22

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

inaccurate, high pressure pump defective.
Set point of fuel volume flow through metering
3141 Low pressure system: Metering unit reflux too
unit is lower than calculated limit
low.
Check for defects according to failure list.
Oil temperature sensor signal above normal Check oil temperature sensor for accuracy and
3147
range check oil system.
3154 Grid heater relay short-circuit to battery relay.
Short circuit of wiring to ground or inside relay.
3155 Grid heater relay short-circuit to ground
3156 Grid heater relay no load
3161 Fan actuator signal low No information available at time of print.
High pressure side: Leakage in high pressure
section, injection nozzle stuck in open position,
worn high pressure pump, worn injector, leaking
3171 Fuel rail/system pressure - too low pressure relieve valve
Low pressure side: Pressure before gear pump
too low, gear pump output too low (fuel filter
clogged, leakage in low pressure side).
Metering unit stuck in open position,
zero-delivery throttle clogged, metering unit
without power due to electrical error.
3172 Fuel rail/system pressure - too high
Low pressure side: Pressure before gear pump
too high (e.g. by pressure relieve valve), pressure
after zero-delivery throttle too high.
3173 Fuel rail/system pressure - too low See fault 3171
3174 Fuel rail/system pressure - too high See fault 3172
Leakage in the high pressure section, injection
nozzle stuck in open position, worn high pressure
3175 Fuel system leak detected – large leak
pump, worn injector, leaking pressure relieve
valve, injector reflux too high.
High pressure system: Leakage in the high
pressure section, injection nozzle stuck in open
position, worn or defective high pressure pump,
Fuel delivery exceeded threshold for pressure worn injector, leaking pressure relieve valve.
3176
in overrun mode Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering
unit).
Check for defects according to failure list.

4005-23

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

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

4005-24

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

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

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

4005-25

CODE DEFINITION
STEPS FOR REPAIR
3253 Error status ADC monitoring

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

Short-circuit to battery at high side power
3258 relay.
stage
Short-circuit to ground at high side power Short circuit of wiring to ground or inside relay.
3259
stage Check of wiring or replace relay
3260 Open load at low side power stage
Short-circuit to battery or excessive
3261 relay.
temperature at low side power stage
Short circuit of wiring to ground or inside relay.
3262 Short-circuit to ground at low side power stage
Electronic disturbances, requested torque
increase via tester, wrong application of injection
Energizing time exceeds limit of over run
3265 relevant parameters, defective ECU.
monitoring
Check injection relevant application, if failure
persists replace ECU
3266 Electronic disturbances, internal ECU problem.

Plausibility error in engine speed check
If failure persists after reinstallation replace ECU
Excessive voltage supply of a CJ940 component:
High battery voltage, defective wiring, internal
defect of the EDC.
3278 Supply voltage CJ940 upper limit
Check the battery for correct voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Insufficient voltage supply of a CJ940
component: Low battery voltage, defective wiring,
internal defect of the EDC.
3279 Supply voltage CJ940 lower limit
Check the battery for sufficient voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3280 Sensor supply voltage 1 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC

4005-26

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

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

4005-27
TRANSMISSION FAULT CODES
1. Check the cables from the TCU to the FNR

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

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

4005-28
Short circuit to battery voltage or open circuit

4148 1. Check the cables from TCU to the sensor.
at turbine speed sensor input
Short circuit to ground at turbine speed sensor 3. Check the speed sensor.
4149
input
4150 Logical error at turbine speed sensor input 3. Check the speed sensor.
TCU.
4151 Short circuit to battery voltage or open circuit

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

4005-29
4209 Short circuit to battery voltage at clutch K1

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

4005-30

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

4005-31

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

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

4005-32
INSTRUMENT CLUSTER FAULT CODES

CODE DEFINITION
STEPS FOR REPAIR
9128 CAN timed out during operation

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

5001
Section
5001
REMOVAL AND INSTALLATION OF STEERING

COMPONENTS

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

5001-3
STEERING CONTROL VALVE
Removal STEP 7
STEP 1
Remove the cab skirts from the cab or canopy.
STEP 2
Remove all dirt and grease from steering control
valve.
STEP 3
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.
BD06G245
STEP 4 Remove the mounting nut and washers from the
Tag hoses connected to steering control valve. steering shaft.
STEP 5 STEP 8
BD06G262 BD06G246
Disconnect hoses from steering control valve, cap or Remove the steering wheel from the shaft.
plug the fittings and hoses, turn off the vacuum
pump.
STEP 9
STEP 6
BD06G247
Remove the six mounting screws from the instrument

BD06G244
cover.
Remove the center cap from the steering wheel.

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

5001-5
STEP 16 Installation
STEP 18
BD06G261
Remove the three vents from the front trim, remove

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

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

steering control valve.

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

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

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

5001-7
STEP 27 STEP 30
BD06G247 BD06G262
Install and tighten the six mounting screws for the Start the vacuum pump, remove the caps and plugs
instrument cover. the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
STEP 28 removal, remove and discard the tags.
STEP 31
Remove the vacuum pump from the reservoir, install
and tighten the reservoir fill cap.
STEP 32
Start and run the machine at low idle, turn the wheel
to full left and then to full right, stop the machine and
check for leaks.
STEP 33
BD06G245
Install the skirts onto the cab or canopy.
Install the steering wheel, install and tighten the
mounting nut and washers. STEP 34
Check fluid level in hydraulic reservoir. Add oil as
STEP 29 required. See Section 1002 for specifications.
BD06G244
Install the center cap on the steering wheel.

5001-8
AUXILIARY STEERING PRIORITY VALVE

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

5001-9
1
2
10
4
9
5
6
8 7
BC05M084
1. STEERING LOAD SENSING HOSE TO PRIORITY VALVE 6. CAP SCREWS AND NUTS
2. STEERING LOAD SENSING HOSE TO STEERING VALVE 7. PRESSURE HOSE
3. PRESSURE SWITCH 8. STEERING SOLENOID
4. SUCTION PORT 9. STEERING PRESSURE HOSE
5. PUMP OUT PRESSURE TUBE FITTING 10. TANK RETURN TUBE
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

5001-10
STEERING PRIORITY VALVE

1. Park loader on level ground and lower bucket to 1. Install bolts with washers (8) through priority
ground. Put transmission in NEUTRAL, apply valve. Install new O-ring on top of priority valve
parking brake, and shut down engine, (not shown). Install priority valve (7) onto low
pressure pump, tighten bolts to37 to 48 Nm
2. Put master disconnect switch in OFF position.
(27 to 35.5 pound feet).
3. Remove all dirt and grease from steering priority 2. Install new O-rings (6) onto high pressure pump
valve (7) and adjacent area. See illustration on discharge tube (5).
page 11.
3. Place tube into position and intsall four split
4. Remove hydraulic reservoir fill cap. flanges (3) and eight bolts (4) with washers,
5. Connect a vacuum pump to hydraulic reservoir. tighten bolts.
4. Connect all hoses as tagged to the steering
6. Start vacuum pump.
priority valve (7).
7. Tag and disconnect all hoses connected to the
5. Stop vacuum pump.
steering priority valve (7).
6. Disconnect vacuum pump from hydraulic
8. Loosen and remove eight bolts (4) and four spit
reservoir.
flanges (3).
7. Install fill cap on hydraulic reservoir.
9. Remove the high pressure pump discharge tube
(5), discard O-rings (6). 8. Put battery disconnect switch in ON position.
Start engine and run at low idle for 30 seconds.
10. Support the steering priority valve (7), remove
Stop engine and check for leaks.
mounting bolts (8).
9. Check to make sure steering priority valve
11. Remove steering priority valve (7).
operates correctly. See Section 5002.
required. See Section 1002 for specifications.

5001-11
4
5
4
3 8
BC05M087
1. LOW PRESSURE PUMP (LOADER PUMP) 5. STEERING PUMP OUTPUT LINE

2. HIGH PRESSURE PUMP (STEERING PUMP) 6. O-RINGS
3. SPLIT FLANGE 7. STEERING PRIORITY VALVE
4. BOLT 8. BOLT
STEERING PRIORITY VALVE ILLUSTRATION

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

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

5001-13
4
5
BC05M085
1. GROUND CABLE 4. SUCTION HOSE 7. AUXILIARY STEERING PUMP AND MOTOR

2. POSITIVE CABLE 5. PRESSURE TUBE 8. WIRING HARNESS
3. NUT (4) 6. AUXILIARY STEERING PRIORITY VALVE
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

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

5001-15
9 10
8
6
5
3 11
2
1 1 12
13
14
15
11
16
BS03B141
1. GREASE HOSE 5. PIVOT PIN 9. HOSE ASSEMBLY 13. CAP SCREW

2. HOSE ASSEMBLY 6. SPACER 10. HOSE ASSEMBLY 14. WASHER
3. HOSE ASSEMBLY 7. WASHER 11. STEERING CYLINDER 15. LOCKNUT
4. WASHER 8. CAP SCREW 12. PIN 16. GREASE HOSE
STEERING CYLINDER ILLUSTRATION

5001-16
STEERING BACK PRESSURE VALVE
1. Remove the fill cap for the hydraulic reservoir to 1. Install the valve, bolts, spacers and nuts onto the
release pressure in the reser voir, attach a machine, tighten the bolts.
vacuum pump to the reservoir, start the pump.
2. Install new O-rings onto the fittings of the hoses,
2. Disconnect hoses 2 and 6 from the pressure install and tighten the hoses.
valve.
3. Stop the vacuum pump, install and tighten the
3. Remove the nuts, bolts and spacers from the reservoir filler cap.
pressure vale, remove the valve from the
4. Start and run the machine at low idle, turn the
machine.
steering wheel from full left lock to full right lock
holding the steering over relief.
5. Stop the machine and check for leaks.
required. See Section 1002 for specifications.

5001-17
BS06G529
1. STEERING CONTROL VALVE 5. RELIEF VALVE

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

5001-18
NOTES

5002
Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS,

AND TROUBLESHOOTING

5002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Understanding The Results Of The Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5002-3
SPECIAL TOOLS
B785789 B009638
OEM-1239 (CAS-10280) FLOWMETER CAS-1804 PRESSURE TEST FITTING KIT
B797157
CAS-1808 FLOWMETER FITTING KIT
TROUBLESHOOTING THE STEERING SYSTEM

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

5002-4
AUXILIARY STEERING SYSTEM PUMP TEST
Equipment Required
6. Connect the ammeter clamp (1) to the cable as
1. CAS- 10280 Flowmeter in illustration.
2. CAS-1808 Flowmeter fitting kit
Test Procedure
1. Install articulation lock.
BB830300
1. AMMETER CLAMP
7. Make sure that the parking brake is applied and
1 the bucket is on the floor.
BD03A040
8. Make sure that the oil is at operating
temperature.
1. ARTICULATION LOCK
NOTE: When performing this pressure check, 9. Make sure that the load valve for the flowmeter is
always be sure the articulation lock is in place, open (zero pressure).
especially when working in the articulation joint 10. Start and run the engine.
areas.
11. Stop the engine and turn the key back to the On
2. Loosen and remove the outlet hose to the position.
Auxiliary Steering Pump from the Auxiliar y
Steering Priority Valve. 12. Turn the steering wheel, this will activate the
auxiliary steering pump.
3. Install a plug into the Auxiliary Steering Priority
Valve. 13. Turn the load valve on the flowmeter towards
CLOSED until the pressure is 104 bar (1500 psi).
4. Connect the inlet of the flowmeter to the outlet
line of the Auxiliary Steering Pump. 14. Read the flowmeter and ammeter gauges and
record the readings.
5. Install the outlet hose of the flowmeter in the
hydraulic reservoir and hold in place with wire. 15. The flowmeter reading must not be less than
24.6 L/min, (6.5 U.S. gpm). The ammeter reading
must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.

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

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

5002-6
STEERING PRIORITY VALVE

NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to
Section 8002 Testing and Adjusting the Loader/Steering Pump Differential Pressure.
Pressure Setting Test 4. Make sure that the temperature of the hydraulic
oil is at least 54° C (129° F).
1. Install articulation lock (1). 5. To measure the temperature of the oil using the
instrument panel:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored.
6. Apply the parking brake.
7. Start and run the engine at full throttle.
8. Lower the lift arms and hold the control lever in
the FLOAT position.
1 9. Hold the bucket control lever in the rollback

position.
BD03A040 10. Continue holding until the specified temperature
1. ARTICULATION LOCK of the oil is reached.
IMPORTANT: When performing the following
pressure check and adjustment, the articulation lock 12. Start the engine and operate the machine at full
must be installed. Use caution when working in or throttle.
near the articulation area.
13. With the articulation lock still in place, turn and
2. Remove the dust cap from the test port (1). hold the steering wheel for a hard right turn.
14. Continue holding the steering wheel, and read
the pressure gauge.
15. The pressure gauge must indicate 239 to 243
bar (3465 to 3525 psi). If the pressure is not
correct, adjust the steering relief valve.
BD06F148
1. G1 TEST PORT
2. G2 TEST PORT
3. Connect a 345 bar (5000 psi) pressure gauge to
the test port (2).
NOTE: Make sure when you connect the pressure
gauge that you do so in a manner that you can read
the pressure gauge while sitting in the operators
seat.

5002-7
Pressure Setting Adjustment

1. Turn the adjusting screw clockwise to increase
the pressure setting. Turn the adjusting screw
counterclockwise to decrease the pressure
setting.
1
2. Repeat pressure test procedure.
3. If necessary, adjust the limit valve again until
within the specified range.
2
4. Stop the engine before removing the pressure
gauge.
BD06F147
1. STEERING PRIORITY VALVE

2. LIMIT VALVE

5002-8
STEERING CYLINDER LEAK TEST

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

5002-9
STEERING BACK PRESSURE VALVE
BS06G529
1. STEERING CONTROL VALVE 5. RELIEF VALVE

2. RETURN HOSE 6. RETURN HOSE TO FILTERS
3. PRESSURE HOSE 7. RETURN MANIFOLD
4. CONNECTOR M27 ORB

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

pressure.
1. Disconnect the return hose (2) from the
connector (4). 5. The pressure should be 8 to 10 bar (115 to 145
psi).
2. Install a “T” fitting and connect a pressure gauge
capable of reading 35 bar (500 psi). 6. If pressure is not as specified, replace the relief
valve.
3. Start and run the machine at high idle.
NOTE: The relief valve is not adjustable.

Section
5005
STEERING CYLINDERS
5005

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

5005-3
SPECIFICATIONS
Torque for piston cap screw........................................................................ 810 to 925 Nm (597.5 to 682 pound feet)
Torque for gland............................................................................................. 339 to 475 Nm (250 to 350 pound feet)
STEERING CYLINDER
Disassembly Inspection
1. Fasten tube (18) in a vise. Be careful not to 1. Clean all parts in cleaning solvent.
damage the tube. See illustration on page 4.
2. Check to be sure that piston rod (14) is straight. If
2. Remove gland (1) from tube (18). piston rod is bent, install a new piston rod.
3. Pull piston rod (14) and piston (9) straight out of 3. Inspect inside of tube (18) for deep grooves and
tube (18). other damage. If there is any damage to tube, a
new tube must be used.
4. Fasten piston rod (14) yoke in vise and put a
support below piston rod near piston (9). Put a 4. Remove small scratches on piston rod (14) or
shop cloth between support and piston rod to inside tube (18) with emery cloth of medium grit.
prevent damage to piston rod. Use emery cloth with a rotary motion.
5. Loosen and remove bolt and washer (8) that hold 5. Inspect bushing (17). If bushing requires
piston (9). replacement, remove grease fitting (15) and
retaining rings (16) then press bushing from tube
6. Remove piston (9) from piston rod (14).
end.
7. Remove and discard seal (13), loader ring (12),
wear ring (11), and cast iron ring (10) from piston
(9).
8. Remove gland (1) from piston rod (14).
9. Remove and discard O-ring (7), backup ring (6),
rod wiper (2), rod seal (3), buffer seal (4), and
bearing (5) from gland (1).

5005-4
16 15
17
16
18
8
9
19
13
12
11
10
5
4
3
7
6
14
BC05M089
1. GLAND 6. BACKUP RING 11. WEAR RING 15. GREASE FITTING

2. ROD WIPER 7. O-RING 12. RING LOADER 16. RETAINING RING
3. ROD SEAL 8. BOLT AND WASHER 13. SEAL 17. BUSHING
4. BUFFER SEAL 9. PISTON 14. PISTON ROD 18. TUBE
5. BEARING 10. RING CAST IRON
STEERING CYLINDER ILLUSTRATION

5005-5
Assembly 17. Install bolt and hardened washer (8) in piston (9).
1. Install bearing (5) in gland (1). 18. Install piston (9) on piston rod (14) and start bolt
(8) into piston rod.
2. Install buffer seal (4) in gland (1) so that lips of
seal are toward small end of gland. 19. Tighten bolt (8) to a torque of 810 to 925 Nm
(597.5 to 682 pound feet).
3. Install rod seal (3) in gland (1). Rod seal must be
installed so that lips of seal are toward small end 20. Fasten tube (18) in vise. Be careful not to
of gland. Seal can be difficult to install. Use tools damage tube.
that will not damage seal. See illustration on 21. Apply petroleum jelly to O-rings (7) and backup
page 4. ring (6) on gland (1) and to sealing surface in
4. Install rod wiper (2) in gland (1) with wiper lips tube (18).
toward large end of gland. 22. Lubricate piston (9) and inside of tube (18) with
5. clean hydraulic oil.
6. Install O-ring (7) on gland (1). 23. Push the piston (9) straight into tube (18). Be
careful not to damage cast iron ring (10), wear
7. Install backup ring (6) on gland (1). The backup ring (11), and seal (13) on piston (9).
ring must be toward large end of gland. If backup
ring is not flat on both sides, the side that is not 24. When piston (9) is in smooth part of tube (18),
flat must be toward O-ring (7). start gland (1) into tube (18).
8. Fasten piston rod (14) yoke in vise. 25. If the original parts are being assembled:
9. Lubricate piston rod (15) and bore in gland (1) A. Tighten gland to a torque of 339 to 475 Nm
with clean hydraulic oil. (250 to 350 pound-feet).
NOTE: If a new gland (1) is being installed, write B. Install and tighten self-tapping screw (19) to a
part number of cylinder on gland. torque of 2.3 Nm (20 inch-pounds).
10. Push gland (1) onto piston rod (14) large end C. If, after tightening gland, the self-tapping
first. If necessary, use a soft hammer to drive the screw (19) holes are not aligned, a new hole
gland onto piston rod. for self-tapping screw must be drilled. See
Step 26.
11. Put a support below and near the end of piston
rod (14). Put a cloth between support and piston 26. If a new gland (1) or a new tube (18) are being
rod to prevent damaging piston rod. assembled:
12. Install new cast iron ring (10) on piston (9). A. Tighten gland (1) to a torque of 339 to 475 Nm
13. Install new wear ring (11) on piston (9).
B. Use a No. 27 drill bit and drill a hole half in
14. Install a new loader ring (12) on piston (9). gland (1) and half in tube (18). Drill to a depth
15. Install a new seal (13) over loader ring (12). of 11 mm (7/16 inch). Do not drill within 13 mm
(1/2 inch) of a hole for gland wrench.
16. Clean the threads on the end of piston rod (14)
and threads of bolt (8) using Loctite cleaning C. Install and tighten self-tapping screw (19) to a
solvent. Allow to dry. Apply Loctite 243 to piston torque of 2.3 Nm (20 inch-pounds).
rod threads 6.4 mm (1/4 inch) from open end of 27. If hoses were removed with cylinder, install new
piston rod so that there is 12.7 mm (1/2 inch) of O-rings, if equipped, on hose fittings. Lubricate
Loctite 243 on piston rod threads. DO NOT apply O-rings with clean oil. Install hoses.
Loctite to first 6.4 mm (1/4/inch) of piston rod
threads.

5005-6
NOTES

Section
5006
CENTER PIVOT
5006

5006-2
TABLE OF CONTENTS
SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5006-3
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin .......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for bearing retainers and lower pivot pin...........................................................124 Nm (91 pound-feet)
M12 bolts for lower pin plate .......................................................................128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals ............................................................................... Case AKCELA molydisulfide grease
Steering cylinder rod eyes............................................................................. Case AKCELA molydisulfide grease
SPECIAL TOOLS
CAS10219 ....................................................................................................................... Hand pump (hydraulic ram)
CAS10512 ....................................................................................................................................... 10 ton ram (long)
CAS10592 ........................................................................................................... Puller set, includes 24827 leg ends
CAS10600 ................................................................................ Bearing cup and seal puller, includes 24850 adapter
CAS10193 .............................................................................................................................. Vacuum pump (12 volt)
CAS2029 ................................................................................... *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from CAS10592)
BC06A174
CAS2029 DRIVER SET

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

5006-5
1 2
3
4
5
1
6
2
7
5
8
10
6 9
16 12 11
6
8
13
6
2
14
1
8
15 2
2
1
1
BS03B152
1. BOLT 5. REAR CHASSIS 9. UPPER PIVOT BEARING 13. BEARING RETAINER

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

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

24. SPCAER 26. BEARING CUP

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

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

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

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

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

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

5006-9
CONNECTING THE FRONT FRAME TO THE REAR FRAME

1. Release the parking brake. 26. Align the hole in the pivot pin with the holes in the
2. Move the rear frame into alignment with the front steering cylinder rod eye, and install the pivot pin.
frame. 27. Install the bolt and self-locking nut that hold the
3. Move the steering cylinders as required to move pivot pin.
the rear frame into alignment with the front 28. Repeat steps 25, 26 and 27 for the other steering
frame. cylinder.
4. Apply the parking brake. 29. Start the vacuum pump.
5. Apply grease to the upper pivot pin (4). 30. Connect the return hose.
6. Install the upper pivot pin (4), spacer (3), washer 31. Connect the supply hose.
(2) and bolt (1). Be careful not to damage the 32. Put the bracket for the hoses in position on the
seal (6). rear frame. Install the bolts, flat washers, and
7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184 self-locking nuts that fasten the bracket to the
pound-feet). rear frame.
8. Apply grease to the lower pivot pin (10). 33. Put the bracket for the hoses in position on the
9. Install the lower pivot pin (10) in the frames. Be front frame.
careful not to damage the seal (6). 34. Install the bolts, flat washers, and self-locking
10. Use the ram and hand pump to install the bottom nuts that fasten the bracket to the front frame.
spacer (14). See Special Tools in this section. 35. Connect the hoses for the steering cylinders.
11. Install the lower pin plate (15), three inner bolts 36. Connect the brake hose for the front brakes at
(1), and washers (2) that fasten the lower pin the front bracket.
plate (15) to the lower pivot pin (10). 37. Stop the vacuum pump.
12. Tighten the bolts (1) to 69 Nm (51 pound-feet). 38. Connect the front wiring harness to the rear
13. Measure the gap between the lower pin plate wiring harness.
(15) and the bottom pivot. Make a record of the 39. Put the clamp on the wiring harness in position
measurement. Subtract 0.0762 to 0.1016 mm on the bracket. Install the bolt, lock washer, and
(0.003 to 0.004 inch) from the measurement. nut that fasten the clamp on the wiring harness to
Select shims equal to that value. the bracket.
14. Loosen the bolts (1) that fasten the lower pin 40. Put the ground wire in position on the stud. Install
plate (15) to the lower pivot pin (10). the washer and nut that fasten the ground wire to
15. Start the six outer bolts (1) into the lower pin the stud.
plate (15) and the bottom pivot. 41. Install a tie strap to fasten the wiring harness to
16. Install the shims (8). the tube.
17. Tighten the six outer bolts (1) to 128 to 136 Nm 42. Disconnect the vacuum pump from the hydraulic
(94 to 100 pound-feet). reservoir.
18. Tighten the three inner bolts (1) to 124 Nm (91 43. Check the fluid level in the hydraulic reservoir.
pound-feet). Add oil as required.
19. Remove the jacks from the rear frame. 44. Install the fill cap in the hydraulic reservoir.
20. Remove the blocks from the rear axle. 45. Bleed air from the front axle bleed screws. Refer
21. Remove the stands from the front frame. to Section 7002 for complete brake bleeding
instructions.
22. Put the drive shaft in position on the front yoke.
46. Lubricate the pivot pins for the steering cylinder
23. Install new Ferry head screws that fasten the rod eyes.
drive shaft to the front yoke.
47. Install the covers on both sides of the machine.
24. Tighten the Ferry head screws to 61 to 81 Nm
25. Put the steering cylinder rod eye in position in the
frame. Install the washer between the steering
cylinder rod eye and the rear frame.

5006-10
NOTES

Section
5008
AUXILIARY STEERING MOTOR AND PUMP
5008

5008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

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

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

5008-6
NOTES

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

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

6001
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN

COMPONENTS

6001-2
TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6001-3
TRANSMISSION
Removal STEP 7
STEP 1
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 2
position.
STEP 3
Refer to Section 9007 and remove ROPS cab or BD01D315
ROPS canopy. Disconnect transmission wiring harness connector
from control valve connector. Remove socket head
STEP 4 bolt securing wiring harness clamp. Move wiring
Refer to Section 8001 and remove the hydraulic harness away from transmission.
pump.
STEP 8
STEP 5
Put a 25.5 liter (27 quar ts) container under
transmission drain plug. Remove drain plug and drain
transmission oil. Install drain plug after oil has
drained.
STEP 6
BD01D317
Just above where clamp was installed, tag and

disconnect transmission wiring harness connector
from temperature sensor. Move wiring harness away
from transmission.
STEP 9
BD01D306
Identify, tag, and disconnect brake pump pressure

hose and brake to hydraulic reservoir hose. Position
hoses away from transmission. Remove and discard
O-ring face seals from fittings. Plug hoses and cap
fittings to prevent entr y of foreign matter into
hydraulic system.
BD01D310
Remove two socket head bolts securing transmission

wiring harness clamps.
6001-4
STEP 10 STEP 13
BD01D312 BD01F281
Identify, tag, and disconnect transmission wiring Remove two bolts and washers securing hose
harness connectors from engine speed sensor, retainer to front of rear chassis. Move hose retainer
intermediate speed sensor, and turbine speed towards front of machine.
sensor. Move transmission wiring harness away from
transmission. STEP 14
STEP 11
BD03A165
Identify, tag, and disconnect parking brake hose from

BD01D316 parking brake. Plug hose and cap fitting to prevent
Remove socket head bolt securing wiring harness entry of foreign matter into hydraulic system. Move
clamp. Move wiring harness away from transmission. hose away from transmission. Remove four bolts and
two straps securing center drive shaft to transmission
STEP 12 output flange. Disconnect center drive shaft from
transmission.
BD01D314
Identify, tag, and disconnect transmission wiring

harness connectors from filter maintenance switch
and output speed sensor. Move transmission wiring
harness away from transmission.

6001-5
STEP 15 STEP 18
BD03A161 BD01D339
Remove four bolts and two straps securing rear drive Remove fitting. Remove and discard O-ring from
shaft to transmission output flange. Disconnect rear fitting. Install a plug in transmission port.
drive shaft from transmission.
STEP 19
STEP 16
BD01D340
BD03A160 Repeat Steps 17 and 18 and disconnect the other

Remove two bolts. Remove fill tube, with cap and oil cooler hose and remove fitting.
gauge assembled, two seals, and metal strainer.
Discard seals. STEP 20
STEP 17
BD01D343
Connect lifting equipment to transmission lifting eyes.

BD01D318 Take up all slack in lifting equipment.
Identify, tag, and disconnect cooler hose from fitting
installed in LH side of transmission. Install a plug in
hose. Remove and discard O-ring face seal from
fitting.

6001-6
STEP 21 STEP 23
BD01D342 BD03A164
In area between the transmission and the engine, Raise transmission just enough to enable removal of
remove four bolts and two straps. Use pry bar to RH and LH mounting brackets. Remove two bolts
disconnect engine drive shaft from transmission. and washers securing RH and LH mounting brackets
Using 3/4 inch drive socket, extensions, and impact to transmission. Remove RH and LH mounting
wrench, remove four bolts and washers securing brackets.
transmission to top mounting bracket.
STEP 24
STEP 22
BD01D345
BD03A163 Slowly and carefully raise transmission from loader

Remove bolts and washers securing RH and LH while checking that all hoses, electrical connectors,
mounting brackets to rear chassis. and wires have been disconnected and nothing
interferes with transmission removal. Remove
transmission from loader.
STEP 25
BD01D361
If top mounting bracket requires removal, remove bolt

and washer then remove bracket.

6001-7
Transmission Mounting
3 4
C 1
1
4
3
2
2
2
1 1 5
5 5
7
1 6
5 1
2
BS03B153
1. ISOLATOR BOLT 6. MOUNTING BRACKET

2. WASHER 7. TOP MOUNTING BRACKET
3. BOLT A. REAR CHASSIS TRUNNION
4. BOLT B. BRACKET (6 OR 7)
5. BOLT C. SMALLER PIECE ON TOP

6001-8
STEP 26
Check isolators for deterioration, tears, deformation,
or other damage. Replace as necessary: refer to
Page 7.
STEP 27
BD03A164
Install RH and LH mounting brackets on transmission

using two washers and bolts. Do not tighten bolts.
STEP 30
BD01D361
If top mounting bracket was removed, put bracket on

rear chassis trunnion and secure using washer and
bolt. Do not tighten bolt.
STEP 28
BD03A163
Loosely install washers and bolts to secure RH and

LH mounting brackets to rear chassis. Tighten bolts
securing RH and LH mounting brackets to
transmission to a torque of 481 to 590 Nm (355 to
435 pound feet).
BD01D345
Move transmission into position above loader. Slowly

lower transmission into loader.

6001-9
STEP 31 STEP 33
NOTE: In this step, new straps and bolts securing
the drive shaft must be installed whenever these
parts are removed. Bolts have a nylon patch to
maintain torque which requires new bolts.
BD01D343
Disconnect lifting equipment from transmission lifting

eyes.
BD01D342
STEP 34
Using 3/4 inch drive socket, extensions, and impact
wrench, install four washers and bolts to secure top
mounting bracket to transmission. Then tighten bolts
to a torque of 251 to 319 Nm (185 to 235 pound feet).
If bracket had been removed, tighten bolt to a torque
of 890 to 1000 Nm (655 to 735 pound feet). Connect
engine drive shaft to transmission. Install two new
straps and four new bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet).
STEP 32
BD01D340
Install new O-ring on fitting and install fitting in

transmission. Install new O-ring face seal in fitting
then connect cooler hose to fitting following tag
installed during removal. Remove and discard tag.
STEP 35
BD03A163
Tighten bolts securing RH and LH mounting brackets

to a torque of 890 to 1000 Nm (655 to 735 pound
feet).
BD01D318
Install new O-ring on fitting and install fitting in

transmission. Install new O-ring face seal in fitting
then connect cooler hose to fitting following tag
installed during removal. Remove and discard tag.

6001-10
STEP 36 STEP 39
BD03A160 BD01F281
Position fill tube, two new seals, and metal strainer Position hose retainer on front of rear chassis and
on transmission; metal strainer is installed between secure using two washers and bolts.
seals. Secure using two bolts. Tighten bolts to a
torque of 17 to 33 Nm (12 to 24 pound feet). STEP 40
STEP 37
BD01D314
Connect transmission wiring harness connectors to

BD03A161 output speed sensor and filter maintenance switch
Connect rear drive shaft to transmission then install following tags installed during removal. Remove and
two straps and four bolts. Tighten bolts to a torque of discard tags.
STEP 41
STEP 38
BD01D316
BD03A165 Install socket head bolt to secure wiring harness

Connect center drive shaft to transmission and install clamp.
two straps and four bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet). Connect parking
brake hose to parking brake following tag installed
during removal. Remove and discard tag.
6001-11
STEP 42 STEP 45
BD01D312 BD01D315
Connect transmission wiring harness connectors to Install socket head bolt to secure wiring harness
turbine speed sensor, intermediate speed sensor, clamp. Connect transmission wir ing har ness
and engine speed sensor following tags installed connector to control valve connector.
during removal. Remove and discard tags.
STEP 46
STEP 43
BD01D306
BD01D310 At brake valve, install new O-ring face seals in

Install two socket head bolts to secure transmission fittings. Connect brake to hydraulic reservoir hose
wiring harness clamps. and brake pump pressure hose following tags
installed during removal. Remove and discard tags.
STEP 44
STEP 47
BD01D317
Connect transmission wiring harness connector to BD03A177

temperature sensor following tag installed during Check that transmission drain plug is tight.
removal. Remove and discard tag.

6001-12
STEP 48 STEP 50
Fill transmission with 15-40W engine oil until oil level Refer to Section 9007 and install ROPS cab or ROPS
is up to the arrow in sight glass. canopy.
STEP 49 STEP 51
Refer to Section 8001 and install the hydraulic pump. Start and run engine at idle speed with transmission
in neutral. If transmission oil level is at or below
bottom of crosshatch region, put articulation lock in
LOCKED position and add engine oil, 15-40W, until
oil level is up to crosshatch region. Shut down engine
and put articulation lock in OPERATING position.

6001-13
FRONT AXLE
Removal STEP 4
STEP 1
BD03A167
Remove four bolts and two straps securing front drive

BD03A040
shaft to front axle.
Park machine on level surface. Have assistant put
articulation lock in LOCKED position. STEP 5
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.
STEP 2
BD03A166
Remove clamp securing lubrication hose to machine

and nut securing opposite end of hose. Remove four
bolts and two straps securing center drive shaft to
front drive shaft. Use a pry bar to separate drive
shafts. While supporting center bearing and front
BD03A092 drive shaft, remove four nuts and bolts and eight
Raise bucket and have assistant install safety link. washers. Lower center bearing and front drive shaft
Lowe r loa der ar ms slowly until sa fety link is from mounting plate and remove from machine.
supporting loader arms.
STEP 3
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.

6001-14
STEP 6 STEP 9
BD03A168 BD01F297
Disconnect brake hose from elbow. Remove and Use an acceptable jack to hold front axle.
discard O-ring face seal from elbow.
STEP 10
STEP 7
BD01F295
BD01F298 Remove bolts and washers from front wheels.

Remove both wheels from front axle.
STEP 11
BD01D392
Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand
under machine. BD01F296
Remove eight nuts bolts, and washers securing front

STEP 8 axle to machine.
Repeat Step 68 to raise other front axle tire from
ground. STEP 12
Carefully lower front axle and remove from under
machine.

6001-15
Front Axle Mounting
BS03B151
1. BOLT 4. NUT
2. WASHER 5. FRONT AXLE
3. WASHER

6001-16
STEP 13
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 14
BD01F295
BD01F296
Apply one drop of engine oil to threads prior to

assembly. Install eight washers, bolts, washers, and
nuts to secure front axle to machine. Tighten bolts to
a torque of 765 to 865 Nm (565 to 630 pound feet).
BS06G052
Install both wheels on front axle and secure. Tighten

bolts to a preliminary torque of 298 Nm (230 pound
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same
sequence.
STEP 16
BD01F297
Remove jack from front axle.

6001-17
STEP 17 STEP 20
BD01F298 BD03A166
Position and support center bearing and front drive

shaft and install eight washers and four bolts and
nuts. Tighten bolts to a torque of 99 to 128 Nm (73 to
94 pound feet). Install two straps and four bolts.
Tighten bolts to a torque of 61 to 81 Nm (45 to 60
pound feet). Secure lubrication hose to machine
using clamp; secure opposite end of hose using nut.
STEP 21
BD01D392
Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.
STEP 18
Repeat Step 78 to remove other jack stand from
under machine.
STEP 19
BD03A167
Secure drive shaft to front axle using two straps and

four bolts. Tighten bolts to a torque of 61 to 81 Nm
(45 to 60 pound feet).
STEP 22
If necessary, fill axle with gear lubricant specified in
Section 1002.
STEP 23
Refer to Section 7002 and bleed brakes.
BD03A168
STEP 24
Install a new O-ring face seal in elbow. Connect
Star t engine and raise bucket. Have assistant
brake hose to elbow.
remove safety link. Lower bucket to ground and stop
engine.
STEP 25

6001-18
REAR AXLE
Removal STEP 5
STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and for th at least 30 times to release any
pressure from hydraulic circuit.
STEP 2
BD03A169
Disconnect brake hose from elbow. Remove and

discard O-ring face seal from elbow.
STEP 6
BD03A040
Put articulation lock in LOCKED position.
STEP 3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting. BD01F299
Using an acceptable hydraulic jack, raise one tire

STEP 4 from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.
STEP 7
BD03A162
Remove four bolts and two straps. Use a pry bar to

disconnect rear drive shaft from rear axle.
BD01F302
Use an acceptable jack to hold rear axle.

6001-19
STEP 8 STEP 10
Carefully lower rear axle and remove through side of
machine.
STEP 11
Remove and discard two seals from rear axle pivot
point.
BD01F295
Remove bolts and washers from rear wheels.

Remove both wheels from rear axle.
STEP 9
BD03A170
At front of trunnion, remove two Allen head bolts and

washers. Remove front cap: if necessary use two
M12 by 32 mm (1.25 inches) bolts in puller holes (A);
tighten bolts evenly to pull cap from axle and
trunnion. Remove and discard O-ring from cap.
Repeat this step at rear of trunnion except remove
and retain shim(s) after removal of rear cap. Remove
pivot sh aft using accep table sleeve or rod if
necessary.

6001-20
Rear Axle Mounting
6
1 5
4
3
2
6
5
7
10
5
6 2 9
3
11
12 8
5
6
BS01D132
1. TRUNNION 5. WASHER 9. REAR AXLE

2. O-RING 6. BOLT 10. PIVOT PIN
3. SEAL 7. WASHER 11. SHIM(S)
4. FRONT CAP 8. BOLT 12. REAR CAP

6001-21
NOTE: If shim(s) (11) have been lost or pivot pin
(10) has been replaced, do Step 12 to determine
required shim(s) otherwise go to Step 13. A
STEP 12
6 1 6
1
10
4
12
BD01D482A
A
B
BS01E091A
Install pivot pin (10) and caps (4 and 12) in trunnion

(1) without rear axle or shim(s). Install washers (5)
a n d b o l t s ( 6 ) . T i g h t e n b o l t s s e c u r e l y. P u s h
assembled pivot pin and caps to rear of machine as
far as possible. Measure and record gap (A) between
rear cap (12) and trunnion. Select shims from the
following:
BD01D499
NOTE: Shims are available in following sizes: 0.50
mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm Clean front (A) and rear (B) pivot area of rear axle
(0.059 inch). where seals (3) will be installed.
MEASURED SHIM(S) REQUIRED STEP 14

GAP (mm) (mm)
0.07 to 0.55 None A
0.56 to 1.09 0.50
3
1.10 to 1.59 1.0
4
1.60 to 2.09 1.50
12
2.10 to 2.59 0.50 plus 1.50
2.60 to 3.02 1.0 plus 1.50
2
BS01E092
Lubricate two new seals (3) and new O-rings (2)

using Molydisulfide Grease. Install seals, smooth
side out, into front and rear of axle housing (A) until
flush with housing or recessed 2.0 mm (0.079 inch).
Install an O-ring in each cap (4 and 12).
STEP 15
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.

6001-22
STEP 16 STEP 17
11
A 4 6
6 12
10 1
1
BS01E091 BD01F295
Lubricate pivot pin (10) using Molydisulfide Grease.

At rear of trunnion (1), install pivot pin into trunnion
and axle (A). Install shim pack (11), rear cap (12)
with O-ring installed, and two washers and bolts (6).
At front of trunnion install front cap (4) with O-ring
installed, and two washers and bolts (6). Tighten
bolts (6) to a torque of 651 to 678 Nm (480 to 500
pound feet).
BS06G052
Install both wheels on front axle and secure. Tighten

bolts to a preliminary torque of 298 Nm (220 pound
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same
sequence.
STEP 18
Remove hydraulic jack supporting rear axle and jack
stands supporting loader.

6001-23
STEP 19 STEP 21
If necessary, fill axle with gear lubricant specified in
Section 1002.
STEP 22
Refer to Section 7002 and bleed brakes.
STEP 23
BD03A169
Install a new O-ring face seal in elbow. Connect

brake hose to elbow.
STEP 20
BD03A162
Connect rear drive shaft to rear axle. Install two

straps and four bolts. Tighten bolts to a torque of 61
to 81 Nm (45 to 60 pound feet).

6001-24
NOTES

6002
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING

6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 19

6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi)
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm)
Transmission oil operating temperature..........................................................................80 to 120 °C (176 to 248 °F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)

6002-4
4 1
3 2
5 12
9
6
11
14
13 7
10
BS01A190
1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR
2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR
5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE
6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH
7. TRANSMISSION 14. PLUG
COMPONENT LOCATIONS SYSTEMS

6002-5
12
11
1
2
10
9
4
5
15
6
14
8
13 7
BS03A262
1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP
2. POWER TAKE OFF 10. INPUT FLANGE
3. CLUTCH SHAFT KV 11. CONVERTER
4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED
5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K4
6. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE
7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K1
8. OUTPUT SHAFT
COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6
2 2
2
2
1 3
4
BS01A191
3. OUTPUT FLANGE CONVERTER
1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK
SIDE
2. TRANSMISSION SUSPENSION BORES 4. OIL DRAIN PLUG
COMPONENT LOCATIONS FRONT VIEW

6002-7
1
2
3
10
6
7
BS01A192
1. CONVERTER BELL HOUSING 6. OUTPUT FLANGE REAR
2. BREATHER 7. OIL DRAIN PLUG
3. TRANSMISSION CASE COVER 8. OUTPUT FLANGE CONVERTER SIDE
4. FILTER HEAD 9. TRANSMISSION CASE
5. FILTER 10. PARKING BRAKE
COMPONENT LOCATIONS SIDE VIEW

6002-8
2
1
1
7 3
4 4
BS01B048
1. LIFTING LUGS 5. OUTPUT FLANGE REAR
2. POWER TAKE OFF 6. FILTER
3. TRANSMISSION CONTROL VALVE 7. FILTER HEAD
4. TRANSMISSION SUSPENSION BORES
COMPONENT LOCATIONS REAR VIEW

6002-9
TRANSMISSION OPERATION
General Transmission ECM Tasks

The transmission is equipped with a Transmission The Transmission ECM performs a variety of tasks in
ECM (Electronic Control Module). This module the overall system. The Transmission ECM:
controls modulation and shifting that were normally
A. Determines which clutches to engage in the
a s s o c i a t e d w i t h hy d r a u l i c a l l y m o d u l a t e d
transmission.
transmissions, providing smoother shifts and
enhanced clutch life. B. Protects the engine and transmission turbine
from overspeed conditions dur ing
The Transmission ECM relies on signals from several
downloading.
sensors that are incorporated into the design. These
sensors measure the speed of several components, C. Receives speed information from the engine
as well as other sensors that measure temperature. speed sensor, the turbine speed sensor, the
These solenoids and sensors are further defined in intermediate shaft speed sensor and the
the following paragraphs. transmission output shaft speed sensor.
T h e s e s p e e d s e n s o r s a r e c h e ck e d t o
In a d d i t i o n , th e t ra n s m i s s i o n i n c o r p o ra t e s a
deter mine if nor mal sensor operation is
two-piece transmission case for ease of transmission
present. The data is also used to control
maintenance, helical cut gears that help reduce
modulation during shifting and to determine
noise, and all external hoses have been eliminated
the appropriate shift patterns.
(all oil passages are internal).
D. Detects system failures and determines the
Transmission ECM appropriate alternative actions.
Modulation and shifting are controlled by the E. Provides various diagnostic messages to the
Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e Information Center.
(Transmission ECM). This module replaces the oil F. Provides other information to the information
and springs that are found in hydraulically modulated center, which in turn displays engine speed,
transmissions. wheel speed, gear shift selection, and actual
T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h gear selection.
e n g a g e m e n t , p r ov i d i n g s m o o t h e r s h i f t s a n d G. Provides a method to calibrate the
enhanced clutch life, whether the transmission is set transmission clutch control.
to the automatic or manual shift mode.
H. Establishes clutch modulation pressure during
The Transmission ECM also informs the Information transmission shifts.
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.
Electrical Shift Solenoids

Electrical Shift Solenoids control the modulation of
the clutches, eliminating the need for a modulation
valve, and providing a smooth shift while maintaining
constant control over clutch engagement as follows:
A. A temperature sensor relays the oil
temperature to the Transmission ECM.
B. The Transmission ECM times the rate the
solenoid energizes and de-energizes.
C. As the transmission changes gears, there is
reduced hesitation from one gear to the next.

6002-10
Transmission Sensor Data Clutch Modulation Substitute Mode

Collection In this mode, the transmission clutch modulation is
The Transmission ECM collects and uses information time dependant rather than load dependant. The
from four sensors to accurately shift the transmission transmission will go into the Clutch Modulation
and determine if any clutches are slipping. These Substitute Mode if any of the four speed sensors fail.
sensors are: If the output speed sensor is working and the
Engine (Speed) Sensor - monitors engine speed to transmission is in gear, the shift points in Automatic
determine the load on the engine for shift points and mode will be speed dependant but the modulation
sends the engine rpm to the Transmission ECM, will be a predetermined amount of time.
which sends the information to the tachometer in the If the output speed sensor is not working and the
Information Center. transmission is in gear, the shift points will be load
Turbine (Speed) Sensor - assists the engine speed d e p e n d a n t bu t t h e m o d u l a t i o n w i l l s t i l l b e a
sensor in deter mining the load going into the predetermined amount of time.
transmission and helps determine shift points. If the transmission is shifted from neutral into a
Intermediate (Shaft Speed) Sensor - determines direction in the Clutch Modulation Substitute Mode in
differential gear speed in the transmission to check automatic, the transmission will shift into 4th gear
for clutch slippage. and shift down until it gets the correct output speed
from the turbine.
Output (Speed) Sensor - monitors transmission
output shaft speed to help determine the load on the Limp-Home Mode
transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM In this mode, the transmission will go into second
which sends the information to the speedometer in gear, forward or reverse, no matter what gear is
the Information Center. selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
T h e t ra n s m i s s i o n E C M a l s o r ev i ew s vo l t a g e
g e a r s u n t i l a n o p e r a b l e g e a r i s fo u n d . T h e
infor mation from the shifter and transmission
transmission will go into the Limp Home Mode if
solenoids to determine if there are any short circuits
there is a fault on one clutch, a fault on one clutch
or open circuits in the system.
valve, or a fault on more than one speed sensor.
Automatic Problem Modes Transmission/Transmission ECM

If the Transmission ECM detects an error condition in Shutdown Mode
the transmission system, it will generate a service
code in the Information Center and will enter one of In this mode, the Transmission ECM has detected a
three modes: s e ve r e fa i l u r e t h a t d i s a b l e s c o n t r o l o f t h e
transmission. The transmission will go into Shutdown
A. Clutch Modulation Substitute Mode
Mode if there is a fault on more than one clutch, a
B. Limp-Home Mode fault on the solenoid power supply, or invalid voltage.
C. Transmission/Transmission ECM Shutdown In this mode, the Transmission ECM will shut off all
Mode solenoid valves and the power supply and the
transmission shifts into and stays in neutral.
If the Transmission ECM generates a code, the
wren ch over th e se r vice m anual ico n will be
displayed on the Information Center.

6002-11
Transmission Clutch Calibration Gear Selections

The Transmission ECM has the capability to find the The transmission provides 4 forward and 3 reverse
optimal adjustment of the clutch filling parameters for gear selections. The transmission ratios were
each individual transmission, providing the ability to designed to give optimized speed and torque for
individually adjust the optimum fill time for the each gear selection. The torque converter is a single
individual transmission in the machine. Clutch Filling stage torque converter (one locking unit in the torque
Parameter Calibration is performed on each machine converter).
at the plant and should be repeated at the first 250
hours of use and every 1000 hours thereafter. Automatic/Manual Modes
Before doing the following transmission clutch The automatic/manual switch is located on the right
calibration procedures make sure of the following: control panel. The transmission is in automatic mode
1. The machine is running and the transmission oil when the top of the automatic/manual switch is
is warm. depressed. The Transmission Display Center
indicates when the machine is in the automatic
2. Engine low idle speed is correct. mode.
3. The transmission is in neutral.
4. The park brake is applied.
Upshifting in Automatic Mode
5. If steps 1 through 4 have been accomplished, Upshifting is determined by machine speed and the
calibrate the transmission clutches as follows: torque on the transmission.
A. Press and hold the enter key for 2 to 3 The transmission will shift from first or second gear
seconds and the monitor will change to up to the highest gear selected as the accelerator is
SELECT. depressed, machine speed increases, and required
torque is reduced.
B. Use the down arrow and high light “CONFIG”,
press the enter key. If the machine speed is increasing, but the operator
is not depressing the accelerator (such as when
C. Press the down arrow and high light “CALIB going down a hill), the transmission will not upshift.
G/B”, press the enter key.
As the operator depresses the accelerator and the
D. Monitor will state “CALIB G/B” “CONFIRM torque on the transmission is lowered, the
PLEASE”, press the enter key. transmission will upshift.
E. If the conditions are not correct for clutch
calibration the monitor will display the problem Downshifting in Automatic Mode
that needs to be corrected.
Downshifting is determined directly by machine
F. Clutch calibration status will be displayed on speed and transmission torque. The transmission will
the monitor, “ADJUST K1, K2, K3, K4, KV, downshift to first or second gear as machine speed
KR”. decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
G. After completing the Clutch Calibration and the machine speed decreases, as the torque
procedure, turn the machine OFF for 15 requirement increases, the transmission will
seconds. This sets the calibration in the downshift into third, then second, and down to first
controller. gear, if necessary.
Upshifting in Manual Mode

In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the
operator selects another gear or direction. The
transmission can be upshifted without reducing
engine speed or machine speed.
If the gear selected is two or more gears higher than
the present gear, the transmission will shift up
through the gears at 2.5 second intervals until the
selected gear has been reached.

6002-12
Downshifting in Manual Mode Manual Mode

The transmission can be downshifted in the manual In the manual mode, the downshift button toggles
mode without reducing engine speed or machine between 1st and 2nd gear. The manual mode is
speed. useful in short haul operations. In this mode, the
downshift button functions in two ways in 1st and 2nd
If 1st gear is selected from 3rd or 4th gear, the
gear.
transmission will downshift into 2nd gear for 1.2
seconds and then will shift into 1st gear. When the operator is in 2nd gear and pushes the
downshift button, the transmission instantly shifts into
Downshift Button 1st gear. When the operator pushes the downshift
button again, the transmission upshifts into 2nd gear.
The downshift button is located on front of the
joystick control lever in machines with a single lever If the machine is in 2nd gear and the downshift
configuration, and on top of the control tower in button is pushed, the transmission instantly shifts into
machines with a three lever configuration. 1st gear. When the operator shuttles the shifter, the
transmission upshifts back into 2nd gear.
With the number of different ways the downshift
button functions, the operator can tailor the use of the Cold Start Protection System
machine to the application at hand.
The transmission has a cold start protection system.
Automatic Mode When the transmission sump temperature is minus
10° C (14° F), the Transmission ECM will keep the
In the Automatic Mode, the downshift button only transmission in neutral.
shifts down. The downshift button allows the operator
to downshift through the entire range of gears. This is When the transmission sump temperature warms up
useful in long haul applications or roading. to minus 10° C (14°F) (within approximately one
minute), the machine will operate in all gears.
Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then Brake Pedal Transmission
from 3rd to 2nd, and then from 2nd to 1st.
Declutch
The transmission will automatically downshift and
then upshift, as needed, to the last gear that was A transmission declutch feature concentrates more
selected with the downshift button. engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and
Example: If the downshift button was used to shift starts. Total disconnection of the transmission from
from 4th to 3rd gear, the transmission will the engine is prevented. This feature will function in
automatically shift from 3rd down and then back up to 1st, 2nd, or 3rd gear only. It will not function in 4th
3rd again. It will not shift into 4th until the gear.
transmission has been returned to the full range
automatic mode. When the transmission declutch switch is in the on
p o s i t i o n a n d t h e b ra ke p e d a l i s p u s h e d , t h e
The transmission will retur n to the full range Transmission ECM reduces the pressure to the
automatic mode when: transmission forward or reverse clutch.
A. Another gear is selected. T h e Tr a n s m i s s i o n E C M w i l l n o t c o m p l e t e l y
B. The shifter is moved into neutral and then into disconnect the clutch from the engine, but gradually
forward or reverse. reduces the forward or reverse clutch pressure down
to a lower level.
C. The autoshift switch is recycled.
When the brake pedal is released, the Transmission
ECM gradually increases the forward or reverse
clutch back up to system clutch pressure.
If the direction is changed while the transmission is
declutched, the selected forward or reverse clutch
will be filled and maintain a low pressure until the
brake pedal is released. Then the selected forward or
reverse clutch pressure will gradually increase up to
system clutch pressure.

6002-13
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

DESIGNATION ON
No. IDENTIFICATION/LOCATION CONNECTION
VALVE BLOCK
Measuring Points for Pressure Oil and Temperature
51 Before the Converter - Opening Pressure 8 bar (116 psi) M10x1 H
52 Behind the Converter - Opening Pressure 2.5 bar (36 psi) M14x1.5
53 Clutch Forward 16+2 bar (232 + 29 psi) KV M10x1 B
55 Clutch Reverse 16+2 bar (232 + 29 psi) KR M10x1 E
56 Clutch 16+2 bar (232 + 29 psi) K1 M10x1 D
57 Clutch 16+2 bar (232 + 29 psi) K2 M10x1 A
58 Clutch 16+2 bar (232 + 29 psi) K3 M10x1 C
60 Clutch 16+2 bar (232 + 29 psi) K4 M10x1 F
63 Behind the Converter Temperature 100° C, Short Time 120° C M14x1/5
65 System Pressure 16+2 bar (232 + 29 psi) M10x1 K
Measuring Points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16” - 12 UNF-2B
16 Connection from the Heat Exchanger 1 5/16” - 12 UNF-2B
Inductive Transmitter and Speed Sensor
21 Inductive Transmitter for Turbine Speed M18x1.5
34 Output Speed Sensor
47 Inductive Transmitter for Central Gear Train Speed M18x1.5
48 Inductive Transmitter for Engine Speed M18x1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 System Pressure M16x1.5 G
69 Pilot Pressure M16x1.5 J
NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.

6002-14
BC01B047
MEASURING POINTS AND CONNECTIONS

6002-15
CHART FOR RECORDING PRESSURE READINGS

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

6002-16
PRESSURE TEST RESULTS
All or Most Pressures Low and/or Not Enough Power

Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
3. Oil operating temperature high.
A. Check engine and fuel system for problem.
4. Screen for suction tube plugged.
B. Check that torque converter installation is
5. Suction tube or gaskets leak. correct.
6. Main pressure valve, springs, or valve bore. 3. Engine RPM above Stall Test specified RPM.
7. Reduction valve, springs, or valve bore. (Refer to Section 2002 for specifications.)
8. Charge pump seals or gaskets leak. A. Check converter pressures and flow.
9. Charge pump worn. B. Check that torque converter installation is

correct.
10. Oil supply flange not sealing correctly.
Machine Stops or Hesitates While
Some Pressures Low Shifting - Intermittent
Possible causes include:
Possible causes include:
1. Circuit isolation does not correct low pressure.
1. Check orifice and O-ring. (See Section 6007 for
A. Control valve or gasket. replacing.)
B. Channel plate or gasket. 2. Check for foreign material plugging orifices or
sticking valves.
2. Circuit isolation corrects low pressure.
3. Check for reduced pressure at test pressure
A. Clutch shaft or seals.
points.
B. Clutch drum or piston.
4. See Electrical Troubleshooting in this Section for
electrical system problem.

6002-17
CONVERTER OUT PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge.
0 to 28 bar (400 psi) gauge with hose long enough to 4. Heat the oil to an operating temperature of 80 to
take readings in the cab and CAS-2324 Special 100° C (176 to 212° F).
Adapter. 5. While in the cab, put the transmission in
NEUTRAL. Run the engine at full throttle. Record
Test Procedure the reading in the chart on page 16. Pressure
must be a minimum of 3.5 to 6.5 bar
1. Block the machine tires. (51 to 96 psi).
2. Apply the parking brakes.
LUBRICATION PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 16. Pressure must
be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
Test Equipment Required 3. Heat the oil to an operating temperature of 80 to

100° C (176 to 212° F).
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter. 4. Remove the filter and install the CAS-2702
adapter.
Flowmeter Test Procedure 5. Install the flowmeter between the adapter and
the filter.
1. Block the machine tires.
2. Apply the parking brakes. Put the transmission in NEUTRAL and record the
flow measurement. The correct flow is 80 L/min
(21 U.S. gpm) at 2000 rpm.
CONSUMPTION TEST PROCEDURE

1. Block the machine tires. 6. Repeat the procedure with the transmission in
FORWARD in third gear. The flow must be 9.1
2. Apply the parking brakes.
L/min (2 U.S. gpm).
3. Heat the oil to an operating temperature of 80 to
7. Repeat the procedure with the transmission in
100° C (176 to 212 ° F).
REVERSE in third gear. The flow must be 9.1
4. Install the flowmeter to converter outlet line (line L/min (2 U.S. gpm).
to cooler) in series.
Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 L/min
(2 U.S. gpm).

6002-18
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56°C (100°F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

6002-19
ERROR CODES
In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with
a recorded error number. See section 4005 for error code retrieval procedures and definitions.
TRANSMISSION SHIFTER LOGIC INFORMATION

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

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

6002-20
NOTES

Section
6003
6003
TRANSMISSION

6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6003-3
SPECIAL TOOLS
CAS2885 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
CAS2807 TRANSMISSION
INPUT/OUTPUT SHAFT SEAL CAS2869 TRANSMISSION
INSTALLATION TOOL OUTPUT SHAFT SEAL
CAS2803 TRANSMISSION INSTALLATION TOOL
TORQUE CONVERTER SEAL (521 AND 621
INSTALLATION TOOL MODELS ONLY)
BS02C093 THRU 096

CAS40075 TRANSMISSION TOOL KIT
CAS2802 ALIGNMENT
CAS2799 CLUTCH PACK DOWEL SET
H0LDER AND SPRING
COMPRESSOR TOOLS
CAS2801 TRANSMISSION
CAS2796 NESTING MOUNTING BRACKETS
PLATE
CAS2868 CLUTCH SPRING

COMPRESSOR
(521 AND 621
CAS2800 CLUTCH CAS2797 LIFTING MODELS ONLY)
ASSEMBLY HOLDING EYEBOLT SET
CAS2798 GEAR KNOB SET
PULLER COLLET SET
BS02C097 THRU 104
CAS40079 TRANSMISSION OVERHAUL KIT
SPECIAL TORQUES
Oil pipes
Studs ............................................................................................................................... 9 Nm (80 pound inches)
Socket head screw ...................................................................................................... 23 Nm (204 pound inches)
Screw plug.......................................................................................................................... 51 Nm (38 pound feet)
Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches)
Plugs................................................................................................................................. 25 Nm (221 pound inches)
Output shaft
Output shaft screws (apply Loctite 243 to threads) ..................................................... 23 Nm (204 pound inches)
Housing cover screws (apply Loctite 574 to threads).................................................. 46 Nm (407 pound inches)
Output flange screws................................................................................................... 34 Nm (301 pound inches)
Oil feed housing and transmission pump
Transmission pump screws ......................................................................................... 46 Nm (407 pound inches)
Oil feed housing screws .............................................................................................. 25 Nm (221 pound inches)
Engine connection and converter
Input shaft screws ............................................................................................................ 115 Nm (85 pound feet)
Converter housing screws.................................................................................................. 68 Nm (50 pound feet)
Cover............................................................................................................................ 23 Nm (204 pound inches)
Converter cover........................................................................................................... 46 Nm (407 pound inches)
Input flange .................................................................................................................. 34 Nm (301 pound inches)

6003-4
SPECIAL TORQUES (CONTINUED)

Duct plate
Screws......................................................................................................................... 25 Nm (221 pound inches)
Screw plug................................................................................................................... 30 Nm (265 pound inches)
Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches)
Filter
Filter head screws ....................................................................................................... 25 Nm (221 pound inches)
Oil distribution cover screws........................................................................................ 25 Nm (221 pound inches)
Speed sensor and inductive transmitter
Speed sensor screw.................................................................................................... 23 Nm (204 pound inches)
Inductive transmitter .................................................................................................... 30 Nm (265 pound inches)
Cover plate .................................................................................................................. 23 Nm (204 pound inches)
Screw plug...................................................................................................................... 140 Nm (103 pound feet)
SPECIFICATIONS
Clutch KV and KR plate clearance ......................................................................... 2.7 to 2.9 mm (0.106 to 0.114 in)
Clutch K1plate clearance........................................................................................ 2.4 to 2.6 mm (0.094 to 0.102 in)
Clutch K2 and K3 plate clearance .......................................................................... 1.8 to 2.0 mm (0.071 to 0.079 in)
Clutch K4 plate clearance....................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)

6003-5
DISASSEMBLY
STEP 1 STEP 4
GD98M833 GD98M837
Fasten transmission on an assembly stand using R e m ove t wo s o cke t h e a d s c r ews a n d i n s t a l l

CAS2801 transmission mounting brackets. CAS2885 transmission valve adjustment tool set.
Remove remaining 21 socket head screws securing
STEP 2 control valve. Loosen and remove hex rods (part of
CAS2885) from studs then remove control valve.
STEP 5
GD98M835
Remove and discard oil filter.
STEP 3 GD98M838
Remove both gaskets and the intermediate plate.
STEP 6
GD98M836
Remove hex head screws securing filter head.

Remove filter head from transmission. GD98M839
Remove socket head screws and hex nuts. Remove

duct plate. Remove flat gasket.
6003-6
STEP 7 STEP 10
GD98M844 GD98M847
Bend lock plate away from hex head screws.
Using proper size rod, press input shaft and
Remove two hex head screws, lock plate, and
converter from cover.
washer. Remove input flange from shaft.
STEP 11
STEP 8
GD98M845 GD98M848
Put alignment mar ks on conver ter cover and Remove retaining ring then remove bearing.
housing to aid in assembly. Remove 12 nuts and
hex head screws. STEP 12
STEP 9
GD98M849
R e m o ve fo u r h ex h e a d s c r e w s a n d r e m o ve
GD98M846
diaphragm and input shaft.
C o n n e c t s u i t a bl e l i f t i n g e q u i p m e n t t o s h a f t .
R e m o v e c o v e r, s h a f t , a n d c o n v e r t e r f r o m
transmission and place in hydraulic press.

6003-7
STEP 13 STEP 16
GD98M853
GD98M850
Put input shaft and diaphragm in vise as shown. Remove the socket head screws for removal of the
Remove 12 hex head screws to separate transmission pump.
diaphragm and input shaft.
STEP 17
STEP 14
GD98M854
GD98M851 Apply a bearing separator on the splines shoulder of

Remove the inductive transmitter. the stator shaft and pull the pump out of the housing
bores, using two-leg puller.
STEP 15 NOTE: If traces of wear should be encountered in
the pump housing or the cam disk, the complete
pump has to be replaced.
STEP 18
GD98M852
Remove the hex head screws and remove the

converter housing.
GD98M855
Separate the transmission pump from stator.

Separate the cam plate from pump.
6003-8
STEP 19 STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 24
GD98M856
Remove the hex head screws and remove the oil

feed housing. Remove the flat gasket.
STEP 20 GD98M862
Remove the speed sensor and both inductive

transmitters.
STEP 25
GD98M860
Remove the hex head screws, cover, and flat gasket.
STEP 21
GD98M863
Remove the hex nuts and the two covers.
STEP 26
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 22 GD98M864
Pry the shaft seal out of the housing bore. Install CAS2802 alignment dowel set.
NOTE: The following steps describe the common
removal of all clutches.
6003-9
STEP 27 STEP 30
Remove CAS2800 clutch assembly holding knob
set and lift cover free.
STEP 31
BK00D029
Install CAS2800 clutch assembly holding knob set.

With knobs installed on all clutches in housing cover,
install CAS2797 lifting eyebolt set and lifting device to
transmission cover. GD98M867
Remove the socket head screws and remove the

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

transmission housing, using lifting device. GD98M872
STEP 29 Remove clutch K2.
STEP 33
BK00D026
Place clutch disc carriers onto CAS2796 nesting

GD98M873
plate.
Remove clutch K1 while lifting clutch K4.

6003-10
STEP 34 STEP 37
GD98M877
GD98M874
Remove clutch K3. Remove the bearing outer race and pull output shaft
out of the housing bore.
STEP 35
STEP 38
GD98M875
GD98M878
Remove clutch K4 while lifting input shaft slightly.
Remove the rectangular ring and separate ball
STEP 36 bearing from the shaft.
NOTE: The following steps are for the disassembly
of the clutch KV. The disassembly of the clutch KR is
similar.
STEP 39
GD98M876
Remove clutches KV and KR together with input

shaft.
GD98M979
Remove the sealing ring. Pull the tapered roller

bearing from the shaft. Remove the opposite tapered
roller bearing.
6003-11
STEP 40 STEP 43
GD98M881 BK00D020
Separate the clutch disc carrier from the shaft. Remove snap ring.
STEP 41 STEP 44
GD98M882 BK00D019
Remove the snap ring and remove the clutch disc Remove the compression spring.
pack.
STEP 45
STEP 42
GD98M885
BK00D018 Remove piston from clutch pack holder. Remove and

Preload compression spring using CAS2799 clutch discard the O-rings from piston.
pack holder and spring compressor tool.

6003-12
STEP 46 STEP 48
GD98M886 GD98M889
Remove the snap ring. Remove the snap ring and remove the ball bearing.
STEP 47 NOTE: The following steps are for disassembly of

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

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

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

washer.

6003-13
STEP 51 STEP 54
GD98M893 BK00D018
Remove the idler gear. Preload compression spring using CAS2799 clutch
STEP 52
STEP 55
GD98M894
Remove the needle bearings and thrust bearing. BKOOD020
Remove the snap ring.

STEP 53
STEP 56
GD98M895
Remove the snap ring and remove the clutch disc BK00D019
pack. Remove the compression spring.

6003-14
STEP 57 STEP 59
BS00G001 GD98M800
Remove the sealing ring. Remove bearing using Remove and discard two sealing rings. Pull two
bearing puller. Tap assembly until piston drops out of bearings from shaft using bearing puller. Remove the
the clutch pack carrier. Then, remove and discard snap ring and separate the clutch disc carrier from
O-rings from piston. the shaft.
STEP 58 STEP 60
BK00D022 GD98M801
Remove the clutch disc carrier from the shaft. Remove the snap ring and remove the clutch disc
pack.
NOTE: The following steps are for the disassembly
of the clutch K4.
STEP 61
BK00D018
Preload compression spring using CAS2799 clutch


6003-15
STEP 62 NOTE: The following two steps are for disassembly
of the input shaft.
NOTE: A snap ring is used to lock turbine shaft in
input shaft. Snap ring will be destroyed when turbine
shaft is pressed from input shaft.
STEP 64
BK00D020
STEP 63
GD98M803
If turbine shaft is to be removed from input shaft, use

proper size diameter sleeve or rod and press turbine
shaft out of input shaft.
STEP 65
Remove bearings from input shaft using a bearing
puller.
BK00D019
Remove the compression spring.

6003-16
ASSEMBLY
NOTE: The following steps are for the reassembly of STEP 69
the oil pipes.
STEP 66
3 GD98M607
Install a new O-ring on plug. Tighten the plug to a

torque of 51 Nm (38 pound feet).
1
STEP 70
GD98M603
Install suction tube (1), pressure pipes (2), and

lubrication pressure pipe (3) in housing.
STEP 67
Secure suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 pound inches)
STEP 68
GD98M608
Install all bearing outer races in housing bores.
STEP 71
GD98M605
Tilt the cover 180 degrees. Install the suction tubes

and pressure pipes into the housing bores using a
rolling tool.
NOTE: Pipe end of the pressure pipes must be GD98M609
slightly below the housing plane face.
Install both oil pipes into the housing cover. Tilt the
cover 180 degrees and install pipes into the housing
bores using a rolling tool.
NOTE: The pipe end must be slightly below the
housing plane face.
6003-17
STEP 72 STEP 75
GD98M610 BK00D019
Install the studs. Tighten the studs to a torque of 9

Nm (80 pound inches).
NOTE: The following steps are for the assembly of
clutches KV and KR, starting with assembly of the
clutch disc carrier.
STEP 73
BK00D018
Install compression spring and two spring cups in

clutch disc carrier. Preload compression spring
using CAS2799 clutch pack holder and spring
compressor tool.
STEP 76
GD98M612
Check that drain hole is clear and free of foreign

matter. Install both O-rings in recesses of the piston
and apply oil.
STEP 74
BK00D020
Install the snap ring.

NOTE: The following steps are for the KV and KR
clutch disc packs. The disc stacking of clutches KV
and KR is identical.
GD98M613
Install piston in clutch disc carrier.

6003-18
STEP 77 STEP 79
GD98M617
225B Install end shim and snap ring.

1. PLATE CARRIER
2. PISTON STEP 80
3. OUTER PLATE - ONE-SIDED COATED
4. INNER PLATES
5. OUTER PLATES - COATED ON BOTH SIDES
6. SNAP RING
7. END SHIM
A RUNNING CLEARANCE 2.7 TO 2.9 MM (0.106 TO 0.114
IN)
Install clutch disc plates in KV and KR clutch disc

carriers in position and sequence shown above.
Install outer plates (3) with steel faced side facing
piston and end shim (7).
NOTE: Snap rings of different thickness are
available for adjustment of the running clearance. To
GD98M618
ensure correct adjustment, do not apply oil to clutch
discs until after adjustment is completed. Adjust running clearance to 2.7 to 2.9 mm (0.106 to
0 . 1 1 4 i n ) . P r e ss d ow n o n t h e e n d s h i m w i th
STEP 78 approximately 10 kg (20 lb). Measure and record
dimension (A) from carrier face to end shim using
depth gauge as shown.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
GD98M616
Install the clutch disc pack.

6003-19
STEP 81 STEP 84
GD98M619 GD98M621
Use tools to lift the end shim against snap ring Apply Loctite 243 to stud. Tighten stud to a torque of
(upward) until contact is obtained. Measure and 17 Nm (150 pound inches).
record dimension (B) from carrier face to end shim
using depth gauge as shown. Subtract this STEP 85
measurement from the measurement of Step 80. The
difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
Dimension B . . . . . . . . . . . . . . . . . 4.45 mm (0.18 in)
Difference = Running. . . . . . . . . . . 2.80 mm (0.11 in)
Clearance
Required running clearance is 2.7 to 2.9 mm (0.106
to 0.114 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
STEP 82
GD98M622
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as Install ball bearing until contact is obtained. Secure
determined in Step 81. using snap ring.
STEP 83 STEP 86
GD98M623
GD98M620
Install idler gear to align and engage all inner discs, Install needle bearing.
then remove idler gear.

6003-20
STEP 87 STEP 90
GD98M624 BP00G020
Support the idler gear on the bearing inner race. Install gear and shaft into heated bore.
Press the idler gear against the shoulder.
STEP 91
STEP 88
BK00D024
GD98M625 Heat bearing.

Secure idler gear using snap ring.
STEP 92
STEP 89
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
BK00D023
Use heat gun to heat assembled clutch disc carrier

inner bore.
BK00D025
Install heated bear ing on shaft against shaft

shoulder.

6003-21
STEP 93 STEP 96
Check operation of the clutch using compressed air.
NOTE: The following steps are for assembly of
clutch K1, K2, and K3.
STEP 94
GD98M632

matter. Install both O-rings in recesses of piston and
apply oil.
STEP 97
GD98M630
Press bearing against shoulder of shaft. Apply

Loctite 243 to the stud and install the stud. Tighten
the stud to a torque of 17 Nm (150 pound inches).
STEP 95
GD98M633
Install piston in clutch disc carrier.
STEP 98
GD98M631
Install the clutch disc carrier until contact is obtained.
GD98M634
Install the compression spring and spring cup.

6003-22
STEP 99 STEP 101
BK00D019
232A
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
A. CLUTCH K1 RUNNING CLEARANCE 2.4 TO 2.6 MM
(0.094 TO 0.102 IN); CLUTCHES K2 AND K3 RUNNING
CLEARANCE 1.8 TO 2.0 MM (0.071 TO 0.079 IN)
Install clutch disc plates in K1, K2, and K3 clutch disc

BK00D018 carriers in position and sequence shown above.
Install compression spring and two spring cups in Install outer plate (3) with steel faced side facing
clutch disc carrier. Preload compression spring piston.
using CAS2799 clutch pack holder and spring NOTE: Snap rings of different thickness are
compressor tool. available for adjustment of the running clearance. To
ensure correct adjustment, do not apply oil to clutch
STEP 100 discs until after adjustment is completed.
STEP 102
BK00D020
Install the snap ring.

GD98M636
NOTE: The following steps are for K1, K2 and K3
clutches. The assembly of clutches K1, K2, and K3 is Install the clutch disc pack.
identical except for running clearance dimensions.

6003-23
STEP 103 STEP 105
GD98M637 GD98M639
Install the end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 104 record dimension (B) from carrier face to end shim
u s i n g d e p t h g a u g e a s s h ow n . S u b t r a c t t h i s
measurement from the measurement of Step 104.
The difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in)
Difference = Running Clearance . . .2.1 mm (0.08 in)
Required running clearance for K1 is 2.4 to 2.6 mm
(0.094 to 0.102 in); for K2 and K3 required running
clearance is 1.8 to 2.0 mm (0.071 to 0.079 in). Use
snap ring(s) of different thickness as necessary to
obtain correct running clearance.
GD98M638
Adjust running clearance for K1 to 2.4 to 2.6 mm STEP 106

(0.094 to 0.102 in); adjust running clearance for K2 Remove clutch disc pack, apply oil to discs, and
and K3 to 1.8 to 2.0 mm (0.071 to 0.079 in). Press install clutch disc pack, end shim, and snap ring as
down on the end shim with approximately 10 kg (20 determined in Step 105.
lb). Measure and record dimension (A) from carrier
face to end shim using depth gauge as shown. STEP 107
Example
Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)
3
2
1
GD98M640
Install the thrust washer (1), thrust bearing (2), and

thrust washer (3).
NOTE: Install the thrust washer (1) with the chamfer
facing the thrust bearing.

6003-24
STEP 108 STEP 111
GD98M641 BK00D024
Install both needle bearings. Heat bearing.
STEP 109 STEP 112

SM121A
GD98M642
Install idler gear until all inner discs are engaged.
STEP 110
BK00D025
1 Place heated bearing on the shaft.
2 STEP 113
3
GD98M643
Install the thrust washer (3), thrust bearing (2), and

thrust washer (1). Install the thrust washer (1) with
the chamfer facing the thrust bearing.
NOTE: Ensure the thrust washer (1) is overlapping
with the chaff collar to accommodate all the inner
discs.

6003-25
NOTE: The following steps are for assembly of STEP 116
clutch K4.
STEP 114
SM121A
GD98M649
Apply Loctite 243 to the stud and install the stud.

Tighten the stud to a torque of 17 Nm (150 pound
inches).
STEP 117
GD98M647
Heat the gear to about 120° C (248° F) and install

until seated in position.
STEP 115
GD98M650

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

bottoms out.

6003-26
STEP 119 STEP 121
BK00D019 BS02C131
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
A. RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055
IN)
Install clutch disc plates in K4 clutch disc carrier in

position and sequence shown above. Install outer
plate (3) with steel faced side facing piston.
NOTE: Snap rings of different thickness are
BK00D018 available for adjustment of the running clearance. To
Install compression spring and two spring cups in ensure correct adjustment, do not apply oil to clutch
clutch disc carrier. Preload compression spring discs until after adjustment is completed.
using CAS2799 clutch pack holder and spring
compressor tool. STEP 122
STEP 120
GD98M653
Install clutch disc pack.

BK00D020
Install snap ring.

NOTE: The following steps are for installing the
clutch disc pack in clutch K4.

6003-27
STEP 123 STEP 125
GD98M654 GD98M656
Install end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 124 record dimension (B) from carrier face to end shim
u s i n g d e p t h g a u g e a s s h ow n . S u b t r a c t t h i s
measurement from the measurement of Step 124.
The difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in)
Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in)
Clearance
Required running clearance is 1.2 to 1.4 mm (0.047
to 0.055 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
GD98M655 STEP 126
Adjust running clearance to 1.2 to 1.4 mm (0.047 to Remove clutch disc pack, apply oil to discs, and
0 . 0 5 5 i n ) . P r e s s d ow n o n t h e e n d s h i m w i t h install clutch disc pack, end shim, and snap ring as
approximately 10 kg (20 lb). Measure and record determined in Step 125.
dimension (A) from carrier face to end shim using
depth gauge as shown. STEP 127
Example
Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.

6003-28
STEP 128 STEP 131
GD98M658 GD98M661
Assemble two thrust washers and thrust bearing. Assemble thrust washer (3), thrust bearing (2), and
thrust washer (1). Install the thrust washer (1) with
NOTE: Upper and lower thrust washers are the
the chamfer facing the thrust bearing.
same thickness.
STEP 132
STEP 129
GD98M662
GD98M659
Install the assembled clutch disc carrier until all the
Install both needle bearings.
inner discs are engaged.
STEP 130 STEP 133
GD98M660
GD98M663
Install the idler gear.
Install snap ring to secure clutch disc carrier.

6003-29
STEP 134 STEP 138
SM121A
BK00D024
Heat bearing.
STEP 135
WARNING: Always wear heat protective GD98M666
gloves to prevent burning your hand when Heat gear to about 120° C (248° F) and install on
handling heated parts. input shaft until contact is obtained.
SM121A
STEP 139
BK00D025
Install heated bearing on the shaft shoulder. GD98M667
Secure gear with snap ring.

STEP 136
Repeat Steps 134 and 135 to install bearing on STEP 140
opposite end of shaft.
STEP 137
NOTE: The following steps are for the reassembly of
the input shaft.
GD98M668
Install snap ring into recess of turbine shaft.

6003-30
STEP 141 STEP 144
GD98M669 GD98M672
Install the turbine shaft until the snap ring snaps into Install output shaft into housing bore until contact is
the recess of the input shaft. made.
STEP 142 NOTE: The following steps are for the installation of
the output shaft and clutches. All clutches have a
WARNING: Always wear heat protective common installation.
handling heated parts. STEP 145
SM121A
K1 K4
AN KR
AB
K3 K2
KV
GD98M673
BK00D024 Install bearing outer races into housing cover until

Heat bearings and install on turbine shaft until contact is obtained.
bearings are against shoulder.
STEP 146
STEP 143
BK00F003
GD98M671 Install the clutches onto CAS2796 nesting plate.

Install bearing then install rectangular ring.

6003-31
STEP 147 STEP 150
BK00D029 GD98M681
Using CAS2797 lifting eye bolt set and acceptable Install the sealing rings and insert rings in their
liftin g eq uipm en t, in stall ho using cove r o nto respective grooves. Apply grease to the sealing rings
clutches. Install CAS2800 clutch assembly holding and align the rings centrally.
knob set to secure clutch shafts to cover.
STEP 151
STEP 148
KR
KV
K4
K2
K1 K3
GD98M692
GD98M679 Install both the O-rings into the annular groove of the
The above photo shows the position of the single oil pipes and apply grease.
clutches in the housing cover.
STEP 152
STEP 149
Tilt the housing cover 180 degrees.
AN
KV KR
K2 K4
K3 K1
AB
GD98M866
The above shows the position of the single clutches

and the input and output clutches.

6003-32
STEP 153 STEP 156
BK00D028 GD98M686
Install output gear and shaft in transmission housing. Install screen sheet on output shaft. Press front and
Install alignment screws. Carefully lower the cover rear bearings on output shaft until contact with
and clutches into the gear box housing. shoulder of output shaft is made.
STEP 154 STEP 157

Remove CAS2800 clutch assembly holding knob set.
STEP 155
GD98M688
Install the screening plate.
GD98M685 STEP 158

Separate the housing cover from the gearbox, using
a lifting device.
NOTE: The following steps are for the reassembly of
the output shaft.
GD98M689
Install the output shaft.

6003-33
STEP 159 STEP 162
GD98M690 GD98M697
Apply Loctite 243 to the socket head screws and Heat the output flange to about 90° C (194° F). Apply
install the screws. Tighten the screws to a torque of Loctite 574 to the contact area and assemble the
23 Nm (204 pound inches). flange with the washers and hex head screws.
Tighten the screws to a torque of 34 Nm (301 pound
STEP 160 inches). Bend corner of lock plate over hex head
screws.
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
the oil feed housing and transmission pump.
STEP 164
GD98M691
Install rectangular rings in grooves of clutch shafts.

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

A p p l y g r e a s e t o s e a l i n g l i p. U s e C A S 2 8 0 7
transmission output shaft seal installation tool to
install seal.

6003-34
STEP 165 STEP 168
GD98M703 GD98M706
Install the oil feed housing with washers and hex Install transmission pump.
head screws. Screw the hex head screws in only until
contact is obtained, do not tighten. STEP 169
STEP 166
GD98M707
Apply grease to new O-rings. Install the O-rings on

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

GD98M705 screws. Tighten screws to a torque of 46 Nm (407
Apply oil and install the O-ring. pound inches).

6003-35
STEP 171 STEP 173
GD98M709 GD98M712
Install the oil feed housing with the hex head screws Position converter housing. Secure with hex head
and flat washers. Tighten the screws to a torque of screws. Tighten the screws to a torque of 68 Nm (50
25 Nm (221 pound inches). pound feet).
STEP 172 STEP 174
GD98M711 GD98M713
Position the gasket and cover. Secure the cover with P u t in p u t s h a f t in a v i s e a s s h ow n . Po s i t io n

the hex head screws. Tighten the screws to a torque diaphragm on input shaft and secure using 12 hex
of 23 Nm (204 pound inches). head screws. Tighten screws to a torque of 115 Nm
(85 pound feet).
the engine connection and converter. STEP 175
GD98M714
Position diaphragm and input shaft on converter.

Apply Loctite 262 to threads of hex head screws.
Install screws and tighten to a torque of 115 Nm (85
pound feet).
6003-36
STEP 176 STEP 178
GD98M715 GD98M718
Position converter cover on converter housing. Make

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

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

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

against shoulder in cover. Secure using retaining
ring.

6003-37
STEP 180 NOTE: The following steps are for installation of
transmission control valve.
STEP 183
GD98M720
Tighten input flange hex head screws to a torque of

34 Nm (301 pound inches). Lock screws by bending
258
corners of lock plate over screws.
Install CAS2885 transmission valve adjustment tool
STEP 181 set. Be sure hex rods (par t of tool set) are not
installed on studs. Mount the gasket (1), intermediate
plate (2), and gasket (3).
STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 pound inches).
STEP 185
GD98M724
Install new sealing rings and both plugs in duct plate.
STEP 182
GD98M727
Install control valve on duct plate and CAS2885

studs. Install hex rods on studs and tighten against
control valve. Install 21 socket head screws. Tighten
screws to a torque of 9.5 Nm (84 pound inches).
Remove CAS2885 transmission valve adjustment
tool set. Install remaining two socket head screws.
Tighten screws to a torque of 9.5 Nm (84 pound
inches).
GD98M725
NOTE: The following steps are for the installation of
Install the gasket and place the duct plate against the filter.
shoulder. Install socket head screws and hex nuts.
Tighten to a torque of 25 Nm (221 pound inches).

6003-38
STEP 186 STEP 189
GD98M729 GD98M735
Install new O-rings in recesses of oil filter head. Apply grease to the new O-ring and install the speed
Position filter head on transmission and secure using sensor with the socket head screw. Tighten the screw
two socket head screws. Tighten screws to a torque to a torque of 23 Nm (204 pound inches).
of 25 Nm (221 pound inches).
STEP 190
STEP 187
GD98M736
GD98M730 With new O-rings, install the inductive transmitters.

Install a new transmission filter. Tighten to a torque of 30 Nm (265 pound inches).
STEP 188 STEP 191

Install the breather.
STEP 192
GD98M733
Install new O-rings in oil distribution covers. Install GD98M737

the two oil distribution covers on the housing with hex
Install the gasket and the cover plate. Tighten to a
nuts and flat washers. Tighten to a torque of 25 Nm
torque of 23 Nm (204 pound inches). With a new
(221 pound inches).
O-ring, install the screw plug. Tighten to a torque of
140 Nm (103 pound feet).
Section
6004
6004
FRONT AXLE

6004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISASSEMBLY OF DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DISASSEMBLY OF THE BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ASSEMBLY OF DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Determine Shim Thickness for a Perfect Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjust Rolling Moment of Drive Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6004-3
SPECIAL TOOLS
Planetary bearing puller collet set ............................................................................................................... CAS2881
Brake housing seal installer......................................................................................................................... CAS2880
Differential bearing cone puller collet set..................................................................................................... CAS2871
Differential bearing preload wrench ............................................................................................................. CAS2851
Brake housing inner bearing cup installer ................................................................................................... CAS2877
Brake housing outer bearing cup installer ................................................................................................... CAS2878
Brake housing inner bearing cup installer ................................................................................................... CAS2879
Wear ring installer adapter .......................................................................................................................... CAS2874
Wear ring installer adapter ......................................................................................................................... CAS2875
Pinion depth gauge set................................................................................................................................ CAS2872
Pinion depth gauge block ............................................................................................................................ CAS2873
Puller body and screw ................................................................................................................................. CAS2882
Support bracket ........................................................................................................................................... CAS2883
Slide hammer puller adapter ..................................................................................................................... CAS10846
Slide hammer ..............................................................................................................................................OEM4252
Replacer ...................................................................................................................................................... CAS2297
Magnetic base with indicator ................................................................................................................... CAS10066A
Heat gun .................................................................................................................................................... CAS10810
Lifting sling...................................................................................................................................................OEM4106
Engine stand................................................................................................................................................OEM4135
Snap ring pliers............................................................................................................................................OEM6484
Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288
Step plate ............................................................................................................................................................8061
Step plate ............................................................................................................................................................8067
Step plate ............................................................................................................................................................8073

6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)

6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015

6004-6
LUBRICATION
4 4
5
5
4 4
3 2
2 3
2 1 1
2
BS00M069 BS00M070
1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a
changed braking behavior.
A wear measurement has to be made on both wheel ends.
Remove screw plug, actuate brake and determine dimension “X” using a feeler gauge.
If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.
Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).

6004-7
WHEEL END AND BRAKES
Disassembly STEP 3
STEP 1
BD00M238
Pry the cover off the wheel end.

BD00M235
Fasten the axle on a stand. STEP 4
STEP 2
BD03B008
Use OEM4252 slide hammer and CAS10846-3

adapter, remove the slotted pin from wheel end lock
BD00M236
nut.
STEP 5
BD00M237
BD03B009
Loosen the screw plugs and drain the oil from the Using CAS2876 locknut socket and CAS2883
axle casting. support bracket, loosen and remove the locknut.

6004-8
STEP 6 STEP 9
BD00M241 BD00M244
Use acceptable lifting equipment and hold the wheel Remove the shim(s) from the sun gear shaft.
end in place. Loosen and remove the bolts.
STEP 10
STEP 7
BD00M245
BD03B010 Pull the sun gear shaft out of the planet gears.
Separate the wheel end from the axle casing.
STEP 11
STEP 8
BD03B011
BD00M243 Lift planet carrier out of the brake housing using
Pull the stub shaft out of the sun gear shaft. OEM4054 pulling attachment.
NOTE: Watch for released shim(s).

6004-9
STEP 12 STEP 15
BD03B012
Remove the snap rings from the planet gear shaft BD03B015
using OEM6492 snap ring pliers. Using suitable puller, remove planetary ring gear
from brake housing.
STEP 13
STEP 16
BD03B013
Remove the planet gear using CAS2848 gear puller

and 8061 step plate. BD03B016
Remove O-rings from the annular grooves of the ring

STEP 14 gear.
STEP 17
BD03B014
Remove the bearing from the planetar y using

CAS2881 collet set, CAS2882 puller body and screw, BD03B017
and 8061 step plate. Remove O-ring from recess of the brake housing.

6004-10
STEP 18 STEP 21
BD03B021
BD00M253 Use compressed air to raise piston out of the brake

Remove the brake disc pack from the brake housing. housing.
STEP 19 STEP 22
BD03B019
Drive slotted pins in the support shim until they are BD00M257
flush with the top of the support shim. Remove the support shim out of the piston.
STEP 20 STEP 23
BD03B020 BD03B022
Remove the circlip using OEM6484 external pliers. Drive slotted pins out of the support shim.

6004-11
STEP 24 STEP 27
BD00M259 BD00M262
Preload the cup springs using a press and remove Lift the piston out of the brake housing.
the retaining ring.
STEP 28
STEP 25
BD00M263
BD00M260 Remove and discard the guide ring, support rings

Pull the pin out of the support shim and remove the and U-rings from the grooves of the brake housing.
released cup springs.
NOTE: If replacing brakes only, go to step 44.
STEP 26 STEP 29
BD00M261
BD03B023
Press the gripping rings off of the pins.
Using CAS2850 puller bridge and 8073 step plate,
remove the brake housing from the wheel end shaft.

6004-12
STEP 30 STEP 32
BD03B024
Use acceptable lifting equipment and lift the brake BD00M267
housing from the wheel end shaft. Remove the shaft seal from the brake housing.
STEP 31 STEP 33
If the wheel end pressure ring or bearing needs to be
replaced, remove the bearing from the wheel end
shaft.
STEP 34
BD00M266
If necessary drive both bearing outer rings out of the

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

remove the pressure ring from the wheel end shaft.

6004-13
Assembly
STEP 35 handling heated parts.
SM121A
STEP 38
BD00M271
Install a new pressure ring on the wheel end shaft.
STEP 36 BD00M273
Heat the bearing inner ring and install it onto the

wheel end shaft.
STEP 39
BD01F107
Install the CAS2874 pressure ring installer adapter

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

outer ring into the brake housing using CAS2879.
STEP 40
Freeze the bearing outer ring. Press the bearing
outer ring into the brake housing using CAS2853.
BD01F105
Press the pressure ring over the collar of the wheel

end shaft using CAS2860 pressure ring installer.

6004-14
STEP 41 STEP 42
BD03B024
BD03B027 Use acceptable lifting equipment and install the

Use a solution of 50% water and 50% mineral spirits brake housing over the wheel end shaft until contact.
to wet the outer diameter of the shaft seal. Using
CAS2880 install the shaft seal with the sealing lip WARNING: Always wear heat protective
showing to the oil chamber. See illustration below. gloves to prevent burning your hand when
SM121A
STEP 43
BS00M073
SHAFT SEAL
BD00M277
1. BRAKE HOUSING
2. SHAFT SEAL Heat the bearing inner ring and install it into the
* GREASE FILLING brake housing until contact.

6004-15
STEP 44 STEP 45
BD00M263 BD00M279
Clean the groove of the brake housing with solvent.

Install the guide ring into the groove and fix it with
Loctite 415.
NOTE: Upon installation the guide ring must have
contact on the whole circumference and the orifice
must show upwards (12 o’clock).
STEP 46
BS00M072
1. BRAKE HOUSING 5. U-RING

2. GUIDE RING 6. SUPPORT RING
3. SUPPORT RING 7. WHEEL END SHAFT
4. U-RING
BD00M280
Install the guide ring, support rings and U-rings in the
Apply oil on the sliding surface of the piston. Care
grooves of the brake housing.
fully insert the piston into the brake housing.

6004-16
STEP 47
BD00M281
Insert the pins into the assembly fixture until contact.
STEP 48
BS00M074
1. PIN 4. SUPPORT SHIM

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

the assembly fixture.
ATTENTION: Observe the installation position,
install the gripping rings with the orifices offset by BD00M284
180° to each other. Insert the assembled pins into the support shim and
install the snap ring.
STEP 49
STEP 51
BD00M283
Install the cup springs onto the pins. See illustration BD00M285
below. Insert the assembled support shim into the piston.

6004-17
STEP 52 STEP 54
1
BD00M286 BD00M288
1. SPLINE
Install the circlip into the brake housing.
Drive the stop bolt into the planet carrier. Then coat
STEP 53 the spline with anti-corrosive antiseize.
STEP 55
BD03B028
BD00M289
Insert the planet carrier into the spline of the wheel

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

2. CIRCLIP 5. PISTON
X INSTALLATION DIMENSION
3. SLOTTED PIN
5.0 MM ± 0.5 MM
Drive slotted pins into the bores of the support shim
to lock the circlip.

6004-18
STEP 56 STEP 58
BD03B016
Grease both O-rings.
STEP 59
3
4
BS06A166
1. BRAKE PISTON 3. PLATE 4 MM

2. BRAKE DISC 4. PLATE 2 MM
BD03B030
Install the discs (2), plates (3), and plates (4) as Install two aligning dowels in the brake housing,
shown. Lubricate the brake disc with clean axle oil. install ring gear onto the brake housing.
NOTE: The number of brake discs may vary from NOTE: Make sure alignment is correct on ring gear.
your machine, the procedure is the same.
STEP 60
STEP 57
BD03B029
BD01C009
Insert O-ring into the recess of the brake housing. Heat the bearing inner rings with a hot air gun.

6004-19
WARNING: Always wear heat protective WARNING: Always wear heat protective
gloves to prevent burning your hand when gloves to prevent burning your hand when
handling heated parts. handling heated parts.
SM121A SM121A
STEP 61 STEP 63
BD00M292 BD00M294
Install the bearings with the big radius showing to the Heat the bearing inner rings and install into the
planet carrier (downwards). planet gears.
STEP 62 STEP 64
BD00M293 BD03B031
Put the planet gears onto the bearing inner rings. Install the snap rings on the planet gear shafts using
OEM6492 snap ring pliers.

6004-20
Adjust end play of sun gear shaft 0.5 to STEP 67
2.0 mm (0.02 to 0.08 inch)
STEP 65
BD00M298
Insert the sun gear shaft onto the stub shaft until
contact.
BD00M296
Determine dimension I, from the mounting face of the STEP 68

brake housing up to the face of the stop bolt.
Dimension I e.g. . . . . . . . . . . . 46.20 mm (1.82 inch)
STEP 66
BD00M299
Determine dimension II from the face of the sun gear

shaft up to the mounting face of the axle casing.
Dimension II e.g. . . . . . . . . . . 43.00 mm (1.69 inch)
BD00M297 Example:
Insert the stub shaft into the spline of the axle bevel Dimension I +46.20 mm (1.82 inch)
gear until contact.
Dimension II −43.00 mm (1.69 inch)
Difference 3.20 mm (0.13 inch)
Required end play e.g. − 1.00 mm (0.04 inch)
Difference = shim e.g. s = 2.20 mm (0.09 inch)

6004-21
STEP 69 STEP 72
BD00M245 BD00M300
Insert the sun gear shaft into the planet carrier. Install the washers and bolts by hand.
Tightening torque . . . . . . . 390 Nm (288 pound-feet)
STEP 70
STEP 73
BD00M244
Install the determined shim(s), e.g. S. = 2.20 mm BD03B033

(0.09 inch) into the sun gear shaft with grease. Install the locknut by hand and tighten it using
CAS2876 locknut socket and CAS2883 suppor t
STEP 71 bracket.
Tighten torque . . . 700+300 Nm (516 +221pound-feet)
STEP 74
BD03B032
Install O-ring and hold into place with grease, install

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

6004-22
STEP 75 STEP 76
BD00M303 BD00M304
1. O-RING
Insert the cover into the wheel end.
Install an O-ring on the cover.

6004-23
LEAKAGE TEST OF THE BRAKE HYDRAULICS

NOTE: Prior to start the test, ventilate the brake hydraulics and then actuate it several times.
High Pressure Test

STEP 77 Low Pressure Test
Reduce test pressure to p = 5 bar (72.5 psi) and
close the shutoff valve again.
During a 5 minute testing time a pressure drop is not
allowed.
BD00M305
Increase test pressure up to p =100 bar (1450 psi)

maximum and close connection to HD pump by
means of shutoff valve. During a 5 minute testing
time, a pressure drop of maximum 2 bar (29 psi) is
allowed.
ATTENTION: If the maximum pressure of 100 bar
(1450 psi) is exceeded, there will be an excessive
piston adjustment and a repeated disassembly of the
brake or the adjusting is required to reset the gripping
rings to the adjusting dimension.

6004-24
DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES

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

Remove O-ring.
STEP 5
BD00M237
Loosen the screw plugs and drain the oil from the
axle casing.
BD00M243
Pull the stub shaft out of the sun gear shaft. Repeat
steps 3 through 5 for the other wheel end.
NOTE: Pay attention to the released shim(s).

6004-25
STEP 6 STEP 9
BD00M395 BD00M398
Remove the bolts from the differential carrier. Drive out the slotted pins from the differential carrier.
NOTE: Mark the location of the differential carrier to
the axle casing. STEP 10
STEP 7
BD01F072
Loosen and remove both adjusting nuts using

CAS2851 wrench.
BD03B035
Use suitable lifting equipment and lift the differential

carrier out of the axle casing. STEP 11
STEP 8
BD00M400
Heat the axle drive housing with a hot air gun.

BD03B036 NOTE: Bolts are installed with Loctite.
Fasten the differential carrier on OEM4135 engine
stand using CAS2847 mounting bracket.

6004-26
STEP 12 STEP 13
BD00M401 BD00M402
Loosen the bolts and take off both bearing brackets. Remove both bearing outer rings from the differential
carrier.
NOTE: Make an alignment mark between the
bearing bracket and the housing.
STEP 14
ATTENTION: Loosen the bolts by hand only.
BD00M403
Use acceptable lifting equipment and lift the

differential out of the differential carrier.

6004-27
DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL

STEP 15 STEP 17
BD00M406
Place the differential in a press to prevent it from

BD01F089
turning. Remove the bolts and the released housing
Using CAS2294 cone puller and 8065 step plate,
cover.
remove the bearing inner ring from the differential
housing.
STEP 18
STEP 16
BD00M407
Remove all the single parts from the differential

housing.
BD01F096
Remove the bearing inner ring from the housing STEP 19

cover using CAS2294 cone puller and 8065 step
plate.
BD00M408
Press off the ring gear from the differential housing.

6004-28
DISASSEMBLY OF DRIVE PINION

STEP 20 STEP 23
BD00M409 BD00M412
Heat the pinion shaft locknut with a hot air gun. Remove the shaft seal from the differential carrier.
NOTE: Locknut is held with Loctite Type No. 262.
STEP 24
STEP 21 Use a rubber hammer to remove the drive pinion out
of the differential carrier.
STEP 25
Take off the spacer ring and pull the bearing inner
ring from the drive pinion shaft.
STEP 26
BD01F091
Using CAS1579A yoke holding wrench, loosen the

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

the differential carrier.
BD00M411
Pull the input yoke from the drive pinion shaft.

6004-29
DISASSEMBLY OF THE BRAKE TUBES

STEP 27 STEP 30
BD00M334 BD00M337
Remove the screw plug with the vent valve from the Disconnect the pipe union and remove the released
axle casing. brake tube from the axle casing.
STEP 28 STEP 31
BD00M335 BD00M338
Loosen and remove the hexagon screw from the Remove the vent valve from the connection part.
axle.
STEP 32
STEP 29
BD00M339
BD00M336 Loosen the connection part and remove it from the

Loosen and remove the union screw from the axle. axle. Repeat steps 28 to 32 for the other wheel end.

6004-30
ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER

STEP 33 STEP 36
1 2
3
4
BD00M340 BD00M343
1. O-RING
1. VENT 2. CONNECTION 3. O-RING 4. RECTANGULAR
VALVE PART RING Install an O-ring into the groove of the brake tube.
Assemble the part as shown in the photo above.
STEP 37
STEP 34
2
1
BD00M344
1. BRAKE TUBE
BD00M341
2. UNION SCREW
Install the connection part on the axle casing.
Tightening torque . . . . . . . . .130 Nm (96 pound feet) Insert the brake tube into the axle casing, assembling
the connection part through the union screw.
STEP 35
BD00M342
Install the union screw with a new O-ring on the axle.


6004-31
STEP 38 Assemble the screw plug as shown in the above
photo.
STEP 41
BD00M345
Fasten the brake tube with the hexagon nut and

union nut.
Tightening torque . . . . . . . . . 70 Nm (52 pound-feet) MD00M348
Install the screw plug on the axle casing.

STEP 39 Tightening torque . . . . . . . . 70 Nm (52 pound-feet)
BD00M346
Tightening torque . . . . . . . . . 80 Nm (60 pound-feet)
NOTE: Repeat steps 33 to 39 for the other wheel
end.
STEP 40
1
2
BD00M347
1. O-RING
2. SCREW PLUG
3. VENT VALVE

6004-32
ASSEMBLY OF DIFFERENTIAL CARRIER

NOTE: If the ring gear or drive pinion are damaged, STEP 44
both parts have to be replaced together. For new
installation of a complete bevel gear set pay attention
to the same pair number of drive pinion and ring
gear.
Determine Shim Thickness for a

Perfect Tooth Contact Pattern
NOTE: Make the following measuring steps at
maximum accuracy. In exact measurements result in
a faulty tooth contact pattern and require a repeated
disassembly and assembly of the drive pinion as well
as of the differential.
BD00M350
STEP 42 Determine Dimension I (bearing width).

Install the CAS2873 pinion depth gauge block and Dimension I e.g. . . . . . . . . . . 36.00 mm (1.417 inch)
CAS2289-1 gauge tube on the differential carrier.
STEP 45
STEP 43
BD00M351
1. 168.0 +0.05
BD01F106
Determine the gap between the measuring shaft and Read Dimension II (dimension for pinion).
the measuring pin with a feeler gauge. Dimension II e.g. . . . . . . . . . 168.05 mm (6.62 inch)
Dim. B e.g. . . . . . . . . . . . . . . . 1.00 mm (0.039 inch) Example B:
Example A.: 36.00 mm
Dimension I
204.25 mm ------(1.417 inch)
Dimension A (tool constant)
------(8.041 inch) +168.05 mm
Dimension II
+1.00 mm ------(6.616 inch)
Dimension B (gap)
------(0.039 inch) s = 204.05 mm
Results in Dimension Y
s = 205.25 mm -----(8.04 inch)
Results in Dimension X
-----(8.08 inch)
Example C:
Dimension X 205.25 mm (8.081 inch)
Dimension Y −204.05 mm (8.033 inch)
Difference = Shim e.g. s = 1.20 mm (0.048)

6004-33
Install the Drive Pinion STEP 49
STEP 46
BD01F065
Press the bearing inner ring on the drive pinion shaft

BD00M352
using CAS2297 and 8073 step plate.
Place the determined shim e.g. S. =1.20 mm (0.05
inch) into the bearing bore in the differential carrier.
STEP 47
BD01F063
Freeze the bearing outer ring and insert into the

differential carrier using CAS2293-1, CAS2293-2,
and 8073 step plate.
STEP 48
BD01F087
Freeze the bearing outer ring on the input side and

install using CAS2293-2 and 8073 step plate.

6004-34
Adjust Rolling Moment of Drive STEP 52

Pinion Bearing
STEP 50
BD01F101
Press the dust shield onto the input yoke using

CAS2882 puller tube.
BD00M356
Install the spacer ring on the pinion shaft. STEP 53

NOTE: As per experience the required rolling
movement is obtained by use of the spacer ring [e.g.
s=8.70 mm (0.34 inch)] available at disassembly.
However, a later checking of the rolling movement
must be done.

SM121A
STEP 51
BD00M359
Install the input yoke on the pinion shaft.
STEP 54
BD00M357
Insert the assembled drive pinion into the differential

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

6004-35
STEP 55 STEP 58
BD01F091 BD01F098
Install the locknut by hand. Using CAS1579A yoke Using CAS2288 and CAS2299, install the shaft seal
holding wrench tighten the locknut. with the sealing lip showing to the oil chamber
Tightening torque . . . . . . . 700 Nm (516 pound-feet) (downwards).
NOTE: When tightening rotate the drive pinion in ATTENTION: Just before the installation wet the
both directions several times. outer diameter of the shaft seal with a solution of
50% water and 50% mineral spirits. Fill the space
STEP 56 between the sealing and dust lip with grease.
STEP 59
BD00M362
Check rolling movement. Rolling movement should

be 1.5 to 3.0 Nm (1.10 to 2.21 pound-feet). BD01F091
Put the input yoke in place and install the washer and
NOTE: For new bearings it should be tried to locknut. Using CAS1579A yoke holding wrench
achieve the maximum value of the rolling movement. tighten the locknut.
ATTENTION: If the required rolling movement is not Tighten torque . . . . . . . . . 700 Nm (516 pound-feet)
obtained, correct it with an adequate spacer ring, ATTENTION: Apply Loctite, Type No. 262, onto the
according to the following indications: thread of the locknut.
Rolling movement too low - install a thinner spacer
ring.
Rolling movement too high - install a thicker spacer
ring.
STEP 57
Remove the locknut again and pull off the input yoke
from the drive pinion shaft.

6004-36
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL

STEP 60 STEP 63
BD00M427 BD00M430
Place both thrust washers into the differential Insert the axle bevel gear and slide the splined shaft
housing. into the clutch discs.
STEP 61 STEP 64
BD00M428 BD00M431
Starting with an outer clutch disc install alternately Assemble the differential spider and insert it into the
the outer and inner clutch discs. differential housing.
ATTENTION: Thickness of the disc pack must be
identical on both sides. STEP 65
STEP 62
BD00M432
Insert the second axle bevel gear.

BD00M429
Insert the pressure ring into the differential housing.

6004-37
STEP 66 Determine the Disc Clearance
STEP 68
BD00M433
Insert the second pressure ring into the differential

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

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

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

the outer clutch disc to the mounting face of the
housing cover.
Dimension II e.g. . . . . . . . . . . 37.75 mm (1.48 inch)
38.05 mm
Dimension I
-------(1.50 inch)
+ 37.75mm
Dimension II
-------(1.49 inch)
= 0.30 mm
Difference = Disc clearance
------(0.01 inch)
NOTE: If the required disc clearance is not obtained,
correct it with the adequate outer clutch discs [s=2.1,
s=2.2, s=2.3, s=2.4 or s=2.5 mm (0.083, 0.087,
0.091, 0.094, 0.098 inch)], taking care that the
difference in thickness between the left and the right
disc pack must only be 0.1 mm (0.004 inch) at a
maximum.
6004-38
STEP 70 STEP 73
BD00M437 BD00M440
Fix the thrust washer with grease into the recess of Press both bearing inner rings onto the differential
the differential housing cover. housing.
STEP 71 STEP 74
BD00M438 BD00M441
Put the housing cover in place on the differential Use acceptable lifting equipment and insert the
housing. Heat the ring gear and install onto the differential into the differential carrier.
differential housing.
STEP 75
STEP 72
BD00M442
BD00M439 Place the bearing outer ring into the differential

Put the differential in a press to prevent it from carrier.
turning and install the bolts on the ring gear.
ATTENTION: Use new locking bolts.

6004-39
STEP 76 STEP 79
BC00M443 BD00M446
Install the adjusting nut by hand on the differential Install both bearing brackets and install the bolts and
carrier. washers.
Tighten torque . . . . . . . . . 280 Nm (207 pound-feet)
STEP 77
ATTENTION: Apply Loctite Type No. 262 onto
threads of the bolts.
BD00M444
Install the ring gear sided bearing outer ring.
STEP 78
BD00M445
Install the adjusting nut by hand on the differential

carrier.

6004-40
Adjust Backlash and Bearing STEP 82

Preload Tighten the adjusting nut slowly until firm contact is
made with the bearing.
STEP 80 NOTE: As the adjusting nut makes firm contact with
the bearing, the adjusting nut will immediately begin
to turn much harder.
STEP 83
To adjust the bearing preload, note the position of the
adjusting nut. Now tighten the nut two additional
notches.
STEP 84
As the bearing preload is adjusted as described in
steps 81, 82 and 83, pinion to ring gear backlash
may increase slightly. Check pinion backlash to
BD00M447
confirm that it is within specifications. If backlash is
Place a dial indicator right-angled at the outer outside of specified range, repeat step 80 through 84
diameter of the tooth flank (ring gear). again.
Adjust the pinion to ring gear backlash to the low side STEP 85
of specifications (see value etched on the outer
diameter of the ring gear) by alternately turning each
of the adjusting nuts to move the ring gear closer to
or further away from the pinion. Backlash is checked
using a dial indicator against a tooth on the ring gear.
NOTE: Rotate the differential several times and
recheck the backlash.
STEP 81
BD00M449
Coat several teeth on the ring gear with marking ink

and roll the ring gear in both directions over the drive
pinion.
Compare the obtained tooth contact pattern with the
examples on page 4 and 5.
ATTENTION: If the tooth contact pattern differs,
there has been a measuring error at determination of
BD01F072
the shim. This must be corrected.
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release
pressure on the bearing. It should be very noticeable
that pressure is released on the bearing, as the
adjusting nut will turn much easier.

6004-41
STEP 86 1.
BD00M450 BD00M453
Install both adjusting nuts with the slotted pins on the Insert the stub shaft into the spline of the axle bevel
differential carrier. gear.
STEP 87 STEP 89
BD03B035 BD00M454
Use suitable lifting equipment and inser t the Install the thrust washer removed at disassembly in
differential carrier into the axle casing. the sun gear shaft with grease.
NOTE: Align the two alignment marks together.
ATTENTION: Apply sealing compound on the
mounting surface.
STEP 88
BD00M452
Install new bolts on the differential carrier.

Tighten torque . . . . . . . . . 250 Nm (185 pound-feet)
6004-42
STEP 90 STEP 91
BD03B032 BD00M456
Install O-ring and hold into place with grease. Use Install the bolts and washers on the wheel end.
acceptable lifting equipment and place the wheel end Tightening torque . . . . . . . 390 Nm (288 pound-feet)
on the axle housing.
NOTE: Repeat steps 1 to 91 for the other wheel end.
NOTE: Prior to putting into operation of the axle, fill
with oil. See section 1002.

Section
6004
6004
REAR AXLE

6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REPLACE HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6004-3
SPECIFICATIONS
Lubricant Capacity............................................................................................................ 26.5 liters (28 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ......................................10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim .........................................................................4.0 to 4.5 mm (0.15 to 0.18 inch)
Sun Gear Shaft End Play.............................................................................................................1.00 mm (0.04 inch)
Drive Pinion Rolling Torque ................................................................................. 1.5 to 3.0 Nm (13.2 to 26.5 lb-inch)
Differential Carrier Disc Clearance ..............................................................................................0.40 mm (0.02 inch)
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing......................................................................... 440 Nm (325 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads).................................................. 700 Nm (516 pound feet)
Bolts Securing Differential Ring Gear .................................................................................. 390 Nm (288 pound feet)
Bolts Securing Axle Housing to Center Section .................................................................. 290 Nm (215 pound feet)
Locknut Securing Planetary Carrier................................................................................... 1000 Nm (737 pound feet)
SPECIAL TOOLS
Slide hammer puller adapter . . . . . . . . . CAS10846-3
Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252
Pressure Ring Installer . . . . . . . . . . . . . . . CAS2860
Planetary Bearing Puller . . . . . . . . . . . . . . CAS2881
Planetary Bearing Puller . . . . . . . . . . . . . . CAS2849
Bearing Cone Puller . . . . . . . . . . . . . . . . . CAS2843
Bearing Cone Puller Body . . . . . . . . . . . . . CAS2844
Pinion Shaft Seal Installer . . . . . . . . . . . . . CAS2841
Seal Driver. . . . . . . . . . . . . . . . . . . . . . . . . CAS2859
Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . CAS2510
Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . OEM4106
Wheel Nut Socket . . . . . . . . . . . . . . . . . . 380100000
Bearing Cup Installer . . . . . . . . . . . . . . . . 380100001

6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)

6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015

6004-6
LUBRICATION
6
4
3
5
5
4
6
2
1
BC06G003
1. OIL DRAIN HOLE (AXLE HOUSING) 3. OIL FILL PLUG & DIPSTICK 5. BREATHER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER 6. BRAKE INLET
NOTE: Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement
should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking
function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 50 Nm (40 pound feet).

6004-7
WHEEL END AND BRAKE
Disassembly STEP 3
NOTE: Tools and axle shown in the following
photographs may appear slightly different than the
tools and axle you may have. The use of the tools
and disassembly/assembly of axle is the same
regardless of appearance.
STEP 1
BD06G004
Use lifting bracket, OEM4106, to hold wheel end.

Loosen and remove the bolts and washers.
STEP 4
Carefully pull the wheel end from the axle housing.
Remove and discard O-ring from axle housing wheel
end.
BD06G001
Fasten axle on a stand.

STEP 5
STEP 2
BD06G005
Mount the wheel end on a stand.

BD06G002
BD06G003
Remove drain plugs and drain oil from axle housing.

6004-8
STEP 6 STEP 9
BD06G006 BD06G009
Using pry bar, remove cover from output shaft. Using OEM4054 pulling attachment, remove the
Remove and discard O-ring from cover. planetary carrier.
STEP 7 STEP 10
BD06G007 BD06G012
Remove pin from lock nut using OEM4252 slide Remove retaining ring.
hammer and CAS10846-3 adapter.
STEP 11
STEP 8
BD06G013
BD06G008 Using CAS2848 planetary gear puller and step plate

Remove lock nut using socket 380100000. 8061, remove planetary gear and outer bearing from
planetary carrier shaft. Using a suitable puller,
remove the inner bearing from carrier shaft.

6004-9
STEP 12 STEP 15
BD06G014
Remove the bearing from the planetar y using BD00M250

CAS2881 collet set, CAS2849 puller body and screw. Put alignment marks on planetary ring gear and
brake housing to aid in assembly. Using suitable
STEP 13 puller, remove planetar y ring gear from brake
Repeat Steps 10, 11, and 12 to remove the housing.
remaining three retaining rings, planetary gears, and
six bearings. STEP 16
STEP 14
BD00M251
Remove and discard two O-rings from planetary ring

BD06G015 gear.
Inspect the stop pin for wear, if necessary drill a hole
into the pin, use CAS10846-3 adapter and OEM4252 STEP 17
striker and remove the pin.
BD06G017
Remove and discard O-ring from brake housing port,

remove the brake disc pack from brake housing.

6004-10
STEP 18 STEP 21
BD06G020
BD06G018
Using suitable tool, push the three pins down until Remove the support shim from the brake piston.
pins are even with top surface of shim.
STEP 22
STEP 19
BD06G022
BD06G047 Remove three pins from support shim.

STEP 23
STEP 20
BD06G023
BD06G019 Put support shim in a press and compress Belleville

W E A R FAC E P R OT E C T I O N W H E N U S I N G washers. Remove retaining ring and pull pin with
COMPRESSED AIR. Apply compressed air to brake Belleville washers and rings installed from support
housing por t to push brake piston from brake shim. Repeat this step to remove the remaining five
housing. retaining rings and pins from support shim.

6004-11
STEP 24 STEP 27
BD00M260 BD00M263
Remove seven Belleville washers from each pin.
STEP 25
BD06G024
BS00M072
Using a press, remove four gripping rings from each
pin. 1. BRAKE HOUSING 5. GROOVED RING
2. GUIDE RING 6. SUPPORT RING
3. SUPPORT RING 7. WHEEL END SHAFT
STEP 26 4. GROOVED RING
Remove the guide ring (2), support rings (3 and 6),
and U-rings (4 and 5) from the grooves of the brake
housing.
BD00M262
Lift and remove the piston from the brake housing.

6004-12
STEP 28 STEP 31
BD01F102A BD06G028
Using the CAS2850 brake housing puller bridge and Remove the face seal from the brake housing.
CAS2510 step plate, pull the brake housing from the
wheel end shaft and remove the inner bearing. STEP 32
STEP 29
BD06G029
Remove and discard the face seal metal ring from

BD06G026
the wheel end shaft.
Use acceptable lifting equipment and lift the brake
housing from the wheel end shaft. STEP 33
If the wheel end pressure ring or bearing need to be
STEP 30 replaced, remove the bearing from the wheel end
shaft.
BD06G027
If replacement of bearing cups is necessary, drive

both bearing cups out of the brake housing.

6004-13
Cleaning and Inspection Assembly

IMPORTANT: Do not use compressed air to dry
bearings. Allow bearings to air dry. STEP 39
STEP 34
Clean all parts except friction plates in brake disc
p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FAC E
PROTECTION WHEN USING COMPRESSED AIR.
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 35
I n s p e c t b e a r i n g r o l l e r s fo r p i t t i n g , s c o r i n g ,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
da ma ge. Che ck asso ciat ed b e ar ing cup s for BD06G033
scratches, grooves, or cracks. Check bearings for Apply Loctite 574 to the seal ring mounting surface.
rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth, WARNING: Always wear heat protective
replace the bearing. gloves to prevent burning your hand when
STEP 36 SM121A
Inspect bearing cups for pitting, scoring, cracks, or

other damage. Replace if any of these conditions are STEP 40
seen.
NOTE: If a bearing or bearing cup requires
replacement, the associated part must also be
replaced.
STEP 37
Check planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of
these conditions are seen. Check planetary carrier
shaft splines for bro ken, cracke d, or twisted
condition. Replace if necessary.
BD06G034
STEP 38 Heat the seal ring to approximately 120° C (248° F),

place the face seal ring on the wheel end shaft.
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.

6004-14
STEP 41 STEP 43
BD06G035 BD06G037
Use special tool CAS2860 and drive the busing into Using CAS2877 inner bearing cup installer, press the
position onto the hub. inner bearing cup into the brake housing until seated
against the shoulder in the brake housing.
NOTE: Only use the special tool to install the sealing
ring to ensure proper seating.
STEP 44
STEP 42 Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
WARNING: Always wear heat protective against the shoulder in the brake housing.
SM121A
BD06G036
Heat the wheel end shaft outer bearing to 120° C

(248° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the shoulder on
the wheel end shaft.

6004-15
STEP 45 STEP 47
SM121A
BD06G032
A A
A 1
BD06G039
Heat the wheel end shaft inner bearing to 120° C

(248° F) in a bearing oven. Wearing heat resistant
2 gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the bearing cup
in the brake housing.
BS00M073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use
CAS2880 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to
seal as indicated by (A) above.
STEP 46
BD06G038
Use acceptable lifting equipment and install the

brake housing on the wheel end shaft.

6004-16
STEP 48 STEP 49
A B
BD00M278 BD00M279
Clean the groove of the brake housing with cleaning

solvent. Install the guide ring in the groove. Make
sure the ends (A) of the guide ring are facing up
towards the top (B) of the brake housing and the
guide ring is installed completely in its groove in the
brake housing. Apply Loctite 415 to ID of guide ring
to secure guide ring in its groove.
STEP 50
BC06G002
GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION
1. SUPPORT RING 4. SUPPORT RING

2. GROOVED RING 5. GUIDE RING
3. GROOVED RING A. BRAKE HOUSING
BD00M280
Install the support rings and U-rings in the grooves of Apply oil on the sliding surface of the piston, support
the brake housing. rings, U-rings and guide ring. Carefully install piston
in the brake housing.

6004-17
STEP 51 STEP 53
BD00M282 BD00M284
1. GRIPPING RINGS
Put the assembled pins into the support shim and
Press the gripping rings on the pins. Ends of gripping install the snap ring.
rings must be 180° opposite from each other.
STEP 54
STEP 52
BD00M283
BD00M285
5 4 Put the assembled support shim in the piston.
STEP 55
3
A
2
BS00M074
1. PIN 4. SUPPORT SHIM

2. GRIPPING RINGS 5. RETAINING RING
3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43
INCH)
BD00M286
Install the Belleville springs on the pins. Make sure Install the snap ring to secure the support shim, slot
dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch). of the snap ring must be between two pins.

6004-18
STEP 56 STEP 58
BD00M287 BD06G051
Apply grease to new O-ring and install in the brake

A housing port.
STEP 59
BS00M075
1. BRAKE HOUSING 4. SUPPORT SHIM

2. SNAP RING 5. PISTON
3. PIN A. 4.0 TO 4.5 MM
(0.15 TO 0.18 INCH)
BD00M251
Install the six pins (3) in the support shim (4) to lock Apply grease to new O-rings and install on planetary
the snap ring (2). Dimension (A) between top of pins ring gear.
(3) and top of support shim (4) must be 4.5 to 5.0 mm
(0.18 to 0.20 inch). STEP 60
STEP 57
BD06G052
Install two alignment studs in the brake housing.

BD06G049
Position the planetar y r ing gear on the brake
Apply oil to the clutch discs. Install the outer and
housing. Make sure alignment marks made during
inner clutch discs alternately starting with an outer
disassembly are aligned. Use a soft faced hammer
clutch disc.
and tap the planetary ring gear into brake housing.

6004-19
STEP 61 STEP 64
SM121A
BD06G053
If removed, drive the stop bolt into the planetary

carrier until contact.
STEP 62
BD06G055
WARNING: Always wear heat protective Heat the planetary gears outer bearings to 120° C
gloves to prevent burning your hand when (248° F) in a bearing oven. Wearing heat resistant
handling heated parts. gloves or mittens, install the bearings on the shafts
SM121A until the bearing is against the gear.
STEP 65
BD06G054
Heat the planetary gears inner bearings to 120° C

(248° F) in a bearing oven. Wearing heat resistant BD06G056
gloves or mittens, install the bearings on the shafts Install the retaining rings on the planetary gear
until the bearing is against the bottom of the shaft. shafts.
STEP 63
Install the planetary gears on the bearings.

6004-20
STEP 66 STEP 69
BD06G057 BD06G060
Coat the spline with Loctite No. 767 antiseize Rotate the housing until the planet carrier gears are
lubricant. flush with the ring gear.
STEP 67 STEP 70
BD06G058 BD06G061
Align the slots of the brake disks. Pivot the housing on the stand and install the lock
nut.
STEP 68
STEP 71
BD06G059
Install the planet carrier into the spline of the wheel BD06G062
end shaft using OEM4054. Tighten the lock nut to a torque of 1000 Nm (737
pound feet) using socket 380100000, rotate the
brake housing several time in both directions and
recheck torque.

6004-21
STEP 72 STEP 74
BD06G063 BD06G065
Install a new slotted pin into the wheel end lock nut. Install the cover into the wheel end.
NOTE: If the slot is not aligned tighten the nut to
align the slot, never loosen the nut to align the slot.
STEP 73
BD06G064
Install a new O-ring on the wheel end cover.

6004-22
Sun Gear Shaft End Play Adjustment STEP 79
STEP 75
BD06G068
Determine dimension B from the face of the stub

BD06G066 shaft to the mounting face of the axle housing.
Using two M18 bolts of suitable length, secure Example:
planetary ring gear to brake housing.
Dimension B . . . . . . . . . . . . . 100.20 mm (3.95 inch)
STEP 76 STEP 80
Take a measurement from the straight edge to the
Subtract dimension A from dimension B. Then
face of the planetar y gear ring, the difference
subtract 1.30 mm (0.05 inch) from the difference. The
between this measurement and the measurement in
difference is the required shim size.
the next step will be dimension A.
Example:
STEP 77 Dimension B 100.20 mm (3.94 inch)
Dimension A −97.90 mm (3.85 inch)
Difference 2.30 mm (0.09 inch)
Required end play − 1.30 mm (0.05 inch)
Difference = shim
1.00 mm (0.04 inch)
size
STEP 81
BD06G067
Mount the sun gear into the planet gears. Then,

determine dimension A, from the inner face of the
sun gear to the face of the planetary ring gear.
Example:
Dimension A . . . . . . . . . . . . . 97.90 mm (3.85 inch)
BD06G069
STEP 78
Install the shim set (size as determined in Step 80
Install the stub shaft in the spline of the axle bevel
above) into the sun gear shaft with grease.
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear.

6004-23
STEP 82 STEP 84
BD06G072
BD06G070. Use lifting bracket, OEM4106, and install the

Remove the two M18 bolts securing the planetary assembled wheel end onto the axle housing.
ring gear to brake the housing.
NOTE: Turn the input flange to align splines of the
stub shaft into the sun gear.
STEP 83
STEP 85
BD06G071
Apply grease to a new O-ring and install O-ring in

BD00M300
brake port.
Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of
440 Nm (325 pound feet).

6004-24
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 High Pressure Test
PSI) PRESSURE IN THE FOLLOWING STEPS. If
the maximum pressure of 100 bar (1450 psi) is
STEP 87
exceeded, the piston will move too much changing
the gripping rings adjustment. If the gripping rings Operate the hand pump to increase pressure to 100
adjustment changes, the wheel end must be bar (1450 psi) maximum. Close connection to hand
removed and disassembled and the gripping rings pump using the shutoff valve. During a 5 minute
adjusted to the correct dimension (Step 51). period, pressure shall not drop more than 2 bar (29
psi).
STEP 86
Low Pressure Test
STEP 88
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
BD00M305
Connect a hand pump with pressure gauge to the

brake port as shown above. Fill the hand pump with
hydraulic oil. Build up pressure in the axle internal
brake lines then bleed air from the lines. After air is
bled, actuate the brakes a minimum of 5 times to a
pressure of 100 bar (1450 psi) by operating the hand
pump.

6004-25
REPLACE HUB SEAL
Removal STEP 92
STEP 89
BD06G077
Loosen and remove the lock nut using socket

BD06G074
380100000.
Remove drain plug and drain oil from the brake
housing. STEP 93
STEP 90
BD06G078
BD06G075
Use lifting bracket, OEM4106, to hold wheel end.
Use pry bar and remove the end cover. Separate the output shaft using a puller.
STEP 91 STEP 94
BD06G076
BD06G079
Use a slide puller and remove the slotted pin from the
lock nut. Use a pry bar and remove the seal form the brake
housing.

6004-26
STEP 95 STEP 98
BD06G080 BD06G082
Inspect the bushing for wear marks where the seal Put a bead of Loctite 574 on the bushing mounting
makes contact, if required remove the bushing. surface.
STEP 96 gloves to prevent burning your hand when
SM121A
BC06G005
Install the seal as shown above with wipers (3) facing
out towards bushing (4).
BD06G083
Heat the bushing to 120° C (248° F) and place the
STEP 97 bushing onto the output shaft.
BD06G081
Lubricate the outer diameter of the seal with water,
use driver CAS2859 and install the seal.

6004-27
STEP 100 STEP 103
BD06G084 BD06G087
Use special tool CAS2860 and drive the busing into Install the lock nut, tighten the lock nut to a torque of
position onto the hub. 1000 Nm (737 pound feet) using socket 380100000,
rotate the brake housing several time in both
NOTE: Only use the special tool to install the sealing
directions and recheck torque.
ring to ensure proper seating.
STEP 104
STEP 101
BD06G088
BD06G085
Install a new slotted pin into the wheel end lock nut.
Heat the inner bearing to 120° C (248° F).
NOTE: If the slot is not aligned tighten the nut to
STEP 102 align the slot, never loosen the nut to align the slot.
STEP 105
BD06G086
Grease the seal lip of the shaft seal, use lifting
bracket, OEM4106, and install the wheel end onto BD00M304
the brake housing. Install a new O-ring on the wheel end cover, install
the cover into the wheel end.

6004-28
DIFFERENTIAL
Removal STEP 108
STEP 106
BD06G127
Connect lifting equipment to the differential and

BD06G002
remove the differential from axle housing.
NOTE: Make sure that the right axle stub shaft
releases from the differential.
Disassembly
STEP 109
BD06G003
Remove drain plugs and drain oil from axle.
STEP 107
BD01F059
Remove the bearing from the differential housing

using CAS2848 puller, OEM4175 pulling attachment,
1103 puller legs, and 8065 step plate.
BD06G126
Fasten the axle to a stand, support the center of the

axle as shown, facing the input shaft attach suitable
lifting equipment to the left axle housing, remove the
mounting bolts and axle half.
ATTENTION: Differential can fall out of housing
when axle half is removed.
6004-29
STEP 110 STEP 113
BD01F075 BD06G129
Remove the bearing from the housing cover using Remove all parts from the differential housing.
CAS2871 collet set, CAS2882 puller body, and 8067
step plate. STEP 114
STEP 111
BD00M326
BD00M323 Press the ring gear from the differential housing.

Place the differential in a press to prevent it from
turning. Remove the bolts. STEP 115
STEP 112
BD06G131
Pull the outer bearing ring and shims from both axle
BD00M324 housings.
Remove the housing cover from the differential
NOTE: Make sure to identify the shims into which
housing.
axle housing they were removed.

6004-30
8
7
6
5
3 4
2
1
9
10
12 1
4
3
11
5
6
8 7
BC06G001
1. BEARING 5. OUTER CLUTCH 9. PINION, BEVEL

2. HOUSING 6. PLATE 10. SHAFT
3. WASHER, THRUST 7. DIVIDER 11. COVER
4. SHIM 8. GEAR, BEVEL 12. BOLT, M15 X 45

6004-31
Assembly STEP 118

NOTE: The ring gear and the drive pinion are a
matched gear set and cannot be serviced separately.
STEP 116
SM121A
BD06G151
Install the disk package starting with an outer clutch,

refer to illustration on page 30.
STEP 119
BD06G149
Heat the ring gear to 120° C (248° F) in a bearing

oven. Wearing heat resistance gloves or mittens,
install the ring gear on the differential.
NOTE: Make sure to align the bolt holes.
STEP 117
BD06G152
Install the divider in the differential housing.
STEP 120
BD06G150
Install both thrust washers into the differential carrier,

the brass thrust washer must be towards the bevel
gear as shown, refer to illustration on page 30.
NOTE: Be sure to apply oil to all parts before BD06G153
assembly. Install the axle bevel gear. Make sure axle bevel gear
splines mate with splines of all inner clutch plates.

6004-32
STEP 121 STEP 124
BD06G154 BD06G157
Assemble the differential spider and install into the Starting with an clutch plate, install alternately the
differential housing. plate and outer clutch.
NOTE: Thickness of disc packs must be the same
STEP 122 on both sides.
Determine Disc Clearance
STEP 125
BD06G155
Install the second axle bevel gear.
STEP 123 BD06G158
Determine dimension A, from mounting face of the

differential housing to face of the outer clutch disc.
Dimension A (Example). . . . . . 38.05 mm (1.50 inch)
BD06G156
Install the second divider in the differential housing.

6004-33
STEP 126 STEP 128
BD06G159 BD06G161
Determine dimension B, from contact surface of the Place the differential in a press to prevent it from
outer clutch disc to mounting face of the housing turning. Install new bolts and tighten bolts to a torque
cover. of 390 Nm (288 pound feet).
Dimension B (Example). . . . . . 37.65 mm (1.48 inch) NOTE: Use new bolts only.
Example B:
38.05 mm STEP 129
Dimension A
-------(1.50 inch)
+37.65 mm
Dimension B
-------(1.48 inch)
= 0.40 mm
Difference = Disc clearance
------(0.02 inch)
NOTE: If required disc clearance of 0.040 mm (0.02
inch) is not obtained, install new outer clutch discs of
thickness necessary to obtain 0.040 mm (0.002 inch)
disc clearance. The left and right clutch packs must
be the same thickness. Outer clutch discs are
available in following thicknesses: 2.9 mm (0.114
inch), 3.0 mm (0.118 inch), 3.1 mm (0.122 inch).
STEP 127 BD06G162
Press both bearings on the differential.
BD06G160
Install the thrust washers with grease in the recess of

the housing cover.
NOTE: Mount the brass thrust washer (on top)
towards the bevel gear.

6004-34
Drive Pinion Removal STEP 134

STEP 130
Heat lock nut securing flange with a hot air blower to
loosen Loctite, approximately 120° C (248° F).
STEP 131
BD06G134
Press the input pinion out of the housing.
STEP 135
BD06G132
Install holding wrench on input flange. Hold flange

using holding wrench, CAS1579A, and remove lock
nut and washer. Remove holding tool from flange.
STEP 132
Remove the input flange from the drive pinion.
STEP 133
BD06G135
Remove the spacer ring from the drive pinion.
STEP 136
BD06G133
Remove the shaft seal from the axle drive housing.
BD06G136
Press the bearing inner ring from the drive pinion

using CAS2843 and CAS2844 puller body and collet
set.
STEP 137
Drive out both bearing cups from the differential
carrier.

6004-35
Drive Pinion Installation STEP 140
STEP 138
2
BD06G139
1. MATING NUMBER (MARKED MANUALLY)
2. PINION BASIC DIMENSION (STAMPED)
BD06G137 3. PINION DISTANCE DEVIATION + OR - (MARKED
Find and record the housing dimension “X”. MANUALLY)
Dimension X (Example). . . . . 205.30 mm (8.08 inch) Distance deviation is indicated in 1/100 mm. If no
distance deviation is indicated the pinion basic
STEP 139 dimension is identical with the pinion dimension.
Record this as dimension “II”.
Dimension II (Example) 168 -0.05 mm = 167.95 mm
. . . . . . . . . (6.614 inch -0.002 inch = 6.612 inch)
STEP 141
Calculation example A:
36.13 mm
Dimension I
-------(1.422 inch)
+167.95 mm
Dimension II
-------(6.612 inch)
= 204.08 mm
Results in dimension Y
------(8.034 inch)
BD06G138
Calculation example B:
Measure the thickness of the inner bearing and
record its measurement, dimension “I”. 205.30 mm
Dimension X
Dimension I (Example) . . . . . 36.13 mm (1.422 inch) -------(8.080 inch)
NOTE: Deduct the thickness of the gauge blocks −204.08 mm
Dimension Y
being used to support the bearing from the overall -------(8.034 inch)
measurement, Difference = shim = 1.22 mm
IE: overall measurement 106.13 mm (4.178 inch) thickness ------(0.046 inch)
minus gauge block thickness 70 mm (2.756 inch) will
equal dimension I.
NOTE: Shims are available in 0.10 mm (0.004 inch),
round up or down to the next available shim
thickness, s = 1.20 (0.044 inch)

6004-36
STEP 142 STEP 145
BD06G140 BD06G143
Heat the bearing hole to approximately 120° C (248° Press the inner bearing on the drive pinion shaft.
F) and install the outer bearing until contact is made
using the outer bearing cup installer of 380100001. Drive Pinion Bearing Rolling
STEP 143
Torque Adjustment
STEP 146
BD06G141
Install the shim set determined in Step 141 in the

BD06G144
bearing bore on the differential carrier.
Install an 9.03 mm (0.35 inch) thick spacer on the
pinion shaft.
STEP 144
BD06G142
Heat the bearing hole to approximately 120° C (248°

F) and pull the bearing into to the bearing hole using
380100001.

6004-37
STEP 147 STEP 149
SM121A
BD06G147
Install the input flange on the pinion shaft.
STEP 150
Put the washer in place on the pinion shaft.
BD06G145
Heat the pinion shaft outer bearing to 120° C (248°

F) in a bearing oven. Wearing heat resistance gloves STEP 151
or mittens, install the bearing on the pinion shaft until Install holding wrench, CAS1579A, on input flange.
contact. Hold flange using holding tool and tighten nut to a
torque of 700 Nm (515 pound feet). Remove holding
NOTE: Prior to mounting the input flange and wrench.
tightening the nut, allow the bearing to cool to
ambient temperature. NOTE: When tightening rotate the pinion shaft in
both directions several times.
STEP 148
STEP 152
BD06G146
Press the dust shield on the input flange. BD06G148
Check the rolling torque of the drive pinion bearing.

The rolling torque should be 1.5 to 3.0 Nm (13.3 to
26.5 lb-inch). If rolling torque is too low, install a
thinner spacer (Step 146); if rolling torque is too high,
install a thicker spacer (Step 146).
STEP 153
Remove the nut and input yoke from the drive pinion
shaft.

6004-38
Setting Backlash and Bearing

Preload
Deviation Value -20 -10 0 +10 +20
Shim A 1.20 1.10 1.00 0.90 0.80
Shim B 0.80 0.90 1.00 1.10 1.20
STEP 154 STEP 155
1 2
A B
BD06G163
Record the deviation value on the ring gear, the value

will be a + or -, use the table to determine shim
thicknesses needed.
Example: Deviation value of +10 requires the
following shims: 5 3
Shim A = 0.90 4
BC06G004
Shim B = 1.10
1. DIFFERENTIAL 5. AXLE HOUSING
2. DRIVE HOUSING A. RING GEAR SIDE
3. AXLE HOUSING B. CARRIER SIDE
4. INPUT PINION
STEP 156
BD06G164
Insert shim A (0.90 mm) and install the bearing outer

ring until seated.

6004-39
STEP 157 STEP 160
BD06G165
Insert shim B (1.10 mm) and install the bearing outer BD06G168
ring until seated. Position the axle housing on the drive housing, install
4 bolts, top center, bottom center, front center, rear
Contact Pattern Check center, torque bolts evenly to 390 Nm (285 pound
feet).
STEP 158
STEP 161
BD06G166
BD06G169
Apply marking ink on several teeth of the ring gear.
Roll the input pinion several times in both directions
over the ring gear. Remove the differential and
STEP 159
compare the contact pattern with examples on page
4 and page 5.
NOTE: If the tooth contact pattern differs, the wrong
shim size was selected in Step 143. Remove
differential and repeat Steps 138 though 144.
BD06G167
Position the differential assembly in the axle drive

housing.

6004-40
STEP 162
BD06G172
Install the shaft seal with the sealing lip towards oil
BD06G170
sump using pinion shaft seal install CAS2841.
Install a new O-ring on the axle housing. Position the NOTE: Wet the outer diameter of the seal with a
axle housing on the drive housing, install bolts and solution of 50% water and 50% mineral spirits. Fill
torque bolts evenly to 290 Nm (215 pound feet). the space between the sealing and dust lip with
grease.
STEP 163
STEP 165
BD06G171
Loosen and remove the nut and input flange. BD06G173
Install the input flange. Install holding wrench,

CAS1579A, on input flange. Apply Loctite No. 262,
on the threads of the locknut. Install the washer and
locknut by hand. Hold flange using holding tool and
tighten nut to a torque of 700 Nm (516 pound feet).
NOTE: Rotate the input pinion several times in both
directions when tightening.

Section
6005
DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL

JOINTS
6005

6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6005-3
SPECIAL TORQUES
Coupler to Flywheel Bolts...................................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler Bolts ...................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Transmission Bolts.............................................................. 75 to 81 Nm (55 to 60 pound feet)
Center, Rear and Front Drive Shaft Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet)
Carrier Bearing Bolts ........................................................................................... 99 to 128 Nm (73 to 94 pound feet)
Lock Nut for Yoke on Front Drive Shaft.......................................................... 339 to 375 Nm (250 to 275 pound feet)
FRONT DRIVE SHAFT
Removal STEP 4
Use an acceptable puller and remove the yoke from
STEP 1 the end of the front drive shaft.
STEP 5
Loosen the set screws that secure the center bearing
to the front drive shaft.
STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD03A166
Loosen and remove the bolts and straps that fasten
the center drive shaft to the yoke of the front drive
shaft.
STEP 2
BD03A167
Loosen and remove the bolts and straps that fasten

the front drive shaft to the front axle.
STEP 8
Use a prybar to disengage the front drive shaft from
BD03A183 the front axle and remove the front drive shaft from
Remove the lock nut that fastens the yoke to the front the machine.
drive shaft.
NOTE: If necessary, use a brass hammer to drive
the front drive shaft out of the center bearing.
STEP 3
Make an alignment mark on the yoke and the end of
the front drive shaft to make sure that the yoke is
installed correctly.

6005-4
FRONT DRIVE SHAFT
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11
BD03A183
Install the lock nut and washer which fastens the

yoke to the front drive shaft. Tighten the lock nut to a
torque of 339 to 375 Nm (250 to 275 pound feet).
STEP 15
Tighten the set screws that secure the center bearing
to the front drive shaft alternately until they stop
turning and the hex head socket wrench starts to
spring.
BD03A167
STEP 16
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed, BD03A166
make sure the yoke being installed is 90° to the yoke Install the bolts and straps that fasten the front drive
on the other end of the front drive shaft. shaft to the center drive shaft. Tighten the bolts to a
torque of 75 to 81 Nm (55 to 60 pound feet).

6005-5
CENTER BEARING
Removal STEP 20
Make an alignment mark on the yoke and the front
STEP 17 drive shaft to be sure that the yoke is installed
correctly.
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD03A166
STEP 23
Loosen and remove the bolts and straps that fasten Loosen the set screws that secure the center bearing
the center drive shaft to the front drive shaft. to the front drive shaft.
STEP 18 STEP 24
BD03A183 BD03A183
Loosen and remove the lubrication hose from the Loosen and remove the bolts, washers and nuts that
center bearing fasten the bearing housing to the front frame.
STEP 19 STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD03A183
Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
6005-6
CENTER BEARING
Apply antiseize compound to the splines on the front
NOTE: The center bearing and the bearing housing drive shaft. Install the yoke to the front drive shaft,
are not serviced separately. If the center bearing is making sure the alignment marks made during
worn or damaged or if the bearing housing is removal are aligned.
cracked, a new center bearing and bearing housing
must be used.
STEP 31
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 27
Install the bearing housing so that the lubrication
fitting is at the top.
STEP 28
BD03A183
Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
of 339 to 375 Nm (250 to 275 pound feet).
STEP 32
BD03A183
Apply Loctite 242 to bolt threads. Install the bolts,
washers and nuts that fasten the bearing housing to
the front frame. Tighten the bolts to a torque of 99 to
128 Nm (73 to 94 pound feet).
STEP 29
BD03A166
Install the straps and bolts that fasten the center
drive shaft to the yoke on the front drive shaft.
Tighten the bolts to a torque of 75 to 81 Nm (55 to 60
pound feet).
STEP 33
Install the lubrication hose into the fitting on the
bearing housing.
BC05M214 STEP 34
Turn the set screw down to the shaft and then back it Lubr icate the center bear ing with the grease
off 1/4th turn and lock it with the jam nut. Repeat the specified in Section 1002.
procedure with the other set screw.

6005-7
CENTER DRIVE SHAFT
STEP 35 STEP 39
BD03A166 BD03A165
Loosen and remove the bolts and straps that fasten Hold the center drive shaft in position and install the
the center drive shaft to the yoke of the front drive bolts and straps that fasten the center drive shaft to
shaft. the transmission. Tighten the bolts to a torque of 75
to 81 Nm (55 to 60 pound feet).
STEP 36
Use a prybar to disengage the center drive shaft from STEP 40
the yoke of the front drive shaft.
STEP 37
BD03A166
Install the bolts and straps that fasten the center

drive shaft to the yoke of the front drive shaft. Tighten
BD03A165
the bolts to a torque of 75 to 81 Nm (55 to 60 pound
Loosen and remove the bolts and straps that fasten feet).
the center drive shaft to the transmission.
STEP 38
Hold the center drive shaft and remove from the
machine.

6005-8
REAR DRIVE SHAFT
STEP 41 STEP 45
BD01D323 BD01F304
Loosen and remove the bolts and straps that fasten Hold the rear drive shaft into position and install the
the rear drive shaft to the transmission. bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 75 to 81 Nm
STEP 42 (55 to 60 pound feet).
Use a prybar to disengage the rear drive shaft from
the transmission. STEP 46
STEP 43
BD01D323
Install the bolts and straps that fasten the rear drive
BD01F304
shaft to the transmission. Tighten the bolts to a
Loosen and remove the bolts and straps that fasten torque of 75 to 81 Nm (55 to 60 pound feet).
the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the
machine.

6005-9
ENGINE DRIVE SHAFT
STEP 47 STEP 50
BD01D342 BD01D342
Remove and discard the bolts and straps that fasten Place the engine drive shaft into position on the
the engine drive shaft to the transmission. transmission and install new straps and bolts.
Tighten the bolts to a torque of 61 to 81 Nm
IMPORTANT: The bolts and straps that fasten the
(45 to 60 pound feet).
engine drive shaft to the transmission must be
replaced when removed.
STEP 51
STEP 48
BD03A172
Apply Loctite 242 to bolt threads. Install the six bolts

BD03A172
that fasten the engine drive shaft to the engine.
Loosen and remove the six bolts that fasten the
Tighten the bolts to a torque of 53 to 62 Nm (39 to 46
engine drive shaft to the engine.
pound feet)
STEP 49
Remove the engine drive shaft from the machine.

6005-10
UNIVERSAL JOINTS
NOTE: The bearing race and journal that make up
STEP 52 the universal joint are not serviced separately. If the
Remove the drive shaft from the machine. bearing race or journal is worn or damaged, a new
universal joint must be used.
STEP 53
STEP 55
Clean the slots in the yoke of the drive shaft.
2
1
STEP 56
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 53.
STEP 57
Install the drive shaft.
BD01F304
1. RING 2. BEARING
Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on
the machine and is for reference of the ring and
bearing only.
STEP 54
Remove the universal joint from the drive shaft.

Section
6006
WHEELS AND TIRES
6006

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

6006-3
WHEELS AND BOLTS
General Information Torque Specification

The wheel bolts must be tightened after every 20 Tighten the wheel bolts to 298 Nm (220 pound-feet)
hours of operation until the wheel bolts stay tight: in the sequence shown in Figure 1. Then a final
torque of 640 to 720 Nm (475 to 530 pound-feet) in
A. If the machine is new.
the same sequence.
B. If a wheel has been removed and installed.
TIRE PRESSURES
23.5 x 25 L3.......................................................................................................................................2.75 bar (40 psi)
23.5R25 Dirt/Traction.........................................................................................................................2.75 bar (40 psi)
23.5R25 Rock ....................................................................................................................................2.75 bar (40 psi)
CHANGING TIRES
1. Have a qualified tire mechanic service the split
The split rim wheels used on this machine rim wheels used on this machine.
can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and 2. The correct tire equipment, especially a tire
stand at the front or rear of the tire. inflation cage, is required. Using the wrong
procedure for a split rim wheel can result in
When inflating a tire off the machine, put death.
the wheel in a tire inflation cage. The IMPORTANT: When installing a Michelin tire,
retaining ring and rim can come off with lubricate the tire with a tire mounting lubricant and
enough force to result in death to a person inflate the tire to 551 kPa, 5.5 bar (80 psi) to make
in front of the rim. sure that the tire is seated on the rim. Then decrease
48-44 the pressure to the specified pressure.
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and 4. Tighten the wheel bolts to 298 Nm (220
axle flange are clean and free of dirt and grease. pound-feet) in the sequence shown in Figure 1.
Then tighten the wheel bolts in the same
2. Install the wheel, hardened washers and wheel
sequence to 640 to 720 Nm (475 to 530
bolts.
pound-feet).
3. Use a hand wrench (not an impact) to tighten the
wheel b olts to pu ll the whee l against the
planetar y housing. DO NOT use an impact
wrench to tighten the wheel bolts.

6006-4
BS06G052
WHEEL BOLT TORQUE SEQUENCE

Section
6007
TRANSMISSION CONTROL VALVE
6007

245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-81450 Issued March, 2006
6007-2
TABLE OF CONTENTS
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6007-3
CONTROL VALVE
Disassembly STEP 4
STEP 1
BD06A010
Loosen and remove the cap screws, remove the

BD06A007
cover. Remove the opposite cover.
Mark the installation position of the wiring harness to
the valve block. STEP 5
STEP 2
BD06A011
Remove the wiring harness.

BD06A008
Loosen and remove the cap screws that secure the STEP 6
distribution plate and intermediate plate to the valve
body, remove the intermediate plate and distribution
plate.
STEP 3
BD06A012
Loosen and remove the retaining plate cap screws,

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

6007-4
STEP 7 STEP 9
BD06A013 BD06A015
Loosen and remove two cap screws, install two Remove the components.
adjusting screws. Loosen and remove the remaining
cap screws. STEP 10
STEP 8
BD06A016
Remove the opposite solenoids, housing, and

BD06A014 components.
Separate the housing from the valve body by equally
loosening the adjusting screws.

6007-5
Inspection Assembly
1. Clean all metal parts in cleaning solvent. NOTE: Apply clean engine oil (15W-40) to pistons
and springs, orifices, new O-rings, and filter screens
2. Immerse end housings, valve housing, valve
before assembly.
plate, and distribution plate in cleaning solvent
and agitate cleaning solvent. WEAR EYE
PROTECTION WHEN USING COMPRESSED STEP 11
AIR. Use compressed air to remove foreign
matter from interior of housings and plates and to
ensure that all bores are clear of foreign matter.
3. WEAR EYE PROTECTION WHEN USING
COMPRESSED AIR. Use compressed air to
ensure that orifices are clear of foreign matter.
4. Check filter screens for blockage, rips, or tears.
Replace if any of these conditions are seen.
5. Inspect the plates, housings and covers for
corrosion, cracks, breaks, chipping or other
damage. Check bores in housings for deep BD06A017
scratches, gouges, and other damage. Replace Place the valve body on the bench with the orifices
a housing or cover if any of the above conditions up.
are seen.
6. Check pressure regulators for cracks, breaks, or STEP 12
other damage. Check connector contacts for
looseness or signs of corrosion. Replace a
pressure regulator if any of these conditions are
seen. Check resistance of pressure regulators
using a multimeter. Replace a pressure regulator
if resistance is not 17 to 21 ohms.
7. Check wiring harness connectors for signs of 3
breaks, cracks, or other damage. Check contacts
for foreign matter or corrosion. Check harness
wiring for signs of broken or cracked insulation 1 1
and broken or frayed wiring at connection to 2 2
connectors. Replace wiring harness if any of BD06A018
these conditions are seen.
1. VIBRATION DAMPER 3. PRESSURE REDUCING
8. Check springs for cracks, breaks, distortion, or 2. PISTONS VALVE
signs of permanent set. Replace a spring if any Install components in positions shown.
of these conditions are seen.
9. Inspect pistons for cracks, breaks, chipping, STEP 13
grooves, or other damage. Replace if any of
BD06A019
Preload the compression springs of the pistons,

install a roll pin of a diameter of 5.0 mm (0.20 inch).
6007-6
STEP 14 STEP 17
BD06A020 BD06A023
Install the adjusting screws, gasket, and housing Install the cap screws and torque in a criss cross
cover. pattern to 7.5 Nm (66.3 pound-inch).
STEP 15 STEP 18
BD06A021 BD06A024
Tighten the adjusting screws equally until the cover is Install the solenoids and secure them with the
flush on the valve body. retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
STEP 16 NOTE: Install the retaining plate with the neck
towards valve body, install controllers with
connectors as shown.
STEP 19
BD06A022
Push the pistons down through the pressure 3

controller wholes and remove the roll pins. 1
1
2 2
BD06A025
1. VIBRATION DAMPER 3. MAIN PRESSURE VALVE

2. PISTONS
Install components in positions shown.

6007-7
STEP 20 STEP 23
BD06A026 BD06A028
Preload the compression springs of the pistons, Install the wiring harness with connector on side of
install a roll pin of a diameter of 5.0 mm (0.20 inch). valve body marking made during disassembly.
Install the adjusting screws, gasket, and housing Connect wiring harness to the solenoids.
cover.
STEP 24
STEP 21
BD06A029
BD06A023 Install the gasket, install the wiring harness plug in

Install the cap screws and torque in a criss cross the cover. Install the cap screws and torque in a criss
pattern to 7.5 Nm (66.3 pound-inch). cross pattern to 7.5 Nm (66.3 pound-inch).
STEP 22 STEP 25
BD06A027 BD06A030
Install the solenoids and secure them with the Install the wiring harness retaining clamp.
retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
NOTE: Install the retaining plate with the neck
towards valve body, install controllers with
connectors as shown.

6007-8
STEP 26 STEP 28
BD06A031 BD06A033
Install the screens into the bores of the intermediate Install the distribution plate, install the cap screws
plate towards the distribution plate. and torque in a criss cross pattern to 9.5 Nm (84
pound-inch).
STEP 27
STEP 29
BD06A032
Install two adjusting screws. Place the intermediate BD06A034
plate with the screens facing up. Install new o-rings on the plugs, install and torque
plugs to 6 Nm (53 pound-inch).

SECTION INDEX
BRAKES
Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001

Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003
Brake Accumulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008

7001
Section
7001
REMOVAL AND INSTALLATION OF BRAKE

COMPONENTS

7001-2
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7001-3
1
4
BC05M136
1. FRONT AXLE 5. FRONT ACCUMULATOR

2. REAR AXLE 6. REAR ACCUMULATOR
3. BRAKE VALVE 7. BRAKE PUMP
4. PARKING BRAKE ACCUMULATOR 8. CONNECTOR TO FAN VALVE
COMPONENT LOCATION ILLUSTRATION

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

7001-5
1
6
2 7
9
4 10
8
5
BC05M137
1. BRAKE VALVE 6. FRONT BRAKE LINE

2. REAR ACCUMULATOR LINE 7. REAR BRAKE LINE
3. PARKING BRAKE LINE 8. FRONT ACCUMULATOR
4. BRAKE PUMP INPUT 9. RETURN TO TANK
5. BRAKE VALVE DISCHARGE 10. PARKING BRAKE ACCUMULATOR
BRAKE VALVE ILLUSTRATION

7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS
1. Park the machine on a level surface and lower 1. Mount the accumulators (1) in the accumulators
the loader bucket to the floor. Stop the engine. clamps (7), do not tighten clamps at this time.
Refer to illustration on page 7.
2. Put blocks on both sides of each tire to prevent
machine movement. 2. Connect the tubes to both brake accumulators
(1) and tighten.
3. Make sure the service brake accumulators (1)
and the parking brake accumulator (2) are 3. Tighten accumulator clamp studs (7) to 17Nm
completely discharged. Push down and release (13 pound feet).
the brake pedal at least 30.
4. Install the parking brake accumulator (2) into the
4. Turn the master disconnect switch to the OFF bracket.
position.
5. Install the nut (3) and tighten.
5. Remove the left cab skirt located under the cab
6. Connect the line to the parking brake
or canopy to gain access to accumulators.
accumulator (2).
6. To release the pressure on the parking brake
7. Stop the vacuum pump and remove.
accumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to 8. Install the left cab skirt.
catch the hydraulic oil.
9. Turn the master disconnect switch to the ON
7. Connect a drain hose to the quick disconnect position.
couplings in each brake circuit to release any
10. Bleed the brake system. See Section 7002.
pressure in the brake circuit.
11. Refer to Section 7008 and perform the Parking
8. Clean the brake accumulators (1), parking brake
Brake Test Procedure.
accumulator (2) and lines. Refer to illustration on
page 7. 12. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
9. Put identification tags on the line that is
connected to the parking brake accumulator (2).
reservoir. Start the vacuum pump.
11. Disconnect the tubes from both brake
accumulators (1).
12. Loosen the clamp stud (8) on the accumulator
clamp (7).
13. Remove the accumulators (1) from the
accumulator clamps (7).
14. Install plugs in the tubes.
15. Disconnect the hose from parking brake
accumulator (2).
16. Remove the nut (3), remove the parking brake
accumulator (2).
17. Install a plug in the hose.

7001-7
2 3
6
4
7
8
7
1
1
BC05M138
1. BRAKE ACCUMULATORS 5. TUBE FRONT BRAKE ACCUMULATOR

2. PARKING BRAKE ACCUMULATOR 6. TUBE REAR BRAKE ACCUMULATOR
3. MOUNTING NUT 7. CLAMP ACCUMULATOR
4. HOSE PARKING BRAKE ACCUMULATOR 8. CLAMP STUD
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

7001-8
BRAKE PUMP
1. Park the machine on a level surface and lower 1. Install gear (6) onto the pump shaft, install
the loader bucket to the floor. Stop the engine. washer (7) and slotted nut (8), torque nut to 70 to
79 Nm (52 to 58 pound feet). Refer to the
2. Put blocks on both sides of each tire to prevent
machine movement.
2. Install the cotter pin (9).
3. Turn the master disconnect switch to the OFF
position. 3. Install the brake pump (1), mounting bolts (2) and
washers (3).
4. Clean the brake pump (1) and lines, refer to the
illustration on page 9. 4. Torque mounting bolts (2) to 57 to 65 Nm (42 to
48 pound feet).
5. Put identification tags the lines that are
connected to the brake pump (1). 5. Remove the plugs or caps and connect the lines
to the brake pump (1).
reservoir. Start the vacuum pump. 6. Stop the vacuum pump and remove.
7. Disconnect the lines from the brake pump (1) 7. Turn the master disconnect switch to the ON
and put plugs in each line. position.
8. Remove the mounting bolts (2) and washers (3) 8. Bleed the brake system. See Section 7002.
from the brake pump (1) and remove the brake
9. Check the hydraulic reservoir oil level and add oil
pump (1).
as required. See Section 1002 for the correct oil.

7001-9
9 8
7
6
3
2
BC05M139
1. BRAKE PUMP 4. SUCTION HOSE 7. WASHER

2. MOUNTING BOLT (2) 5. PRESSURE HOSE 8. SLOTTED NUT
3. WASHER (2) 6. DRIVE GEAR 9. COTTER PIN
BRAKE PUMP ILLUSTRATION

7001-10
NOTES

7002
Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING

7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Valve Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7002-3
SPECIFICATIONS
Brake pump output ..............................................................................................................42 to 45 L/min at 172 bar
(11 to 12 gpm at 2500 psi at 2000 rpm)
Accumulator nitrogen charge pressure...........................................................................48 to 59 bar (700 to 850 psi)

Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2280 to 2420 psi)
Accumulator valve cut out pressure....................................................................... 190 to 196 bar (2755 to 2845 psi)
Brake warning pressure switch (normally closed) opening set point ......................106 to 115 bar (1530 to 1670 psi)
Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi)
Brake light pressure switch (normally open) closing set point .............................. 5 to 6 bar increasing (75 to 85 psi)
Modulation pressure front brake cylinders..................................................................80 to 87 bar (1160 to 1260 psi)
Modulation pressure rear brake cylinders...................................................................78 to 85 bar (1130 to 1230 psi)
SPECIAL TOOLS
G
94L95
CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND
CHARGE THE ACCUMULATOR WITH NITROGEN.
BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER

7002-4
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM

NOTE: The hydraulic brake schematic is included in 8. Stop the engine. Turn the ignition switch to the
the hydraulic schematic. Refer to the rear pocket of ON position. Push and release the brake several
this manual. times while reading the pressure on the gauges.
Each push and release of the pedal will result in
1. Check the oil level in the hydraulic reservoir; add
a slight drop in pressure, but not necessarily
oil as necessary.
equal on the two gauges. As the lowest pressure
2. Push and release the brake pedal many times reaches 106 to 115 bar (1530 to 1670 psi) the
with the engine stopped to remove all hydraulic brake warning lamp and alarm buzzer must
pressure from the brake system until there is no actuate. If the warning lamp and alarm buzzer fail
pressure on the pedal. to work, test the low brake pressure warning
switches and electrical circuit. If the warning
3. Install two 207 bar (3000 psi) pressure gauges to
lamp and alarm buzzer actuate at a higher or
front and rear hydraulic brake accumulator test
lower pressure than specified, test the low brake
ports, refer to page 7 for the locations of the test
pressure war ning switches and replace as
ports.
needed.
4. Make sure that the pressure gauge hoses are
9. As the lowest pressure reaches 106 to 115 bar
long enough so the gauges can be read while
(1530 to 1670 psi) the brake warning lamp and
sitting in the operators seat.
alarm buzzer must actuate. If the warning lamp
NOTE: The gauges can not be connected to the test and alarm buzzer fail to work, test the low brake
ports if hydraulic pressure remains in the system. pressure warning switches and electrical circuit.
If the warning lamp and alarm buzzer actuate at
5. Start the engine. Run the engine at low idle while
a higher or lower pressure than specified, test
reading the pressure gauges. The alar ms
the low brake pressure warning switches and
(buzzer, master warning light and brake pressure
replace as needed.
war ning light) should shut off when the
accumulator with the lowest pressure reaches 10. After the low brake pressure light activates, press
106 to 115 bar (1530 to 1670 psi), approximately the brake pedal eight more times.
40 seconds at any engine speed. 11. Record the readings on the pressure gauges.
6. After the alarms stop, run the machine at high The pressure gauges should read at or above
idle to finish charging the accumulators. The 48 to 59 bar (700 to 850 psi).
pressure must increase on both gauges until 190 12. If the pressures are at or above 48 to 59 bar (700
to 196 bar (2757 to 2843 psi) is reached. This is to 850 psi), the test is complete.
the accumulator valve cut-out pressure. It is 13. If the pressures are not within the required
normal for the pressure to drop slightly once the specifications, then the brake system must be
cut-out pressure is reached. bled.
7. With the engine running at high idle, push and 14. After bleeding the brake system, perform the
release the brake pedal rapidly while reading the brake system check again.
drop in pressure on the gauges. The pressure
drops may not be equal, but as the lowest 15. Continue to slowly push and release the brake
pressure reaches 157 to 167 bar (2280 to 2420 pedal several times until the gauge pressure
psi), the system pressure must start to increase. suddenly drops to zero. The last pressure
This is the valve cut in pressure. reading before the drop to zero is the nitrogen
charge pressure in the accumulator. Test the
NOTE: The brake cut-in and cut-out pressures of the pressure in both accumulators. If the pressure is
brake system charge valve are factory preset and are below 48 to 59 bar (700 to 850 psi), charge or
not adjustable. replace the accumulator(s) (see page 5).
NOTE: If the pressure on one of the pressure NOTE: Nominal temperature of 20° C (68° F), colder
gauges is lower than specified, the problem can be a temperature will reduce pressure, hotter temperature
bad accumulator valve. will increase pressure.

7002-5
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is
completely discharged by doing the following: E
C
A. Stop the engine.
B. Push down and release the brake pedal many
times to release the pressure.
F
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.
D B A
4. Turn the stem out of valve F until the stem stops.
94L95
5. Remove the cap screws and guard from the NITROGEN CHARGING KIT
accumulator.
8. Make sure that valve D is open.
6. Remove the cap from the accumulator valve
9. Turn the stem into valve F and read the pressure
stem.
gauge E.
7. Connect valve F to the accumulator valve stem.
10. The pressure must be 48 to 59 bar (700 to 850
psi). If the pressure is too low, charge the
accumulator with dry nitrogen.
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator 5. If the pressure increases above 59 bar
according to the instructions in Checking the (850 psi), quickly open and close valve D and
Nitrogen Charge in the Accumulator. Keep the read gauge E. If the pressure is still too high,
nitrogen charging kit connected to the accumulator. close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
1. Close (turn counterclockwise) valve A and open
pressure shown on gauge E is the charge
valve B. Close valves C and D.
pressure.
2. Turn the stem out of valve F until the stem stops
6. Connect valve F to the accumulator valve stem.
moving. Disconnect valve F from the
Turn the stem into valve F until the stem stops
accumulator valve stem.
m o v i n g a n d o p e n va l ve D t o c h a r g e t h e
3. Connect the nitrogen charging kit to a dry accumulator.
nitrogen tank.
7. After the accumulator stops charging, turn the
4. Slowly turn valve A clockwise and read gauge E stem out of valve F until the stem stops moving.
until the pressure is 48 to 59 bar (700 to 850 psi).
8. Close valve B and disconnect the nitrogen
Stop turning valve A.
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
I n s t a l l t h e g u a r d a n d c a p s c r ew s o n t h e
accumulator.

7002-6
BLEEDING THE BRAKE SYSTEM

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

7002-7
BRAKE MODULATION PRESSURE CHECK
2 3
BD06F145
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
Testing the Brake Modulation 6. Start the engine.

Pressure 7. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
1. Make sure the hydraulic accumulator cut-in and the gauges rise above 170 bar (2645 psi).
cut-out pressures are correct. Refer to page 4 of
this section. 8. Apply and hold the brakes for 10 to 15 seconds.
2. Stop the engine. Pump the brake pedal until 9. Make a note of the pressure on the gauges for
there is no pressure in the brake system. the front and rear brakes.
3. Remove the cab skirts to gain access to the 10. The front brake pressure should read 80 to 87
brake test ports. bar (1160 to 1260 psi). This is the modulation
pressure for the front axle.
4. Connect two 207 bar (3000 psi) pressure gauges
to the front brake test port (1) and the rear brake 11. The rear brake pressure should read 78 to 85 bar
test port (2). (1130 to 1230 psi). This is the modulation
pressure for the rear axle
to the front brake accumulator test port (4) and 12. If the pressures are not within the specified
the rear brake accumulator test port (3). ra n g e, i t w i l l b e n e c e s s a r y t o a d j u s t t h e
modulation pressures.

7002-8
Adjusting the Brake Modulation 1. Remove the tamper evident cover (1).
Pressure NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
NOTE: The adjusting bolt to adjust the modulation pressure is adjusted.
pressure is located in the cab, under the brake pedal.
2. Turn the adjusting bolt (2) to adjust the
modulation pressure.
NOTE: The rear brake modulation pressure cannot
be adjusted separately from the front brake
modulation pressure.
3. Repeat steps 5 through 10 in the Testing the
Brake Modulation Pressure procedure.
2 4. Repeat these steps until the brake modulation
pressure is within the specified range.
1
BD00N121
1. TAMPER RESISTANT COVER

2. ADJUSTING BOLT

7002-9
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)
2 3
4
BD06F145
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
NOTE: Prior to doing this procedure make sure that 6. Start the engine and let idle until both the front
the accumulator pressures are correct. and rear accumulators 3 and 4 are fully charged.
1. Check the level of the hydraulic fluid in the The accumulators are fully charged at 190 to 196
reservoir, add as needed. bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal down slowly, allowing for
full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal down. The
low brake pressure light should activate when the
pressure reaches 106 to 115 bar (1530 to 1670
psi). After the low brake pressure light activates,
press the brake pedal eight more times.
1 10. Record the readings on the pressure gauges.
The pressure gauges should read at or above
BD00M030 48 to 59 bar (700 to 850 psi).
11. If the pressures are at or above 48 to 59 bar (700
2. Install the articulation lock (1) before doing this to 850 psi), the test is complete.
test. 12. If the pressures are not within the required
3. Remove the left side cab skirt to gain access to specifications, then the brake system must be
the brake accumulator test ports. bled.
4. Pump the brake pedal until there is no hydraulic 13. After bleeding the brake system, perform the
pressure in the brake system (approximately 20 brake system check again.
pumps).
to the test ports 3 and 4.

7002-10
BRAKE PUMP OUTPUT TEST

1. Connect the flowmeter to the brake pump as 3. Measure the flow at 0 bar (0 psi). Record the flow
shown, refer to the illustration below. reading. Slowly close the load valve on the
flowmeter and read the flow at 170 bar (2500
2. Make sure the load control of the flowmeter is
psi). Record the flow reading.
open. Start the engine. Run the engine at full
throttle. Make sure the oil is at operating 4. Divide the flow reading at 170 bar (2500 psi) by
temperature. the reading at 0 bar (0 psi). Multiply the result by
100. This is the percent efficiency of the pump. If
the efficiency of the pump is less than 85%,
repair or replace the pump.
NOTE
4
3
BS03B021
1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD

2. PUMP OUTPUT ELBOW 4. FLOWMETER OUTLET HOSE 6. FILTERS
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

7002-11
NOTES

7002-12
2 4
30 5
31
6
32
14 5
33 21
5 30
34
2 7
35 29
5
36 8
27 15
28 10
26 15
11
16 14
24 25 12
14
17
5
23 18 19
15
2
22 5 13
5
21 20
BC05G011
BRAKE VALVE EXPLODED VIEW

7002-13
1. CAP SCREW (T 22 NM (16 LB-FT)) 13. CAP (T 60 NM (44 LB-FT)) 25. CHECK VALVE
2. O-RING 14. SPOOL 26. CARTRIDGE
3. BUSHING 15. PLUG (T 10 NM (88.5 LB-IN)) 27. PLUG (T 60 NM (44 LB-FT))
4. SLEEVE 16. PLUG (T 60 NM (44 LB-FT)) 28. JET
5. SPRING 17. PLUG (T 22NM (16 LB-FT)) 29. WVI UNIT
6. SPRING RETAINER 18. VALVE SEAT 30. PLUG (T 60 NM (44 LB-FT))
7. SPRING RETAINER 19. THROTTLE SCREW 31. PLUG (T 100 NM (74 LB-FT))
8. CIRCLIP 20. PLUG (T 22NM (16 LB-FT)) 32. RV UNIT
9. SHAFT SEAL 21. CAP 33. SPRING RETAINER
10. SLEEVE LVE 22. SLEEVE 34. SLEEVE
11. GUIDE RING 23. SPRING RETAINER 35. THRUST RING
12. O-RING 24. SLEEVE 36. SLEEVE LVV

7002-14
NOTES

Section
7003
7003
BRAKE PUMP

7003-2
TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7003-3
14
17 15
16
10
18
10
19 13
7
8
9
11
12
11
9 10
8
7
5
4 6
3
2
1
BC06F594
1. RETAINING RING 8. BACKUP SEAL 14. WASHER

2. SEAL RETAINER 9. CHANNEL SEAL 15. BOLT
3. 0-RING 10. DOWEL PIN 16. DRIVEN GEAR
4. OUTER LIP SEAL 11. THRUST PLATE 17. DRIVE GEAR
5. INNER LIP SEAL 12. GEAR HOUSING 18. DRIVE SCREW
6. SHAFT END COVER HOUSING 13. PORT END COVER HOUSING 19. NAME PLATE
7. QUAD RING
PUMP ILLUSTRATION

7003-4
BRAKE PUMP
1. Secure the pump by the port end cover (13) in a 1. Install a new lip seal (3) into the seal retainer (2)
soft jawed vise. so the lip of the seal will be facing away from the
2. Draw a line the length of the pump to assist gears when the seal retainer (2) is installed into
during assemble. the shaft end cover housing (6).
3. Loosen and remove bolts (15). 2. Install a new lip seal (4) into the shaft end cover
housing (6) with the lip of the seal facing towards
4. Tap the shaft end cover housing (6) with soft the gears.
hammer to loosen it, remove the shaft end cover
housing (6). 3. Install a new O-ring (3) onto the seal retainer (2),
lubricate the O-ring with hydraulic oil.
5. Remove the backup seal (8), channel seal (9),
and thrust plate (11). 4. Press the seal retainer (2) into the shaft end
cover housing (6) and install the retaining ring
6. Remove the drive gear (17) from the gear (1).
housing (12).
5. Place the shaft end housing (6), facing down,
7. Remove the driven gear (16) from the gear into a soft jawed vise.
housing (12).
6. Install new backup seals (8) and channel seals
8. Tap the gear housing (12) with a soft hammer to (9) into the thrust plates (11).
loosen it, remove the gear housing (12).
7. Place a thrust plate (11) onto the shaft end cover
9. Remove the backup seal (8), channel seal (9), housing (6).
and thrust plate (11).
IMPORTANT: Be sure to place the thrust plate (11)
10. Remove the retaining ring (1) form the shaft end
onto the shaft end cover housing (6) in the position
cover housing (6).
shown in the illustration on page 3.
11. Remove the seal retainer (2), O-ring (3), and
8. Lubricate the driven gear (16) with hydraulic oil,
outer lip seal (4) from the shaft end cover
slide the driven gear (16) through the thrust plate
housing (6).
(11) into the shaft end cover housing (6).
12. Remove the inner lip seal (5) from the shaft end
9. Lubricate the drive gear (17) with hydraulic oil,
cover housing (6).
slide the drive gear (17) through the thrust plate
(11) into the shaft end cover housing (6).
Inspection
10. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
1. Discard all seals and quad rings. Clean all parts either in the gear housing (12) or the shaft end
in cleaning solvent. Check all machined surfaces cover housing (6).
for damage or wear.
11. Align the marks made during disassembly,
2. Hold a straightedge across each gear housing carefully place the gear housing (12) onto the
and use a feeler gauge to measure the amount gears.
of wear caused by the gear teeth in the gear
12. Slide the thrust plate (11) onto the shafts of the
pocket. If the wear in any gear pocket is more
gears.
than 0.18 MM. (0.007 inch), use a new gear
housing. IMPORTANT: Be sure to place the thrust plate (11)
3. Inspect the thrust plates for scoring, pitting, or onto the gears in the position shown in the illustration
other damage. on page 3.
4. Inspect the gears for wear and damage. There 13. Install a new quad ring (7) into the gear housing
must be no scoring on the gear hubs or on the (12). Check that dowel pins (10) are in place
outside edges of the gear teeth. There must be either in the gear housing (12) or the port end
no more than 0.05 MM. (0.002 inch) wear in the cover housing (13).
seal area of the drive shaft. If any gear must be 14. Align the marks made during disassembly, place
discarded, you must use a new hydraulic pump. the port housing (12) onto the gear housing (12).
15. Install bolts (15) with clean and dry threads,
washers (14). Torque bolts to 192 ± 5.5 Nm
(141.5 ± 4 pound feet).
Section
7004
7004
BRAKE ACCUMULATORS

Racine, WI 53404 U.S.A. Bur6-47761 Issued April, 2003/Revised February, 2004
7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7004-3
SPECIAL TOOL
C E
G
D B A
94L95 BC04A001
CAS10899 NITROGEN CHARGING KIT 380001168 ACCUMULATOR CHARGING ADAPTER
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Remove cover from accumulator charge port. 6. Connect valve F to the valve stem on the
Loosen the Allen screw in the charge port. adapter.
NOTE: Do not turn the Allen screw more than 1/8 of 7. Turn the T-handle inward on valve F to engage
a turn or gas will escape uncontrolled. the pin in the valve stem, open valve G.
2. Install adapter on accumulator, use the 8. Open valve D and check the charge pressure on
CAS10899 nitrogen charging kit to discharge the gauge E.
accumulator, refer to illustrations above. The tool
9. To discharge the accumulator, partially open
must be disconnected from the nitrogen tank.
valve B. The accumulator charge will bleed down
3. Close valves B, C and D. through the regulator.
4. Adjust the regulator A to the minimum pressure 10. Once the accumulator is fully discharged,
setting by turning the knob counterclockwise. disconnect valve F from the valve stem and
remove adapter.
5. Turn the T-handle on valve F fully out.
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

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

7004-4
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

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

ACCUMULATOR

Section
7008
PARKING BRAKE
7008

7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7008-3
PARKING BRAKE
Disassembly STEP 7
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wheel chocks on each wheel to prevent
machine movement.
STEP 3
BD03A185
Loosen the jam nut, tur n adjusting bolt

counterclockwise until the brake pads are loose.
STEP 8
BD01F143
Install the articulation lock.
STEP 4
position.
STEP 5 BD03A186
Remove the retainer pin and brake pin.
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP 9
STEP 6
BD03A187
Remove the two brake pads from the parking brake
BD03A184 assembly.
Loosen and remove the cover from the parking
brake.

7008-4
Inspection STEP 14
Disengage the parking brake.
STEP 10 NOTE: Hydraulic pressure will not be applied to the
Clean and inspect all parts for wear and damage. parking brake until the parking brake rocker switch is
Inspect the brake disc for wear and damage. turned off, the service brakes applied and the
transmission is put into gear.
Replace all parts that are worn or damaged.
A. Place the parking brake rocker switch in the
OFF position.
Assembly
B. Apply the service brake and put the machine
STEP 11 into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.
STEP 15
BD03A187
Install the two brake pads in the parking brake

assembly.
STEP 12
BD0CA185
Turn the adjusting bolt clockwise until both brake

pads contact the brake disc, then turn the adjusting
bolt counterclockwise one turn. Tighten the jam nut
to secure the adjusting bolt.
STEP 16
Install the cover on the parking brake.
STEP 17
Perfor m the Parking Brake Test Procedure as
BD03A186
described in this section.
Install the brake pins and retainer pins.
STEP 18
STEP 13
Remove the articulation lock.
Start the machine and run the engine at low idle with
the bucket resting on the ground.
STEP 19
IMPORTANT: It will be necessary to have an Place the master disconnect switch to the ON
assistant help for this procedure. An operator must position.
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.

7008-5
PARKING BRAKE TEST PROCEDURE

STEP 20 STEP 25
While testing, the machine must be on a clear level
surface with the bucket in the travel position.
WARNING: Always know the location of all

workers in your area. Warn them before you
start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015
STEP 21
Start the machine and run the engine at low idle in BD06F142
third gear neutral. Use up or down arrow and highlight config, press the
enter key to select the config menu.
STEP 22
Place the Transmission-Auto switch to the manual STEP 26
position.
STEP 23
Place the Parking Brake switch to the ON position.
STEP 24
BD06F143
Press the up or down arrow and high light brake test,

press the enter key.
BD06F141
Press and hold the enter key for 2 to 3 seconds until

the instrument cluster monitor display changes to the
select screen.

7008-6
STEP 27 STEP 33
Verify that the machine does not move.
STEP 34
Reduce the engine speed to low idle and return the
transmission to neutral.
STEP 35
BD06F144
Monitor will display Test Park Brake if all conditions

are met to test the brake, press the enter key.
NOTE: If all conditions are not met to test the brake
the monitor will display the condition that needs
corrected prior to proceeding. BD06F141
Press the escape switch on the key pad to exit the

STEP 28 test mode.
Monitor will display Test Park Brake Ready.
STEP 36
STEP 29 If any machine movement was detected, the parking
Shift the gear selector into third gear forward and brake must be adjusted, see procedures this section.
slowly increase the engine speed to wide open
throttle.
STEP 30
Verify that the machine does not move.
STEP 31
Reduce the engine speed to low idle and return the
transmission neutral.
STEP 32
Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
throttle.

SECTION INDEX
HYDRAULICS
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004
Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
Ride Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014

8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC

COMPONENTS

8001-2
TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
XT Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8001-3
LOADER CONTROL VALVE
Removal STEP 5
STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with
STEP 2
BD06H198
Relieve the pressure in the ride control accumulator

with the manual bleeder valve located on the top of
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.
STEP 6
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
BD03A092
STEP 7
Raise the lift arms and install the safety link on the lift
arm cylinder. Drain the hydraulic reservoir.
STEP 3 STEP 8
Stop the engine and apply the parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
STEP 4
position.
BD03A093
Loosen and remove the bolts and washers that

fasten the access cover plate for the loader control
valve. Remove the cover plate.

8001-4
REAR OF MACHINE
6
7
5
3
1
2 4
BC05M094
1. GREEN WHITE GREEN 4. ORANGE BLACK GREEN 7. GREEN BLACK GREEN

2. RED WHITE GREEN 5. GREEN WHITE GREEN 8. RED BLACK GREEN
3. YELLOW BLACK GREEN 6. RED WHITE GREEN 9.
HYDRAULIC VALVE PILOT LINE CONNECTIONS

8001-5
1 2
3
4
6 7
BC05M093
1. DUMP LINE 4. RAISE LINE RIGHT 6. LOWER LINE RIGHT

2. ROLLBACK LINE 5. LOADER VALVE 7. RAISE LINE LEFT
3. LOWER LINE LEFT
LOADER CONTROL VALVE LINE CONNECTIONS

8001-6
STEP 9 Installation
Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5,
IMPORTANT: Before installing the fittings or
and 6) from the remote control valve(s) at the loader
connecting the tubes to the fittings, install new
control valve. Refer to the illustration on page 4 for
O-rings on the fittings.
color coding. Install a plug in each hose and a cap on
each fitting.
STEP 16
NOTE: Line 1, 2, 5, and 6 will need to be tagged as
right or left of valve.
STEP 10
Loosen and remove tilt cylinder lines (1 and 2). Install
a plug in each line and a cap on each fitting.
STEP 11
Loosen and remove lines (3 and 4). Install a plug in
each line and a cap on each fitting.
STEP 12 BC05M096
Loosen and remove lines (6 and 7). Install a plug in Install and align the loader control valve with the
each line and a cap on each fitting. valve mounting plate.
STEP 13 STEP 17
Loosen and remove supply and return lines. Install a Install the bolts and washers that fasten the loader
plug in each line and a cap on each fitting. control valve to the valve mounting plate. Tighten the
bolts.
STEP 14
Attach proper lifting equipment to lift loader control STEP 18
valve. Tighten the left lift cylinder lines (6 and 7).
STEP 15 STEP 19
Install and tighten the supply and return lines.
STEP 20
Install and tighten right lift cylinder lines (3 and 4).
STEP 21
Install and tighten tilt cylinder lines (1 and 2).
STEP 22
Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and
6) to the remote control valve(s) at the loader control
BC05M096
valve. Refer to the illustration on page 4 for color
Loosen and remove the three bolts and washers that
coding.
hold the loader control valve to the valve mounting
plate. Remove the loader control valve.

8001-7
STEP 23 STEP 27
Fill the hydraulic reservoir with oil. Refer to Section Run engine at half throttle.
1002 for the correct oil.
STEP 28
STEP 24 Slowly and completely extend and retract all
Tighten the accumulator manual bleeder valve cylinders at least 10 times to remove any air from the
located on the top of the ride control valve to a torque circuits.
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in). STEP 29
Stop the engine and check for leaks.
STEP 25
Place the master disconnect switch in the ON STEP 30
position. Install the access cover on the front of the machine.
STEP 26 STEP 31
Check the level of the hydraulic oil and add hydraulic
oil as required.
BD03A092
Raise the loader arms and remove the safety link.

8001-8
REMOTE CONTROL VALVE
Removal STEP 37
STEP 32
parking brake.
circuit, turn ignition switch OFF. BD06F208
Open and remove the access panel.

STEP 33
Place the master disconnect switch in the OFF STEP 38
position.
STEP 34
Unlatch and open the right hand side access door.
STEP 35
Lift the access door up and remove the access door
from the pins.
STEP 36
BD06F209
Remove the front access panel.
STEP 39
BD06F207
Unlatch and open the window on the right hand side.
BD06F210
Disconnect the electrical connectors for the remote

control valve.
STEP 40
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.

8001-9
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install STEP 45
plugs in the hoses and caps on the fittings. Install new O-rings on the adapters for the remote
control valve.
STEP 42
Loosen and remove the screws and washers holding STEP 46
the hydraulic control tower cover. Remove the cover. Install the remote control valve and screws in the
hydraulic control tower and tighten the screws.
STEP 43
Loosen and remove the screws that fasten the STEP 47
remote control valve to the hydraulic control tower. Install the cover over the remote control valve and
install the screws and washers.
STEP 44
Remove the remote control valve from the hydraulic STEP 48
control tower. Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 11, 12, and 13 as necessary.
STEP 49
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 50
BD06F210
Connect the electrical connectors for the remote

control valve.
STEP 51
position.
STEP 52
Start the engine and run the engine at low idle.
STEP 53
Check to see that the remote control valve works
correctly.

8001-10
STEP 54 STEP 57
Check for hydraulic oil leakage at the remote control
valve.
STEP 55
Check the level of hydraulic oil in the reservoir and
add as required.
STEP 56
BD06F208
Install and close the access panel.
STEP 58
BD06F209
Position the access panel on the ROPS cab or the

ROPS canopy and install and tighten the screw.
BD06F207
Close the right hand window.

8001-11
3
8
6
7
1
5
7 8
7 5
1 2
8 3
6 4
BC05M092
1. PILOT TANK HOSE 4. ORANGE BLACK GREEN 7. GREEN WHITE GREEN

2. PILOT PRESSURE HOSE 5. GREEN BLACK GREEN 8. RED WHITE GREEN
3. YELLOW BLACK GREEN 6. RED BLACK GREEN
JOYSTICK AND 2 LEVER HOSE COLOR CODING

8001-12
5 5
7 1 4 7
3
4
6 3
2 1
6
2
7 7
7 7
1 1
2 2
6 6
3 3
4 5 4 5
BC05M091
1. PILOT TANK HOSE 1. PILOT TANK HOSE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK GREEN 3. RED BLACK GREEN
4. ORANGE BLACK GREEN 4. ORANGE BLACK GREEN
5. YELLOW BLACK GREEN 5. YELLOW BLACK GREEN
6. GREEN BLACK GREEN 6. GREEN BLACK GREEN
7. RED WHITE GREEN 7. RED WHITE GREEN
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING

8001-13
1
5
4 5 4 6
6 3 2
3 1
2
2 1 2 1
6 6
3 3
4 5 4 5
BC05M090

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING

8001-14
HYDRAULIC PUMP
10
7 15
4
6
4
16
5
8 15
6
2 13
3
14
11
9
12
BC05M095
1. PUMP MAIN HYDRAULIC 5. SPLIT FLANGE 9. STEERING HIGH PRESSURE 13. LOADER HIGH PRESSURE
2. MOUNT BOLTS 6. TUBE 10. CLAMPS 14. STEERING PRIORITY MANIFOLD
3. DRAIN HOSE 7. HOSE SUCTION 11. STEERING LOAD SENSE HOSE 15. CLAMPS
4. BOLT 8. HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE 16. FITTINGS

8001-15
Removal STEP 69
Connect lifting equipment to hydraulic pump (1). Take
NOTE: When disconnecting hydraulic fittings, plug
up all slack in lifting equipment. Remove four
hoses and cap fittings to prevent entry of foreign
mounting bolts (2) and washers securing pump to
matter into hydraulic system.
transmission. Pull hydraulic pump from transmission
and remove from loader. Remove and discard O-ring
STEP 59 from pump.
bucket to the floor. Stop the engine and apply the Installation
parking brake.
NOTE: Install new O-rings where required.
STEP 60
Place the master disconnect switch in the OFF STEP 70
position. Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
STEP 61 four washers and bolts (2) to secure pump (1) to
Loosen the filler cap on the reservoir to release any transmission, tighten the bolts. Disconnect lifting
air in the reservoir. Connect a vacuum pump to the equipment from pump.
STEP 71
STEP 62 Connect pump pressure hoses (9 and 13) to steering
Refer to Section 9007 and remove the ROPS cab or priority manifold (14).
ROPS canopy.
STEP 72
STEP 63 Connect drain hose (3).
Remove eight bolts (4) and washers. Remove four
split flanges (5). Disconnect tubes (6) with suction STEP 73
hoses (7) from hydraulic pump. Remove and discard Connect load sense hoses (11 and 12).
O-ring face seals from flange heads of tubes.
STEP 74
STEP 64 Install and connect case drain hoses (8).
Loosen clamps (10). Tag and disconnect suction
hoses (7) from hydraulic reservoir and remove from STEP 75
machine. Install suction hoses (7), tighten clamps (10) to 10 to
11 Nm (90 to 100 pound inches).
STEP 65
Tag and disconnect case drain hoses (8) from fittings STEP 76
(16); remove hoses (8). Remove and discard O-ring Install four split flanges (5). Install eight bolts (4) and
face seals from fittings. washers, tighten bolts (4) to 73 to 90 Nm (53.8 to
66.3 pound feet).
STEP 66
Tag and disconnect load sense hoses (11 and 12). STEP 77
Remove and discard O-ring face seals from fittings. Refer to Section 9007 and install the ROPS cab or
ROPS canopy.
STEP 67
Tag and disconnect drain hose (3). Remove and STEP 78
discard O-ring face seals from fittings. Turn off the vacuum pump and disconnect from the
STEP 68
Tag and disconnect pump pressure hoses (9 and 13) STEP 79
from steering priority manifold (14). Remove and Place the master disconnect switch in the ON
discard O-ring face seals from flange heads of position.
hoses.

8001-16
STEP 80 STEP 81
Start the engine and run the engine at low idle for two Stop the engine and check for hydraulic oil leakage at
minutes. the hydraulic pump.
NOTE: If any unusual vibration is heard coming from
the pump, stop the machine immediately and check STEP 82
for obstructions in the pump suction line. Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.

8001-17
LIFT CYLINDERS
Removal STEP 87
STEP 83
parking brake.
BD01D709
STEP 84 Loosen and remove the bolt, washer and spacer that
Relieve the pressure in the ride control accumulator hold the pivot pin for the yoke.
with the manual bleeder valve located at the rear of
the front chassis. STEP 88
STEP 85
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 86
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 89
BD01D708
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.

8001-18
STEP 93
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 94
BD01D710
Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.
STEP 91
BD01D714
Use a proper lifting device and position the lift

cylinder on the machine.
STEP 95
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 92
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.

8001-19
STEP 96 STEP 99
BD01D710 BD01D712
Align the pivot pin with the front frame and install the Install the pivot pin for the yoke. Stop the engine.
spacer, washer and bolt. Tighten the bolt.
STEP 100
STEP 97
BD01D709
BD01D708 Align the pivot pin with the yoke and install the
Remove the caps and plugs and connect the hoses spacer, washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 101
STEP 98 SLOWLY extend and retract the piston rod three
If the yoke of the lift cylinder is not aligned with the times to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 102
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 103
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the

8001-20
BUCKET CYLINDER - Z-BAR LOADER
Removal STEP 108
STEP 104
parking brake.
STEP 105
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 106
BD01D695
Loosen and remove the two bolts that fasten the

mounting bracket to the machine. Remove the
mounting bracket.
STEP 109
BD01D694
Disconnect the proximity switch connector from the

wiring harness connector.
STEP 107
BD01D697

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.
BD01D696

target bar to the mounting bracket. Remove the
target bar.

8001-21
STEP 110 STEP 113
BD01D699 BD01D701
Disconnect the hoses from each side of the bucket Remove the pivot pin from the rod end of the bucket
cylinder. Install plugs in the hoses and caps on the cylinder.
fittings.
STEP 114
STEP 111
BD01D704
BD01D700 Remove the pivot pin from the head end of the bucket
Use acceptable equipment to hold the bucket cylinder.
cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
STEP 112 replaced.
STEP 115
BD01D698
Loosen and remove the bolt, washer and spacer that

fasten the pivot pin from both ends of the bucket
BD01D706
cylinder.
Raise the bucket cylinder and remove the cylinder
from the machine.

8001-22
STEP 116
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 117
BD01D699
Connect the hoses to each side of the bucket

cylinder.
STEP 121
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD01D706
engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 118 STEP 122

Install the pivot pin and stop the engine.
STEP 123
BD01D704
Install the pivot pin to the head end of the bucket

cylinder.
BD01D698
STEP 119 Install the spacer, washer and bolt that fasten the
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
pivot pin to the front frame. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect
the grease line to the pivot pin.

8001-23
STEP 124 STEP 127
BD01D697 BD01D694
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 125 STEP 128

See Section 9006 for the adjustment procedure for
adjusting the proximity switch.
STEP 129
Start and run the engine at low idle.
STEP 130
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 131
Lubricate the pivot pins with molydisulfide grease.
BD01D695
Install the two bolts for the mounting bracket for the STEP 132
target bar.
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
STEP 126 hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.

8001-24
OIL COOLER
Removal STEP 138
STEP 133
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 134
position.
STEP 135
Raise the engine hood and remove the shield on the
right side of the machine between the tire and the oil BD03A154
cooler. Disconnect the top hose and install a plug in the hose
and a cap on the fitting.
STEP 136
STEP 139
BD03A120
Have assistant hold side panel in raised position,

BD03A179
remove two mounting screws, remove side panel.
Loosen and remove the bolt and washer that fasten
the oil cooler to the cooling frame.
STEP 137
STEP 140
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
BD06H195
Disconnect the hose from the bottom of the oil cooler.
Install a plug in the hose and a cap on the fitting.
Remove the two mounting nuts, remove the oil cooler
from the machine.

8001-25
STEP 141
BD03A120
Have assistant hold side panel in raised position,

install and tighten two mounting screws.
BD06H195
Place the oil cooler in position in the cooling frame.

Connect the lower hose to the oil cooler, install and STEP 145
tighten the two mounting nuts. Turn off the vacuum pump and disconnect from the
STEP 142
STEP 146
position.
STEP 147
Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 148
Install the shield between the right rear tire and the
oil cooler and tighten the two bolts holding the shield.
BD03A179
Install the bolt and washer that fasten the oil cooler to STEP 149
the cooling frame Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
STEP 143
BD03A154
Connect the hose to the top of the oil cooler.

8001-26
RIDE CONTROL ACCUMULATOR
Removal STEP 153
STEP 150
parking brake.
circuit, turn ignition switch OFF. BD06H196
Disconnect the hose from the elbow at the bottom of
STEP 151 the ride control accumulator. Install a plug in the hose
and a cap on the fitting.
STEP 154
BD06H198

the ride control valve. Remove the plug and turn the BD06H197
valve two turns counter-clockwise. Loosen and remove the nuts and washers from the
U-bolt. Remove the U-bolt.
STEP 152
STEP 155
accumulator bracket to the front frame. Remove the
ride control accumulator from the machine.
pump.

8001-27
STEP 156
Place the ride control accumulator in position on the
front frame.
STEP 157
Install the two bolts that fasten the accumulator
bracket to the front frame. Tighten the bolts.
STEP 158
BD06H196
Remove the caps and plugs and install the hose on

the elbow at the bottom of the r ide control
accumulator.
STEP 160
Turn off and disconnect the vacuum pump from the
STEP 161
BD06H197
Tighten the accumulator manual bleeder valve
Install the U-bolt, washers and nuts. Tighten the nuts. located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).
STEP 162
Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.
STEP 163

8001-28
RIDE CONTROL VALVE
Removal STEP 166

STEP 164 release the air pressure in the reservoir. Connect a
Park the machine on a level surface and lower the vacuum pump to the hydraulic reservoir, turn on the
bucket to the floor. Stop the engine and apply the pump.
parking brake.
STEP 167
position.
loader control valve back and forth several times to STEP 168
release any hydraulic pressure in the pilot control Disconnect the electrical connector on top of the ride
circuit, turn ignition switch OFF. control valve.
STEP 165 STEP 169

Tag and disconnect the hoses from the ride control
valve. Install a plug in the hoses and caps on fittings.
STEP 170
Loosen and remove the two bolts and washers that
fasten the ride control valve to the frame.
STEP 171
Remove the ride control valve from the machine.
STEP 172
BD06H198 Remove and discard all O-rings.
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.

8001-29

Connect the electrical connector to the ride control
STEP 173 valve.
Install the ride control valve in position on the front
frame. STEP 179
STEP 174 hydraulic reservoir.
Install the washers and bolts through the frame and
into the ride control valve. Tighten the bolts. STEP 180
STEP 175 position.
STEP 181
Start and run the engine at low idle for two minutes.
STEP 182
Stop the engine and check for hydraulic oil leakage at
the ride control valve.
STEP 183
BD06H198 hydraulic reservoir.
Tighten the accumulator manual bleeder valve
located on the top of the ride control valve to a torque STEP 184
of 3.5 Nm (31 lb-in). Install the plug and torque to Refer to Section 8002 and perform the Ride Control
7 Nm (62 lb-in). Test Procedure.
STEP 176
Lubricate and install new O-rings.
STEP 177
Connect the hoses to the ride control valve.

8001-30
FAN REVERSING VALVE
Removal STEP 188
STEP 185
parking brake.
the brake repeatedly to be sure the brake 2
1
BD03A174
STEP 186 Tag and disconnect the fan forward hose (1) from the
Loosen the filler cap on the hydraulic reservoir to fan reversing valve. Install a plug in the hose and a
release the air pressure in the reservoir. Connect a cap on the fitting. Tag and disconnect the fan reverse
vacuum pump to the hydraulic reservoir, turn on the hose (2) from the fan reversing valve. Install a plug in
pump. the hose and a cap on the fitting.
STEP 187 STEP 189
3
4
BD03A173
BD03A174
Tag and disconnect the fan valve return hose (3) from
Disconnect the electrical connector for the fan the fan reversing valve. Install a plug in the hose and
reversing valve. a cap on the fitting. Tag and disconnect the fan valve
supply hose (4) from the fan reversing valve. Install a
plug in the hose and a cap on the fitting.
STEP 190
Loosen and remove the nuts, washers and bolts.
STEP 191
Remove the fan reversing valve from the machine.
STEP 192
Remove and discard all O-rings from the fittings.

8001-31
STEP 193
Place the fan reversing valve into position on the
machine.
STEP 194
Lubricate and install new O-rings in the fittings.
STEP 195
Install the bolts, washers and nuts. Tighten the nuts.
STEP 196
BD03A174
Connect the electrical connector for the fan reversing

valve.
STEP 199
STEP 200
3 Check the level of the hydraulic oil in the reservoir.
4
STEP 201
BD03A173
Connect the fan valve supply hose (4) to the fitting on Start the engine and run the engine at low idle for two
the fan reversing valve. Connect the fan valve return minutes.
hose (3) to the elbow on the fan reversing valve.
STEP 202
STEP 197 Stop the engine and check for hydraulic oil leakage at
the fan reversing valve.
STEP 203
reservoir.
BD03A174
Connect the fan reverse hose (2) to the fitting on the

fan reversing valve. Connect the fan forward hose (1)
to the fitting on the fan reversing valve.

8001-32
THERMAL VALVE
STEP 204 STEP 208
Park the machine on a level surface and lower the Place the thermal valve into position on the machine.
parking brake. STEP 209
IMPORTANT: With the engine NOT running, pump Lubricate and install new O-rings in the fittings.
accumulators have no hydraulic pressure, put the STEP 210
ignition switch in the ON position then move the Install the bolts, washers and nuts. Tighten the nuts.
release any hydraulic pressure in the pilot control STEP 211
Connect the hoses to the thermal valve, remove and
discard tags.
STEP 205
Loosen the filler cap on the hydraulic reservoir to STEP 212
pump.
STEP 213
STEP 206
Check the level of the hydraulic oil in the reservoir.
STEP 214
Start the engine and run the engine at low idle for two
minutes.
STEP 215
Stop the engine and check for hydraulic oil leakage at
the thermal valve.
STEP 216
BD06F211
Tag and disconnect the hoses from the thermal valve. and add as required. Tighten the filler cap on the
Install a plug in the hose and a cap on the fitting. reservoir.
STEP 207
Remove the mounting bolts from the thermal valve,
remove the valve from the machine.

8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS

8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TESTING AND ADJUSTING THE HIGH PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING THE LOW PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

8002-3
SPECIFICATIONS
Manufacturer........................................................................................................................................ Bosch-Rexroth
High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2500 psi at 2000rpm)
Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2500 psi at 2000rpm)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Circuit relief valve pressure setting
Auxiliary A and B port.................................................................................................................290 bar (4200 psi)
Bucket A port..............................................................................................................................290 bar (4200 psi)
Bucket B port..............................................................................................................................290 bar (4200 psi)
Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Brake accumulator pressure .......................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.

8002-4
SPECIAL TOOLS
633L95 B877168V
CAS-1904 PRESSURE FITTING KIT CAS-1808 FLOWMETER FITTING KIT
632L95 B877895M
CAS-1906 PRESSURE FITTING KIT CAS-10090 HAND PUMP
B785789M B877558M
CAS-10280 FLOWMETER CAS-1804 PRESSURE FITTING KIT

8002-5
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and

damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is Fill the hydraulic reservoir with the hydraulic oil
No specified in Section 1002.
the oil level correct?.
Yes
Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.
Problems in All Circuits

Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for contaminated See Page 18. Do the flow meter test of the
No hydraulic pump.
oil. Is the oil contaminated?
Yes
See Section 8003 and clean or replace the

oil.
Problem in All Loader Circuits

See Page 11 and check the pressure setting
Adjust the limit pressure. See page 11 in this
of the limit pressure in the loader control No section.
valve. Is the pressure setting correct?
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.

8002-6
Problem in a Single Loader Circuit

Star t and run the engine at full throttle. The loader control valve is damaged. See
Operate the control for the bad circuit. Does No Section 8005 and repair the loader control
the cylinder move in both directions? valve
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 20. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of control valve and che ck for wor n or
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes
See Page 13. Do the Steering Pump Limit

Pressure Test and Adjustment
Problem in the Ride Control

Lift ar ms rapidly and continuously sink See the Ride Control Test Procedure page
towards the ground. No 21 in this section.
Yes
Check the manual bleed valve for the ride

control accumulator to be sure that it is
closed.

8002-7
TESTING AND ADJUSTING THE HIGH PRESSURE

PUMP DIFFERENTIAL PRESSURE
Pressure Check STEP 3
STEP 1
BD06G180
BD00M041
1. ARTICULATION LOCK 2
Install articulation lock (1).
STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54°C to 57°C (129°F to 135°F). The following
is the procedure for heating the hydraulic oil.
BD06F148
● To measure the oil temperature with the instrument 1. TEST PORT (LOAD SENSE)
cluster: 2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to
B. Stop at the info screen with the temperatures the test port (2) located on the priority valve, and one
that need to be monitored are on. on the pump load-sense pressure tap (1 closest to
● To heat the hydraulic oil do the following: transmission).
A. Start the engine and run at full throttle. IMPORTANT: Do not steer or operate loader controls
while the gauges are connected, gauges could be
B. Hold the bucket control lever in the damaged.
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full STEP 4
height.
Start the engine and run at low idle.
C. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to STEP 5
135°F).
Make sure all of the controls are in the neutral
After heating oil to operating temperature, lower position and record the readings on the test gauges
bucket to the ground, turn off the engine, and relieve (1) and (2).
all pressure in the hydraulic system.
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).

8002-8
STEP 7 Adjusting the High Pressure Pump
The difference between the two readings should be Differential Pressure
24 to 27 bar (350 to 390 psi).
STEP 9
STEP 8
The load-sense adjusting screw is directly below the
If this reading is more or less than specified, it will be load-sense pressure tap. Turn the screw clockwise to
necessary to adjust the pump load-sense pressure. increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense
pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).

8002-9
TESTING AND ADJUSTING THE LOW PRESSURE

PUMP DIFFERENTIAL PRESSURE
STEP 1
BD06G180
1
2
BD00M041
STEP 2
BD06F148
● To measure the oil temperature with the instrument 1. TEST PORT (LOAD SENSE)
cluster: 2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to
B. Stop at the info screen with the temperatures the test port (2) located on the priority valve, and one
that need to be monitored are on. on the pump load-sense pressure tap (1 furthest
● To heat the hydraulic oil do the following: from the transmission).
A. Start the engine and run at full throttle. IMPORTANT: Do not steer of operate loader controls
while the gauges are connected, gauges could be
B. Hold the bucket control lever in the damaged.
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full STEP 4
height.
Start the engine and run at low idle.
135°F).
Make sure all of the controls are in the neutral
After heating oil to operating temperature, lower position and record the readings on the test gauges
bucket to the ground, turn off the engine, and relieve (1) and (2).
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).

8002-10
STEP 7 Adjusting the Low Pressure Pump
The difference between the two readings should be Differential Pressure
25 to 28 bar (360 to 400 psi).
STEP 9
STEP 8
The differential adjusting screw is directly below the
If this reading is more or less than specified, it will be load-sense pressure tap. Turn the screw clockwise to
necessary to adjust the pump differential pressure. increase the load-sense pressure. Turning the screw
counterclockwise will decrease the differential
pressure.

8002-11
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE

STEP 1 at least 54°C to 57°C (129°F to 135°F). The following
● To measure the oil temperature with the instrument
cluster:
that need to be monitored are on.
● To heat the hydraulic oil do the following:
A. Start the engine and run at full throttle.
1 B. Hold the bucket control lever in the
RO L L B AC K p o s i t i o n w h i l e r a i s i n g a n d
lowering the lift arms from ground level to full
BD00M041
height.
of the hydraulic oil is 54° to 57°C (129° to
135°F).
STEP 2 After heating oil to operating temperature, lower
bucket to the ground, turn off the engine, and relieve
STEP 4
1 Run the engine at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
Record the reading on the test gauge.
BD06F148
1. TEST PORT (LOAD LIMIT) STEP 7

Reading should be 248 to 255 bar (3600 to 3700 psi).
Connect a 345 bar (5000 psi) test gauge to the test
port (1), located on the priority valve. STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump limit pressure.

8002-12
Adjusting the Loader Limit STEP 9

Pressure The limit adjusting screw is located on the left side of
the loader valve. Tur n the screw clockwise to
increase the limit pressure. Turning the screw
counterclockwise will decrease the limit pressure.
BD06H193

8002-13
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE

cluster:
BD00M041
height.
135°F).
STEP 4
1 Start the engine and run at full throttle.
STEP 5
Steer hard in either direction over relief pressure.
STEP 6
BD06F148
1. TEST PORT (LOAD LIMIT) STEP 7

Connect a 345 bar (5000 psi) test gauge to the test
port (1), located on the priority valve. STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the steering limit pressure.

8002-14
Adjusting the Steering Limit STEP 9

Pressure The steering priority valve is located on the hydraulic
p u m p, t h e a d j u s t i n g va l ve i s l o c a t e d o n t h e
transmission side of the priority valve. Turning the
screw clockwise to increase the limit pressure.
Turning the screw counterclockwise will decrease the
limit pressure.
BD06F147
1. STEERING LIMIT VALVE

8002-15
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE

cluster:
BD00M041
height.
135°F).
1 all pressure in the hydraulic system.
STEP 4
Start the engine and run at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
BD06F148
1. TEST PORT (PUMP PRESSURE) STEP 7

Connect two 345 bar (5000 psi) test gauge to the test
port (1) located on the large hydraulic tube on the STEP 8
bottom of the pump. If this reading is more or less than specified, it will be
necessary to adjust the pump cutoff pressure.

8002-16
Adjusting the Loader Pump Cutoff

Pressure
STEP 9
BD06G179
The unloading adjuster is the longer of the two

adjusters on the loader pump. Tur n the screw
clockwise to increase the cutoff pressure. Turning the
screw counterclockwise will decrease the cutoff
pressure.
NOTE: The adjusting screw is located just above the
steering priority valve on the pump furthest from the
transmission.

8002-17
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE

NOTE: This pressure is factory preset and is not STEP 6
adjustable. Open the right side compartment to gain access to
the loader control handle.
Pressure Check
STEP 7
STEP 1 Attach a gauge capable of reading 70 bar (1000 psi)
Make sure that the temperature of the hydraulic oil is to the test port under loader control handle.
is the procedure for heating the hydraulic oil. STEP 8
● To measure the oil temperature with the Start and run the machine at low idle, hold the bucket
instrument cluster: control lever in the ROLLBACK position to increase
the system pressure.
B. Stop at the info screen with the temperatures STEP 9
that need to be monitored are on. A pressure reading of 29.5 to 39.5 bar (425 to 575
● To heat the hydraulic oil do the following: psi) should be obtained, if pressure is not as
specified do the following steps.
B. Hold the bucket control lever in the STEP 10
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d Lower the bucket to the ground and turn off the
lowering the lift arms from ground level to full engine. Tur n the ignition switch to the “RUN”
height. position.
135°F). Operate the pilot controls several times until the
gauge pressure suddenly drops to zero. The last
STEP 2 pressure reading before the drop to zero is the
nitrogen charge pressure in the accumulator. If the
Raise lift arms to the top and turn off the engine. Turn
pressure is below 13 to 15 bar (188 to 218 psi),
the ignition switch to the “RUN” position.
replace the accumulator. If accumulator test is good,
go to next step.
STEP 3
Repeatedly put the loader control lever into “FLOAT” STEP 12
position and back to neutral.
Replace the pilot controls, see section 8001, retest
the system, if test fails go to next step.
STEP 4
The system should allow a minimum of 10 actuations STEP 13
into float and still cause the lift arms to come down.
Replace the loader control valve, see section 8001,
NOTE: If 10 full actuations cannot be made, an retest the system.
internal hydraulic leak exists, proceed to next step.
STEP 5
Start machine and lower the bucket to the ground
and turn off the engine. Turn the ignition switch to the
“RUN” position, operate the pilots controls a
minimum of 30 strokes to relieve any pressure in the
system.

8002-18
HIGH PRESSURE PUMP FLOW TEST

NOTE: The pump differential pressure must be set STEP 6
before attempting any other tests. Refer to page 7 of Using the temperature gauge on the flow meter,
this section. continue to run the engine at high idle until the
temperature of the hydraulic oil is at least 52°C to
STEP 1 60°C (125°F to 140°F).
Connect the flow meter (3) by disconnecting the inlet
hose (6) to the valve supply tube (13), installing a cap STEP 7
(12) on the fitting at the valve supply tube (13). Refer Run the engine at low idle, fully open the flow meter
to illustration on page 19. valve.
STEP 2 STEP 8
Disconnect the load sense hose (7) and install a cap Open the needle valve (8) and operate the engine at
(12) the fitting at the loader valve (15). 2000 rpm. At 0 bar (0 psi) the flow should be 250 to
NOTE: This is the line that returns to the pump 255 L/min (66 to 67.4 gpm).
compensator valve.
STEP 9
STEP 3 Close the flow meter valve slowly and read the flow
Connect a “T” fitting (10) into the loader control valve at 34.5 bar (500 psi) the flow should be 249 to 255
inlet hose (6) and to the flow meter inlet hose (11). L/min (65.8 to 66.8 gpm).
STEP 4 STEP 10
Use a union (9) and connect an in line needle valve Close the flow meter valve slowly and read the flow
(8) to the open port in the “T” fitting (10), connect the at 2000 psi @ 2000 rpm. The flow should read 244.5
load sense hose (7) to the needle valve (8). to 247.5 L/min (64.6 to 65.4 gpm).
STEP 5 STEP 11
Make sure that the flow meter valve and the installed Continue to close the flow meter valve slowly, at
needle valve are in the open position. Start and run approximately 2900 psi the flow should drop
the engine at high idle, slowly close the flow meter significantly, this will be the low pressure pump
valve until a pressure reading of 103 bar (1500 psi) is destroking.
obtained.
STEP 12
Continue slowly closing the flow meter valve until
3500 psi is reached. The flow should read between
120 to 122 L/min (31.6 and 32.1 gpm).
STEP 13
If any of the pump flow readings are not within
specifications, the pump may be out of calibration
a n d Te c h n i c a l S u p p o r t S e r v i c e s s h o u l d b e
contacted.

8002-19
2 4
3
5
6
11
12
13
7
10
9
12
8
14
15
BS06G117
1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB 11. FLOW METER INLET HOSE
2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP
3. FLOW METER 8. NEEDLE VALVE 13. VALVE TUBE SUPPLY
4. PUMPS 9. UNION 14. ELBOW M14 ORB
5. PRIORITY VALVE 10. T FITTING 15. LOADER VALVE
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

8002-20
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Remove the safety strut and lower the bucket to the
STEP 1 floor. Shut off the engine. Find an easy place to
Circuit relief valves are located as shown below. disconnect the line for the circuit to be tested.
4 STEP 5
3 5
1 Connect the hand pump to the disconnected line that
1 goes to the loader control valve.
2
STEP 6
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21°C (70°F).
STEP 7
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
6 be sure of the reading.
STEP 8
Compare the reading to the specifications on Page 3.
STEP 9
1 If the pressure is not correct, adjust the circuit relief
1
valve.
3 5
4 Adjustment
BS03B022
1. CIRCUIT RELIEF VALVES STEP 1

2. PUMP LIMIT PRESSURE ADJUSTMENT Loosen the lock nut. Turn the adjustment screw
3. BUCKET SPOOL
clockwise to increase the pressure or
4. LIFT SPOOL
counterclockwise to decrease the pressure.
5. AUXILIARY SPOOL
6. LOADER CONTROL VALVE NOTE: One turn of the adjusting screw will change
STEP 2
Raise the lift arms and install the safety link on the lift STEP 2
arm cylinder. Check the pressure again. Repeat the adjustment as
necessary.
STEP 3
Loosen and remove the bolts and washers that
fasten the access cover plate for the loader control
valve. Remove the cover plate.

8002-21
TESTING THE RIDE CONTROL

STEP 1 STEP 6
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP 2
Install the ar ticulation lock, star t the machine, STEP 7
activate the parking brake.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
STEP 3 their stops, place the pilot control lever in the neutral
With the pilot controller in neutral, set the ride control position.
rocker switch on the right side console to the “Always
On” position and observe the switch lamp, the lamp STEP 8
should illuminate.
Set the ride control rocker switch to the “Always On”
position. The lift arms should rise 15 to 30 cm (6 to
STEP 4 12 inches) with an empty bucket.
Set the ride control rocker switch to the “Off” position
and observe the switch lamp, the lamp should go out. NOTE: Test results will be for a machine with a
empty factory bucket and no attachments.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not STEP 9
illuminate see section 4002 and troubleshoot the
If there is little or no lift arm raise, the test may have
electrical system for the ride control.
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
STEP 5
Raise the lift arms to the top of their travel and dump NOTE: If test was done to slowly repeat in the
the bucket. allotted time.
STEP 10
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator, see section 8013.

8002-22
HYDRAULIC COMPONENT LOCATIONS
5
6 8
7
9
4 10
2 8
3
11
15 12
14 13
16
19
18
17
1
BC00N140
1. REAR BRAKE CYLINDERS 11. FRONT BRAKE CYLINDERS
2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC 12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND
COUPLER RIDE CONTROL VALVE (OPTIONAL)
3. BRAKE ACCUMULATORS 13. PARKING BRAKE CYLINDER
4. FRONT AND REAR AXLE BRAKE PRESSURE 14. STEERING PRESSURE DIAGNOSTIC COUPLER
DIAGNOSTIC COUPLERS 15. STEERING PRIORITY VALVE
5. BRAKE LIGHT PRESSURE SWITCH 16. STEERING CYLINDERS
6. BRAKE WARNING PRESSURE SWITCH 17. AUXILIARY STEERING PUMP AND MOTOR
7. BRAKE AND ACCUMULATOR CHARGING VALVE
18. AUXILIARY STEERING PRIORITY VALVE
8. LIFT CYLINDERS
19. AUXILIARY STEERING PRESSURE SWITCH
9. BUCKET CYLINDER (TILT CYLINDER)
10. RIDE CONTROL ACCUMULATOR
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

8002-23
23
24
21 25
26
22
20
30
29 27
28
31
32
33
34
BC00N140
20. FAN DRIVE MOTOR 28. PUMP PRESSURE DIAGNOSTIC COUPLER

21. HYDRAULIC RESERVOIR BREATHER 29. LOAD SENSING DIAGNOSTIC COUPLER
22. HYDRAULIC RESERVOIR 30. IMPLEMENT HYDRAULIC PUMP
23. PILOT PRESSURE DIAGNOSTIC COUPLER 31. HYDRAULIC FILTER
24. PILOT CONTROL VALVE 32. HYDRAULIC COOLER
25. PILOT PRESSURE ACCUMULATOR 33. BRAKE HYDRAULIC PUMP
26. LOADER CONTROL VALVE 34. FAN VALVE
27. PARKING BRAKE ACCUMULATOR
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

8002-24
NOTES

Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM

Racine, WI 53404 U.S.A. Bur 7-49641 Issued April, 2003 Revised August, 2006
8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8003-3
SPECIAL TOOLS
806128
CAS10508, fitting kit.
806127
CAS101162A, filter unit, portable.
TR98H032
CAS10192, vacuum pump.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check the
hydraulic system permits efficient operation with a hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.

8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.

8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.

8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39-4
NOTE: Any attachment or part of an attachment that 18. Slowly and completely extend all cylinders. As
is raised must be supported with acceptable the piston rod comes in/out of the cylinder, oil will
equipment to prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that
release pressure in the hydraulic circuits. is raised must be supported with acceptable
4. Loosen and remove the filler cap from the equipment to prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.

8003-8
NOTES

Section
8004
8004
HYDRAULIC PUMP

8004-2
TABLE OF CONTENTS
PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8004-3
PUMP SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
High pressure pump (steering pump next to transmission) ............. 120 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(31.6 U.S. gpm at 2500 psi at 2000rpm)
Low pressure pump (loader pump farthermost from transmission) ... 86 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(22.5 U.S. gpm at 2500 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts...................................................................................................165 Nm (121.5 pound-feet)
Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet)
Control piston plug ..............................................................................................................90 Nm (66 pound-feet)
PREPARING THE EQUIPMENT PUMP FOR USE

Do the following procedure any time you install a new 4. Repeat Step 3 for three minutes.
or overhauled equipment pump:
5. Increase the engine speed to full throttle and
1. Start and run the engine at half throttle for three repeat Steps 3 and 4.
minutes.
6. Stop the engine and check for leaks.
2. With the engine running at half throttle, move the
7. Replace the hydraulic filter.
bucket control lever into roll back position. Hold
the bucket control lever in this position until the
bucket stops moving.
3. Hold the bucket control lever in the roll back
position for five seconds. Then put the bucket
control lever in the NEUTRAL position for five
seconds.

8004-4
EQUIPMENT PUMP
7 8 9
6 5
5 4
4
3
10
2 11
1
12 24
13 23
22
21
20
19
18
17
15
14 16
30
29
15 28
27
26
25
BC06F550
1. SNAP RING 11. TAPERED BEARING 21. PRESSURE PINS

2. SEAL 12. BEARING RACE 22. BACKUP PLATE
3. MAIN BODY 13. SHIM 23. SPRING
4. O-RING 14. SPRING 24. SNAP RING
5. PLUG 15. HALF BEARING 25. PORT PLATE
6. CONTROL VALVE 16. SWASH PLATE 26. SHIM
7. CAP SCREW 17. PISTONS 27. TAPERED BEARING
8. PISTON ROD 18. RETAINING PLATE 28. BEARING RACE
9. CONTROL PISTON 19. BALL 29. DOWEL PIN
10. SHAFT 20. CYLINDER 30. END COVER

8004-5
Disassembly STEP 3
STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.
STEP 2
BC06F552
Remove the control valve.
STEP 4
BC06F551
Put alignment marks on the end cover and housing.
BC06F553
Remove the four bolts.

8004-6
STEP 5 STEP 6
BC06F555
BC06F554
Remove the end cover. Use a suitable bearing race puller and pull the
bearing race from the end cover.
NOTE: Watch for the flow plate, it can be stuck to
either the end cover or pump body. NOTE: Do not damage the sealing surfaces.

8004-7
STEP 7 STEP 9
BC06F558
Remove plug, pull control piston using a suitable tool

as shown.
NOTE: Do not use a magnet to pull the piston.
STEP 10
BC06F556
Remove the bearing and shim.
STEP 8
BC06F559
Remove the piston rod and swash plate. Turn the

swash plate slightly to break it free from the bearings.
BC06F557
Remove the rotary group from the housing in a

horizontal position.

8004-8
STEP 11 STEP 14
BC06F560
Remove the bearing and spring.
STEP 12
BC06F563
Use a suitable bearing race puller and pull the

bearing race from the housing.
STEP 15
BC06F561
Remove the shaft and bearing.
STEP 13
BC06F564
Remove the shim and plug.
BC06F562
Remove the retaining ring an seal.

8004-9
Inspection STEP 19
STEP 16
Clean all parts in cleaning solvent. Be careful not to
remove the alignment mar ks made dur ing
disassembly.
STEP 17
BC06F567
Check the bearing surface.
STEP 20
BC06F565
Check for wear on the splines, seal areas for

grooves, bearing areas for scaring, and key set.
STEP 18
BC06F568
Check that the retaining plate is free of grooves and

that there is no sign of wear.
STEP 21
BC06F566
Check the surface that the pistons contact for

grooves and scaring.
BC06F569
Check the sliding surface for scratches or metal

deposits, check the tightness of the cup on the
piston.
NOTE: If a piston needs to be replaced, all of the
pistons must be replaced.

8004-10
STEP 22 STEP 24
BC06F572
BC06F570
Check the cylinder bores and splines for damage. Check cylinder surface for grooves, wear, embedded
particles. Check flow plate for scratches or wear.
STEP 23
STEP 25
BC06F571
BC06F573
Check ball for grooves and wear.
Check mounting surface for the flow plate for
damage.

8004-11
Assembly STEP 27
STEP 26
BC06F574 BC06F575
Install the plug in the housing and tighten to 127 Nm Put the shaft and bearing in the housing.
(93.5 pound-feet). Install shim and press in the
bearing race. STEP 28
BC06F576
Press in a new race into the end cover.

8004-12
STEP 29 STEP 31
BC06F579
Install the seal and retaining ring.
STEP 32
BC06F577
Install the end cover, 4 bolts and hand tighten.
STEP 30
BC06F578
A bearing pre load of 0.05 mm (0.002 inch) must be

obtained, add remove shims from bear ing as
required.
BC06F580
Put new bearings in the housing. Install the reaction

spring.

8004-13
STEP 33 STEP 34
BC06F582
Install the piston into the housing with flat surface

out. Lubricate the O-ring and install the plug, tighten
the plug to 90 Nm (66 pound-feet).
STEP 35
BC06F581
Install the swash plate into the housing, work the

swash plate from side to side to seat it in the
bearings and spring. Install the piston rod.
BC06F583
Use grease to hold the pressure pins into position,

install the spacer, spring and snap ring.

8004-14
STEP 36 STEP 39
BC06F584
Use a suitable compressor, compress the spring and

install the snap ring.
STEP 37
BC06F585 BC06F587
Place the ball onto the pressure pins, install the Hold the pistons in the rotating housing using an
pistons into the retaining plate. O-ring, install the rotating group into the housing,
remove the O-ring.
STEP 38
BC06F586
Lubricate the piston and retaining plate with clean oil,

install the piston into the rotating housing.

8004-15
STEP 40 STEP 41
BC06F588
Use the shim that was required for the bearing pre
load in step 30. Install the shim and bearing onto the
shaft.
BC06F589
Install a new O-ring on the end cover, place the flow

plate onto the rotating group with aligning notch up.
Place the end cover onto the housing, make sure that
the aligning pin in the end cover aligns with the slot in
the flow plate.

8004-16
STEP 42 STEP 43
BC06F591
Use new O-rings, install and tighten the control valve.
BC06F590
Instal and tighten the four bolts to 165 Nm

(121.5 pound-feet).

Section
8005
LOADER CONTROL VALVE
8005

8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8005-3
SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
Special Torques
End plate mounting bolts.................................................................................................. 70 Nm (51.5 pound feet)
Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound inches)
Allen head plugs.............................................................................................................. 240 Nm (177 pound feet)
Allen head locking screw................................................................................................ 100 Nm (73.7 pound feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches)
Anticavitation valves ....................................................................................................... 100 Nm (73.7 pound feet)
Combination anticavitation and circuit relief ................................................................. 200 Nm (147.5 pound feet)
Main relief valve pressure settings (XT and Z-Bar) ............................................... 248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A port (XT and Z-Bar) ....................................................................................................152 bar (2205 psi)
Bucket B port (XT and Z-Bar) ....................................................................................................290 bar (4206 psi)

8005-4
4
3
5
22
6
6 7
21
6
20
19 8
18
17
6 9
16
10
11
15 14
8
12 12
13
BS03C033
1. BOLT 7. LOAD SENSE SHUTTLE CHECK 13. FLOAT SOLENOID 18. LOAD CHECK
8. ANTICAVITATION AND CIRCUIT
2. WASHER 14. PLUG 19. FLOW LIMIT VALVE
RELIEF
15. REGENERATION CHECK
3. LOCKING SCREWS 9. LOAD SENSE BLEED DOWN ORIFICE 20. PRESSURE RELIEF VALVE
VALVE
4. PLATE 10. FLOW COMPENSATOR SPOOL 16. LOCKING SCREW 21. CONE
5. REGENERATION
11. HOUSING 17. SPRING 22. LOCKING SCREW
RELIEF VALVE
6. O-RINGS 12. PLUG
2 SPOOL VALVE HOUSING CONFIGURATION

8005-5
27
26
25
24
23
6 28
31 29
30
6
6
33 33 32
34
31
6
23 24
24 23
34 6
35
32
30
29
BC06F593
6. O-RINGS 27. BOLT 32. BOLT

23. SPRING RETAINER 28. PISTON 33. COVER
24. SPRING 29. CAP NUT 34. ADJUSTING ROD
25. SPRING 30. JAM NUT 35. SPOOL
26. COVER 31. PISTON
2 SPOOL VALVE SPOOL CONFIGURATION

8005-6
37
36
37
BS03C036
36. HOUSING 37. ANTICAVITATION AND CIRCUIT RELIEF

3 SPOOL MOUNTING CONFIGURATION

8005-7
38
39
BS03C035
38. NUT 39. STUD

4 SPOOL MOUNTING CONFIGURATION

8005-8
31 29
30
33
34
6 6
23
24
23 32
35
33 23
31 24
6
6
34
29
30 32
BS03C037
3 AND 4 SPOOL VALVE SPOOL CONFIGURATION
6. O-RINGS 31. PISTON

23. SPRING RETAINER 32. BOLT
24. SPRING 33. COVER
29. CAP NUT 34. ADJUSTING ROD
30. JAM NUT 35. SPOOL

8005-9
DISSASEMBLY
STEP 1 STEP 7
Remove valve from machine, see section 8001. Remove pressure relief valve (20).
STEP 2 STEP 8
Remove bolts (27), cover (26), springs (24 and 25), Remove flow limit valve (19).
and spring retainer (23).
STEP 9
STEP 3 Remove locking screw (16), spring (17), and cone
Remove bolts (32), covers (33), spring (24), and (18).
spring retainer (23).
STEP 10
STEP 4 Remove regeneration check valve (15).
Use wooden dowel or brass drift and push spools
(35) from housing (11). STEP 11
IMPORTANT: Do not force spools from housing, if Remove locking screw (14).
spool binds work back and forth until spool comes
out freely. STEP 12
NOTE: Repeat steps 3 and 4 for a 3 and 4 spool Remove load sense shuttle check valve (7).
valve configuration.
STEP 13
STEP 5 Remove locking screws (12).
Remove anticavitation valves (5, 8, 10, and 13).
STEP 14
NOTE: Repeat step for a 3 and 4 spool anticavitation
Remove pilot pressure reducing valve (9).
valves (37).
STEP 15
STEP 6
Remove bolts (1) and washers (2), remove plate (4)
Remove locking screw (22) and cone (21).
from housing (11).
NOTE: For 4 spool configuration remove nut (38)
from stud (39), remove housings (36) from housing
(11).

8005-10
STEP 16 STEP 18
2
1
2
1
1
1
BS03C025 BS03C027
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING

Remove and discard O-rings and thrust rings from Remove and discard O-rings and thrust ring from
pilot pressure reducing valve (9). locking screw (14).
STEP 17
2 STEP 19
1
2
1
1
3
1 1
BS03C026 2
1. O-RINGS 2. THRUST RINGS BS03C028
Remove and discard O-rings and thrust rings from 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL
flow limit valve (19).
Remove and discard O-rings, thrust ring, and spool
seal from anticavitation valve (5).

8005-11
STEP 20
1
1
2
BS03C029
1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (20).
STEP 21
1
2
1
2
BS03C030

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).

8005-12
STEP 22
BS03C031
1. O-RINGS 2. COIL
Remove and discard O-rings and thrust rings from anticavitation valve (13).

8005-13
STEP 23
3
4
2 1
1
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 37).

8005-14
INSPECTION
1. Discard all O-rings, thrust rings, and spool seals. 4. Check the parts of the pressure relief valve,
anticavitation valves, and the anticavitation and
2. Clean all parts in cleaning solvent.
circuit relief valves. Use new parts as necessary.
3. Check the spools and the spool bores for
Inspect the other parts of the control valve. If any of
damage and wear.
the parts are damaged, install new parts.
ASSEMBLY
STEP 1
3
4
A
2 1
1 See Note
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (8 and 37). Torque relief valve (A) into
anticavitation valve to 200 Nm (147.5 pound feet).
NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in
direction of arrow.

8005-15
STEP 2
A
1
BS03C031
1. O-RINGS 2. COIL
Install new O-rings and thrust rings on anticavitation valve (13). Hand tighten coil nut (A).
STEP 3
1
2
1
2
1 A
BS03C030

Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm
(73.7 pound feet).

8005-16
STEP 4
1
1
2
BS03C029

Install new O-rings and thrust rings on pressure relief valve (20).

8005-17
STEP 5 STEP 8
2 1
1
1
3
1 1
2
BS03C025 BS03C028
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL

Install new O-rings and thrust rings on pilot pressure Install new O-rings, thrust ring, and spool seal on
reducing valve (9). anticavitation valve (5).
STEP 6 STEP 9
Install and torque regeneration check valve (15) to
2
100 Nm (73.7 pound feet).
STEP 10
Install and torque locking screw (14) to 100 Nm
2 (73.7 pound feet).
1
1 STEP 11
Install and tighten load sense shuttle check valve (7).
STEP 12
BS03C026 Install and torque locking screws (12) to 240 Nm
1. O-RINGS 2. THRUST RINGS (177 pound feet).
Install new O-rings and thrust rings on flow limit valve
(19). STEP 13
Install and torque pilot pressure reducing valve (9) to
STEP 7 60 Nm (44 pound feet).
STEP 14
1 Install new O-rings on housing (11). Install plate (4),
bolts (1) and washers (2), onto housing (11). Torque
2 bolts to 70 Nm (51.5 pound feet).
1 NOTE: For 4 spool configuration install new O-rings

between housings (36) and housing (11), install nuts
(38) on studs (39). Torque nuts to 70 Nm (51.5 pound
feet).
STEP 15
BS03C027 Install anticavitation valves (5, 10, and 13) and torque
1. O-RINGS 2. THRUST RING to 100 Nm (73.7 pound feet).
Install new O-rings and thrust ring on locking screw NOTE: Repeat step for a 3 and 4 spool anticavitation
(14). valves (37).

8005-18
STEP 16 Circuit Relief Pressure Test
Install anticavitation valves (8) and torque to 200 Nm
(147.5 pound feet). STEP 1
Connect the hand pump to the port for anticavitation
STEP 17 and circuit relief valves (21).
Install and torque flow limit valve (19) to 20 to 25 Nm
NOTE: Repeat steps for machines that are
(177 to 221 pound inches).
configured with a 3 or 4 spool valve.
STEP 18 STEP 2
Install cone (18), spring (17), locking screw (16).
Make sure that the hand pump is full of hydraulic oil
Torque locking screw to 100 Nm (73.7 pound feet).
and that the temperature of the oil is approximately
21°C (70°F).
STEP 19
Install cone (21) and locking screw (22). Torque STEP 3
locking screw to 40 Nm (30 pound feet).
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
STEP 20 be sure of the reading.
Lubricate spools with hydraulic oil and push spools
(35) into housing (11). STEP 4
IMPORTANT: Do not force spools into housing. Compare the reading to the specifications on Page 3.
STEP 21 STEP 5
Install spring retainers (23), springs (24), covers (33), If the pressure is not correct, adjust the circuit relief
and bolts (32). Torque bolts to 10.4 Nm (92 pound valve.
inches).
NOTE: Repeat steps 18 and 19 for a 3 and 4 spool Circuit Relief Adjustment
valve configuration.
STEP 1
STEP 22 Loosen the lock nut. Turn the adjustment screw
Install spring retainers (23), spring (24 and 25), cover clockwise to increase the pressure or
(26), and bolts (27). Torque bolts to 6 Nm (53 pound counterclockwise to decrease the pressure.
inches). NOTE: One turn of the adjusting screw will change
NOTE: Prior to installation in the machine, circuit the pressure approximately 138 bar (2000 psi).
reliefs can be tested.
STEP 2
STEP 23 Check the pressure again. Repeat the adjustment as
Install valve in machine, see section 8001. necessary.
STEP 24
Check loader limit pressure, see section 8002.

Section
8006
CYLINDERS
8006

8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8006-3
SPECIFICATIONS
Approximate weight
Lift Cylinder...........................................................................................................................142.2 kg (313.5 pounds)
Bucket Cylinder........................................................................................................................199.2 kg (439 pounds)
SPECIAL TORQUES
Gland Bolts Bucket Cylinder .......................................................................420 to 500 Nm (310 to 368.8 pound-feet)
Screw in Gland for Lift Cylinders ...................................................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders................................................................2830 to 3220 Nm (2087 to 2374.9 pound-feet)
Lock Screw for Lift Cylinders ............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier ......................................................................................................................................... CAS-1039

8006-4
LIFT CYLINDER
1. Clean exterior of cylinder. If hoses were removed 1. Clean all parts in cleaning solvent. Use only lint
with cylinder, remove hoses from cylinder. free cloths for cleaning and drying.
2. Fasten tube (1) in an acceptable repair stand or 2. Check to be sure that piston rod (13) is straight.
other holding equipment. Do not damage tube If piston rod is not straight, replace it with a new
(1). piston rod.
3. Loosen and remove self-tapping screw (12). 3. Shine a light inside tube (1) and check for deep
grooves and other damage. If there is any
4. Use a spanner wrench to loosen and remove
damage to tube, replace with a new tube.
gland (4) from tube (1).
4. Remove any small scratches on piston rod (13)
5. Pull piston rod (13) straight out of tube (1) to
or inside tube (1) with emery cloth of medium
prevent damage to tube.
grit. Use emery cloth with a rotary motion.
6. Fasten piston rod eye or yoke in a vise and put a
5. Inspect bushings (2) in tube eye. Replace as
support under piston rod (13) near piston (15).
required.
Put a shop cloth between support and piston rod
to prevent damage to piston rod. 6. Inspect gland (4) for rust. Clean and remove rust
as necessary.
7. Use a torque multiplier, CAS-1039, to loosen and
remove bolt (14) that fastens piston (15) to piston 7. Inspect gland end of tube (1) for sharp edges
rod (13). that may cut gland O-ring (11) and remove as
necessary.
8. Remove piston (15) from piston rod (13).
8. Inspect piston (15) for damage and wear. If
9. Remove gland (4) from piston rod (13).
piston is damaged or worn, replace with a new
10. Remove and discard seal (16), ring (17), and piston.
wear ring (18) from piston (15).
11. Remove and discard O-ring (10), backup ring (9),
O-ring (11), wiper (5), rod seal (6), buffer seal
(7), and bushing (8) from gland (4).

8006-5
13
5
6
7
4
8
11
9
10
15
12
17
16
18
14
1
3
2
2
3
BC05J002
1. TUBE 6. ROD SEAL 11. O-RING 16. SEAL

2. BUSHING 7. BUFFER SEAL 12. SCREW 17. RING
3. WIPER 8. BUSHING 13. ROD 18. WEAR RING
4. GLAND 9. BACKUP RING 14. BOLT
5. WIPER 10. O-RING 15. PISTON
LIFT CYLINDER

8006-6
Assembly 17. Install a new ring (17) in the other groove on the
outside of the piston (15).
NOTE: If a new gland is being used, put part number
of cylinder on new gland. 18. Install a new seal (16) on top of ring (17).
1. Install bushing (8) in gland (4). 19. Fasten tube (1) in an acceptable repair stand or
other holding equipment. Be careful to prevent
2. Install rod seal (6) in gland (4). Rod seal is to be damage to tube.
installed so that lips of seal are toward bushing
(8). Rod seal (6) can be difficult to install. 20. Lubricate inside of the tube (1) and piston (15)
with clean oil.
3. Install buffer seal (7) in gland (4). The side of
buffer seal with groove must be toward bushing 21. Push piston (15) straight into tube (1).
(8). 22. When the piston (15) is in smooth part of tube
4. Install a new wiper (5) in gland (4). Lips of wiper (1), start gland (4) into tube.
must be toward outside end of gland (4). 23. Lubricate O-rings (10 and 11) on gland (4) with
5. Install a new O-ring (11) in groove on OD of clean oil.
gland (4). 24. Turn gland (4) into tube (1). Tighten gland to a
6. Install a new backup ring (9) in groove on OD of torque of 135 to 542 Nm (100 to 400 pound-feet).
gland (4). If both sides of backup ring are not flat, 25. If the original parts are being assembled:
side that is not flat must be toward small end of
gland (4). A. Tighten gland to a torque of 135 to 542 Nm
7. Install a new O-ring (10) next to backup ring (9)
in groove on outside of gland (4). O-ring must be B. Install and tighten self-tapping screw (12) to a
toward small end of gland. torque of 2.3 Nm (20 inch-pounds).
8. Fasten piston rod (13) eye or yoke in vise. C. If, after tightening gland, the self-tapping
screw (12) holes are not aligned, a new hole
9. Remove any marks and sharp edges on chamfer for self-tapping screw must be drilled. See
at end of piston rod (13). Make sure that piston Step 26.
rod is clean.
26. If a new gland (4) or a new tube (1) are being
10. Lubricate bore of gland (4) and piston rod (13) assembled:
with clean oil.
A. Tighten gland (4) to 135 to 542 Nm (100 to
11. Push gland (4) onto piston rod (13). If necessary, 400 pound-feet).
use a soft hammer to drive gland onto piston rod.
B. Use a No. 27 drill bit and drill a hole half in
12. Put a support below and near end of piston rod gland (4) and half in tube (1). Drill to a depth of
(13). Use a shop cloth between support and the 11 mm (7/16 inch). Do not drill within 13 mm
piston rod to prevent damage to piston rod. (1/2 inch) of a hole for gland wrench.
13. Start piston (15) onto piston rod (13). C. Install and tighten self-tapping screw (12) to a
14. Clean the threads on the end of the piston rod torque of 2.3 Nm (20 inch-pounds).
(13) and the threads of the bolt (14) using Loctite 27. If hoses were removed with cylinder, install new
cleaning solvent. Allow to dry. Apply Loctite 242 O-rings, if equipped, on hose fittings. Lubricate
to piston rod threads 6.3 mm (1/4 inch) from O-rings with clean oil. Install hoses.
open end of piston rod so that there is 13 mm
(1/2 inch) of Loctite 242 on piston rod threads.
DO NOT apply Loctite to first 6.3 mm (1/4 inch)
of piston rod threads.
15. Install bolt (14) into piston rod (13). Tighten bolt
to a torque of 2830 to 3220 Nm (2087 to 2374.9
pound-feet). A torque multiplier can be used to
help torque the bolt.
16. Install a new wear ring (18) in wide groove on
outside of piston (15).

8006-7
BUCKET CYLINDERS
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder. 2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment. Do not damage the 3. Check to be sure that the piston rod is straight. If
tube (1). the piston rod is not straight, replace it with a
3. Loosen and remove the cap screws (2) and new piston rod.
hardened washers (18) from the gland (3) and 4. Illuminate the inside of the tube for deep grooves
the tube (1). and other damage. If there is any damage to the
4. Pull the piston rod (4) straight out of the tube (1) tube, replace it with a new tube.
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod or
5. Fasten the piston rod eye or yoke in a vise and inside the tube with emery cloth of medium grit.
put a support under the piston rod (4) near the Use the emery cloth with a rotary motion.
piston (7). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (4) to prevent damage to the yoke and the tube. Replace as required.
piston rod (4).
7. Inspect the gland for rust and clean and remove
6. Remove the retaining ring (10) that fastens the rust as necessary.
pin (11) in the piston (7) and piston rod (4).
8. Inspect the gland end of the tube for sharp edges
7. Remove the pin (11) from the piston (7) and the that will cut the gland O-ring and remove as
piston rod (4). necessary.
8. Turn the piston (7) off the piston rod (4) and 9. Inspect the piston for damage and wear. If the
remove the piston (7). piston is damaged or worn, replace it with a new
9. Remove the gland (3) from the piston rod (4). piston.
10. Remove the seal (6) from the OD of the piston
(7).
11. Remove the wear ring (5) from the OD of the
piston (7).
12. Remove the backup rings (8) and the O-ring (9)
from the ID of the piston (7).
13. Remove the O-ring (16), backup ring (15), wiper
(12), wide seal (13), narrow seal (14), and
bushing (17) from the gland (3).

8006-8
19
20
19
4
2
18
3
17
15
12
16 13
11 8 14
8 9
7
6
5 1
10
19
20
19
BC05M026
1. TUBE 7. PISTON 12. WIPER 17. BUSHING

2. CAP SCREW 8. BACKUP RING 13. WIDE SEAL 18. HARDENED WASHER
3. GLAND 9. O-RING 14. NARROW SEAL 19. SEAL
4. PISTON ROD 10. RETAINING RING 15. BACKUP RING 20. BUSHING
5. WEAR RING 11. PIN 16. O-RING
6. SEAL
BUCKET CYLINDER

8006-9
Assembly 11. Install a new backup ring (8) in the groove in the
ID of the piston (7). If both sides of the backup
NOTE: If a new gland is being used, put the part ring (8) are not flat, the side that is not flat must
number of the cylinder on the new gland. be toward the O-ring (9).
1. Install the bushing (17) in the gland (3), refer to 12. Install a new O-ring (9) in the groove in the ID of
illustration on page 8. the piston (7) next to the backup ring (8).
2. Install the wide seal (13) in the gland (3). The 13. Install the other new backup ring (8) in the
wide seal (13) is to be installed so that the lips of groove in the ID of the piston (7) next to the
the wide seal (13) are toward the bushing (17). O-ring (9). If both sides of the backup ring (8) are
The wide seal (13) can be difficult to install. not flat, the side that is not flat must be toward
3. Install a new wiper (12) in the gland (3). The lips the O-ring (9).
of the wiper (12) must be toward the outside end 14. Lubricate the ID of the piston (7) with clean oil.
of the gland (3).
15. Start the piston (7) onto the piston rod (4). Turn
4. Install the narrow seal (14) in the gland (3). The the piston (7) onto the piston rod (4) until the
side of the narrow seal (14) with the groove must piston (7) is seated against the shoulder of the
be toward the bushing (17). piston rod (4).
5. Install a new backup ring (15) in the groove on 16. If none of the holes in the piston (7) align with the
the outside of the gland (3). If both sides of the holes in the piston rod (4), turn the piston (7)
backup ring (15) are not flat, the side that is not counterclockwise until one of the holes in the
flat must be toward the small end of the gland piston (7) aligns with one of holes in the piston
(3). rod (4). Do not turn the piston (7) more than 90
6. Install the O-ring (16) next to the backup ring (15) degrees.
in the groove on the outside of the gland (3). The
O-ring (16) must be toward the small end of the 7
gland (3).
11
7. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (4). Make 10
sure that the piston rod (4) is clean.
8. Lubricate the bore of the gland (3) and the piston
rod (4) with clean oil.
9. Push the gland (3) onto the piston rod (4). If
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (4). 4
10. Put a support below and near the end of the
GS98J804
piston rod (4). Use a shop cloth between the
support and the piston rod (4) to prevent damage PISTON AND PISTON ROD HOLE ALIGNMENT
to the piston rod (4). 17. Install the pin (11) in the piston (7) and the piston
rod (4).
18. Install the retaining ring (10) in the pin (11).

8006-10
19. Install a new wear ring (5) in the wide groove on 27. Tighten the cap screws (2) in the sequence
the OD of the piston (7). shown. Torque to 420 to 500 Nm (310 to 368.8
20. Install a new seal (6) in the groove on the OD of pound-feet).
the piston (7).
21. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
damage to the tube (1).
22. Lubricate the inside of the tube (1) and the
outside of the piston (7) with clean oil.
23. Push the piston (7) straight into the tube (1).
24. Lubricate the O-ring (16) on the gland (3) with
clean oil.
25. Push the gland into the tube (1) and align the
holes in the tube (1).
26. Install the cap screws (2) and hardened washers
(18).
BC05M027
TUBE AND GLAND HOLE ALIGNMENT

8006-11
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Removal
1. Put piston tube (4) in a press.
2. Use an acceptable driver to press wipers (1) and
bushings (2) out of piston tube (4) eye.
3
3. Clean bore for bushings (2) in tube (4) eye.
1
Installation
4
1. Use an acceptable driver to press new bushings
(2) into tube (4) eye. Bushings shall be recessed
8 mm (0.315 inch) in tube eye.
2
2. Use an acceptable driver to install wipers (1) until
flush with tube (4) eye. The lips of wipers must 1
be toward outside of bore. 2
BS01C003
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
LIFT CYLINDERS

8006-12
REPLACING BUSHINGS FOR THE BUCKET CYLINDER
Removal
3
1. Put piston rod eye (3) in a press.
2. Use an acceptable driver to press wipers (1) and
bushing (2) out of piston rod eye (3). 2
3. Put tube (4) in a press. 1 1
4. Use an acceptable driver to press bushings (2) 2
out of tube (4) eye.
5. Clean bore for bushings (2) in piston rod eye (3)
and tube (4) eye.
4
1
Installation 2
(2) into piston rod eye (3) until recessed 8 mm
(0.315 inch).
2. Use an acceptable driver to install wipers (1) until
flush with piston rod eye (3). The lips of the 2
wipers (1) must be towards outside of bore.
(2) into tube (4) eye until recessed 8 mm (0.315
inch).
1
4. Use an acceptable driver to install wipers (1) until BS03B201
flush with tube (4) eye. The lips of wipers (1)
1. WIPER 3. PISTON ROD EYE
must be towards outside of bore. 2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
BUCKET CYLINDERS

Section
8007
COUPLER SOLENOID LOCKING VALVE
8007

8007-2
TABLE OF CONTENTS
coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8007-3
COUPLER SOLENOID LOCKING VALVE
Disassembly STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve. STEP 12
Install nut (1) to secure solenoid (2).
STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3). 1
STEP 3
Remove valve cartridge (3) from valve housing (7).
2
STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).
Cleaning and Inspection

STEP 5
Immerse valve cartridge (3) and valve housing (7) in
3
cleaning solvent and agitate cleaning solvent. WEAR
EYE PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign matter
from interior of valve cartridge and housing and to 4
ensure that all passage ways and bores are clear.
6
STEP 6 5
Check valve cartridge for (3) for cracks, breaks, 6
chipping, or other damage. Replace if any of these 6
conditions are seen.
5
6
STEP 7
6
Check bores in valve housing (7) for deep scratches, 5
gouges, and other damage. Replace valve if any of
7 6
STEP 8
Connect an ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve
cartridge (3) if ohmmeter indicates short or open
circuit.
Assembly GS98J818
1. NUT 5. O-RING
STEP 9
2. SOLENOID 6. BACKUP RING
Install new O-rings (4 and 5) and back-up rings (6) as 3. VALVE CARTRIDGE 7. VALVE HOUSING
shown. 4. O-RING
STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
8007-4
NOTES

Section
8013
8013
RIDE CONTROL ACCUMULATOR

8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8
Ride Control Accumulator Fluid Capacity ............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure ...........................................................248.4 bar (3600 psi)
ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap .................................................................................13.6 Nm (10 pound-feet)
Gas Charging Valve.............................................................................................88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)
SPECIAL TOOLS
94L95 B786441M
CAS10899 NITROGEN ACCUMULATOR CHARGING KIT CAS1456 GLAND WRENCH

8013-4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
C E
D B A
94L95
CAS10899 NITROGEN CHARGING KIT
1. Use the CAS-10899 Nitrogen Charging Kit to 7. Turn the T-handle inward on valve F to engage
d i s c h a r g e t h e a c c u m u l a t o r, r e fe r t o t h e the pin in the valve stem.
illustration above. The tool must be disconnected
8. Open valve D and check the charge pressure on
from the nitrogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open
3. Adjust the regulator A to the minimum pressure valve B. The accumulator charge will bleed down
setting by turning the knob counterclockwise. through the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
5. Remove the guard and valve assembly cap from
the accumulator. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the
accumulator.

8013-5
ACCUMULATOR
NOTE: Refer to Section 8001 for the proper 1. Fasten the body (1) in a vise. Be careful not to
procedure for the removal of the ride control damage the body (1). Refer to the illustration on
accumulator. page 6.
WA R N I N G : D O N O T a t t e m p t t o 2. Install a new wear ring (5), O-ring (7) and backup

disassemble any accumulator until the ring (6) on the piston (4).
nitrogen charge is properly discharged. 3. Lubricate the bore of the body (1) and the piston
SM386 (4) with clean oil.
1. Fasten the body (1) in a vise. Be careful not to 4. Start the piston (4) into the body (1), round
damage the body (1), refer to the illustration on surface first. Then push the piston (4) farther into
page 6. the body (1).
2. Remove the screws (9) and guard (11) from the
NOTE: The piston (4) must be installed squarely and
body (1).
slowly into the body (1). Once the piston (4) is started
3. Remove the pressure valve (12) from the straight into the bore of the body (1), use a hammer
body (1). and wood block to gently tap the piston into the
4. Remove and discard the O-ring (10) from the polished area of the bore. Keep force on the piston
pressure valve (12). (4) while tapping into the bore or damage may occur
to the O-ring.
5. Loosen and remove the cap (8) from the body
(1). 5. Install and tighten the cap (8) into the body (1).
6. Loosen and remove the gland (3) from the body 6. Install new seals (2) on the gland (3).
(1).
7. Lubricate the seals (2) with clean oil and start the
7. Remove the piston (4) from the body (1). gland (3) into the body (1).
8. Remove and discard the wear ring (5), O-ring (7)
8. Tighten the gland (3).
and the backup ring (6) from the piston (4).
9. Remove the seals (2) from the gland (3). 9. Install a new O-ring (10) on the pressure valve
(12).
Inspection 10. Install the pressure valve (12) in the body (1).
1. Clean body (1), gland (3), cap (8) and piston (4) 11. Install the guard (11), screws (9) in the body (1).
in cleaning solvent, refer to the illustration on 12. Charge the accumulator with dry nitrogen
page 6. according to instructions on page 7.
2. Inspect the piston (4) for cracks, burrs or other
damage. WA R N I N G : U s e o n l y n i t r o g e n w h e n
charging the accumulator. DO NOT use air
3. Inspect the bore of the body (1) for scratches or or oxygen that will cause an explosion.
scoring using a light. SM115A
NOTE: Minor scratches or scoring in the bore of the

body (1) can be removed using crocus cloth.
4. Inspect the pressure valve (12) and replace as
needed.

8013-6
1 2 5 6 7 9
8
3 4
10 11
12
9
BS01B224
1. BODY 5. WEAR RING 9. SCREW

2. SEALS (2) 6. BACKUP RING 10. O-RING
3. GLAND 7. O-RING 11. GUARD
4. PISTON 8. CAP 12. PRESSURE VALVE
RIDE CONTROL ACCUMULATOR ILLUSTRATION

8013-7
CHARGING THE ACCUMULATOR WITH NITROGEN
6 5
4 3
GS98N801
1. VALVE C 4. VALVE B
2. TO NITROGEN TANK 5. VALVE D
3. VALVE A 6. TO ACCUMULATOR
NITROGEN CHARGING KIT CAS10899
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.

8013-8
1. Close the shutoff valve A by turning it all the way 12. Open the shutoff valve A on the nitrogen supply
to the left (counterclockwise), refer to the tank. While observing the pressure on the gauge,
illustration on page 7. slightly open the needle valve on the
accumulator charge hose. By regulating the
2. Open valve B by turning it out all the way to the
needle valve, fill the accumulator to pressure
left (counterclockwise).
according to temperature chart below. Close the
3. Close valve C by turning it all the way to the right needle valve. Close the shutoff valve A on the
(clockwise). nitrogen supply tank.
4. Close the gauge valve D by turning it all the way TEMPERATURE CHARGE PRESSURE
to the right (clockwise). 10° C 50° F 1606 KPA 233 PSI
13° C 55° F 1634 KPA 237 PSI
5. Connect the charging hose to the nitrogen supply
16° C 60° F 1669 KPA 242 PSI
tank.
18° C 65° F 1696 KPA 246 PSI
6. SLOWLY turn valve A clockwise while watching 21° C 70° F 1724 KPA 250 PSI
the high pressure gauge. Stop turning valve A 24° C 75° F 1751 KPA 254 PSI
when the needle on the gauge reaches 31 bar 27° C 80° F 1779 KPA 258 PSI
(450 psi). 29° C 85° F 1813 KPA 263 PSI
32° C 90° F 1841 KPA 267 PSI
NOTE: If the needle goes over the needed pressure,
35° C 95° F 1868 KPA 271 PSI
quickly open and close valve D and check the
38° C 100° F 1896 KPA 275 PSI
pressure setting again.
The charging kit is now ready to be installed on the TEMPERATURE/CHARGE PRESSURE RIDE CONTROL
accumulator. ACCUMULATOR
13. Close valve B by turning to the right (clockwise).
7. Remove the two cap screws (9) and the
After a few minutes, check the accumulator for
protection bracket (11) from the body (1) on the
leakage.
accumulator, refer to the illustration on pages 6.
14. Back off the needle valve on the accumulator end
8. Remove the valve cap from the pressure valve
of the charging hose by tur ning it
(12) on the accumulator.
counterclockwise the maximum amount. This will
9. Back off the needle valve on the accumulator end p r eve n t n it r o g e n f r o m e s c a p i n g f r o m t h e
of the charging hose by tur ning it accumulator as the hose is removed. Remove
counterclockwise to the maximum amount. This the charging hose from the accumulator pressure
prevents nitrogen from escaping from the valve (12).
accumulator when the charging hose is attached
15. Install the valve cap onto the pressure valve (12)
to the accumulator gas charging valve.
on the accumulator.
10. Install the charging hose fitting onto the
16. Install the protection bracket (11) over the
accumulator pressure valve (12).
pressure valve (12) and secure it with cap screws
11. Tighten the needle valve by turning it clockwise. (9).
Slowly open the gauge valve D and observe the
17. Remove the charging hose from the nitrogen
reading on the gauge. This reading is the
supply tank.
nitrogen pressure level inside the accumulator.

Section
8014
8014
RIDE CONTROL VALVE

8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8014-3
RIDE CONTROL VALVE
9 11
10
8
7 13 12
14
15
6
5
4
3 16
2
1 17
BC05B015.
1. PLUG 6. SPRING 10. ACCUMULATOR DRAIN SCREW 14. POPPET

2. CAP SCREW 7. SPOOL 11. PLUG 15. ORFICE
3. BUSHING 8. PLUG 12. SOLENOID 16. VALVE BLOCK
4. SPRING CARRIER 9. PLUG 13. ORFICE 17. RELIEF VALVE
5. SPRING
Dissasembly STEP 8
Remove the pressure relief valve (17).
STEP 1
Remove ride control valve, refer to section 8001. Inspection
1. Discard all O-rings.
STEP 2
Remove plugs (1), (8), (9), and (11). 2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for
STEP 3 damage and wear.
Remove the solenoid (12). 4. Check the parts of the pressure relief valve.
STEP 4 If any of the parts are damaged, install new parts.

Remove the spool (7) from the valve block (16).
STEP 5
Remove cap screw (2), bushing (3), spring carrier
(4), springs (5 & 6) from spool (7).
STEP 6
Remove orifice (13), poppet (14), and orifice (15).
STEP 7
Remove accumulator drain screw (10).

8014-4
Assembly STEP 6
Install springs (5 &6), spring carrier (4), bushing (3),
STEP 1 cap screw (2) onto spool (7) and torque cap screw
Install new O-rings. (2) to 5.5 Nm (48.5 lb-in).
STEP 2 STEP 7
Install and torque pressure relief valve (17) to 50 Nm Install spool (7) into valve block (16).
(37 lb-ft).
STEP 8
STEP 3 Install and torque plug (1) to 270 Nm (199 lb-ft).
Install and torque accumulator drain screw (10) to
3.5 Nm (31 lb-in). Install the plug for accumulator STEP 9
drain screw and torque to 7 Nm (62 lb-in). Install plug (8) and torque to 140 Nm (103 lb-ft), plug
(9) and torque to 30 Nm (22 lb-ft), and plug (11) and
STEP 4 torque to 90 Nm (66 lb-ft).
Install and torque orifice (15) to 15 Nm (11 lb-ft),
install poppet (14), install and torque orifice (13) to STEP 10
15 Nm (11 lb-ft). Install the ride control valve in the machine, see
section 8001.
STEP 5
Install and torque solenoid valve to 12 Nm (106 lb-in). STEP 11
Test the ride control system, see section 8002.

SECTION INDEX
MOUNTED EQUIPMENT
Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant . . . . . . . . . . . . .9002
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010

9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM

CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT

9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if you
when removed from a system during servicing.
are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioner systems. Refrigerant HFC-134a does not
the air conditioner system before reclaiming
contain any chlorofluorocarbons (CFC’s) which are
refrigerant and when you test the system.
harmful to the earth’s ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with Refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixtures of HFC-134a and air can for m a
Liquid refrigerant getting into the eyes can cause
combustible gas.
ser ious injur y. Do the following if you get
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.

9002-4
299L7C A22094
BELT TENSION TOOL CAS-10808 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, OEM-1415
A22090
109L7
ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES CAS-10073-3

9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
contains five major components: compressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. evap orator mete rs refr ig erant flow based on
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and flowing
pressure gas. The compressor then compresses the through the evaporator fins. The combination of
refrigerant and sends it in the form of a high pressure increased heat and decreased pressure causes the
gas to the condenser. The air flow through the air flow through the evaporator fins to become very
c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A.C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER

9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
Check Page 8
Compressor Runs No
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem

See Pressure Testing, Page 13

9002-7
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
See Mechanical Compressor Check Page 8.

HEATER
Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.
Problem:
System Makes Noise
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.

ELECTRICAL
See Compressor Clutch Check Page 9.
INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13. INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13.

9002-8
SYSTEM CHECKS
Mechanical Compressor Check

1. Too much belt wear - replace a worn belt,
Compressor and Fan Belts because a worn belt will cause too much
slippage.
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
Compressor Mounting Brackets 2. Bracket has cracks or breaks - replace the
bracket.
1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Remove the compressor for
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
Compressor Clutch b e t w e e n t h e f r o n t p l a t e a n d p u l l ey
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor
rotation should be smooth and not require
much effort.
1. The compressor pulley and the

compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Pulley and Belt Alignment Use a straight edge to check pulley
alignment. Adjust the compressor
mounting bracket if needed.

9002-9
Blower and Compressor Clutch Check

NOTE: Check supply voltage with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch
1. If there is electrical system voltage to the
clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.
1. See Section 4002 and check the high and

Low and High Pressure Switches low pressure switches.
Blower Fuse (10 amp) 1. Check for damaged blower fuse.
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor 2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.
1. With key in ON position, turn switch to

maximum cold. Compressor clutch must
engage.
NOTE: Blower must be operating, since
electrical power to temperature control switch
is received from blower switch.
Temperature Control Switch 2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
switch ter minals. If continuity is not
present when switch is on maximum cold,
replace switch.

9002-10
Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers louvers must be closed.
2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning 1. Feel the air conditioning hoses. The high pressure hoses
(small line) must be warmer than the low pressure hose
(large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and

r u n t h e c o m p r e s s o r fo r f i v e m i n u t e s t o m a k e
temperature stable. Refer to page 12.
2. Duct temperature must be below 25° C (72° F) if the
system is operating at maximum efficiency.
Duct Temperature NOTE: Ambient temperature must be 27 to 43° C (80 to
110° F).
3. If temperature is above 25° C (72° F), system is low on
refr igerant, there is a restr iction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
Temperature Sensing Probe Check 4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control switch
should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.

9002-11
Visual and Leak Check

1. Make sure that all hose connections are
tight.
Compressor Hoses 2. Check hoses for bends or cracks. Replace
all hoses that have damage.
1. Shut off the engine.

WARNING: When refrigerant comes in
contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. Use
instructions from manufacturer of leak
Leak Finding Check finding tool.
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion valve
for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.
1. Make sure the condenser is clean and the

seals are in place. Make sure condenser
Condenser fans run when temperature control switch
is ON.

9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fins that have bends or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r i c t i o n s. I f t h e c o r e i s d r y, u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
water drains freely from the
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
1. See Section 9004 for access to the

2. Make sure seals are in place so blower
Evaporator/Heater Core Sealing will pull air only through the
evaporator/heater core and not around the
Filters 1. Make sure the filters are clean.

9002-13
PRESSURE TESTING
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 10 to 35 psi (0.7 to 2.4
NOTE: The gauge set is not accurate enough to bar) after the system has run 10 to 15 minutes.
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether HIGH PRESSURE GAUGE - The high pressure
undercharge or overcharge exists, and then gauge is used to indicate pressures in the high side
evacuate, reclaim and recharge system with the of the system. The gauge must indicate from 0 to 400
recommended quantity (charge) of HFC-134a. psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool During normal operation, the high pressure gauge
used to service the air conditioning system. The will normally indicate from 120 to 310 psi (8.3 to 21.4
manifold gauge set is used to measure the high and bar). See pressure-temperature chart on page 14.
low pressures of the system, as a tool to troubleshoot
for correct refrigerant charge quantity, system Pressure Test Connection
diagnosis, and operating efficiency. The manifold
C o n n e c t t h e m a n ifo l d g a u g e s e t i n t o t h e a i r
gauge set can read both the high (discharge) and low
conditioning system as shown. Make sure that both
(suction) sides at the same time, since pressure must
valves in the manifold gauge set are closed.
be compared in order to make a diagnosis of system
operation.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. It is best used to judge
eva cuat io n effe ctiven ess. A vac uum rea ding
indicates a system malfunction. For this reason, it is
necessar y to use a compound gauge that will
indicate both pressure and vacuum.

9002-14
PRESSURE-TEMPERATURE CHART
AMBIENT NORMAL LOW AIR LOUVER (BEHIND

NORMAL HIGH
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)

(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction
pressure. The table shown represents readings taken 5. Measurements taken 15 minutes after startup.
in low relative humidity. Adjust the chart according to
local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART
PROBLEM LOW PRESSURE HIGH PRESSURE SEE

GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 16
NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25

9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1 STEP 4
Clean the external surfaces of the compressor and Connect the hose from the high pressure gauge to
hoses. Remove the caps from the service ports on the port on the discharge hose.
the suction and pressure hoses.
WARNING: Always wear safety goggles
WARNING: Do not steam clean any air when working with liquid refrigerant. Liquid
conditioning system parts while the system is r e f ri g er a n t i n y o u r ey e s c o u l d c a u s e
charged. The heat will cause the refrigerant blindness. SM105A
to rise to a pressure that could cause the
system to explode. SM104A
STEP 5
Make sure the charging station manifold gauge
STEP 2 valves are in the closed position.
Connect the hoses from the test gauges to the
service ports by turning the knurled knobs on the STEP 6
depressors. Start the engine and run at 1500 RPM maximum
speed. Operate the air conditioner system at
STEP 3 maximum cooling setting and blower speed for 15
Connect the hose from the low pressure gauge to the minutes with the cab door open. Observe the test
port on the suction hose. gauges and check the chart on page 13 against the
gauge readings.

9002-16
PROBLEM: NO COOLING
VERY LOW VERY LOW
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate and reclaim remaining

refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow

the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off 4. Check level of oil in compressor - possible
Yes
rapidly after start-up. (A/C warning light for compressor to have an oil loss.
in cab should illuminate).
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See

Section 9003.
7. Continue performance test for other

possible problems.

9002-17
HIGH HIGH
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm Yes 3. Remove air and moisture from the
Section 9003.
Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
reclaim and recharge refrigerant until gauge
pressure is normal. See Section 9003.
4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
caused by oil or reduced heat transfer.
condenser) is very hot.
A. Remove refrigerant from the system. See
B. Discharge air from evaporator warm.
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible

problems.

9002-18
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at See Section 9004 and replace the expansion
compressor. valve.
C. Much condensation on evaporator
outlet.
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
Refrigerant Contamination
table represent the boiling point for HFC-134a.
C. Pressure readings below range given in chart indicate
contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart
Temperature ° F (° C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)

9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO
SLIGHTLY HIGH NORMAL
476L7
Air in the System - Indications:

1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand. 3. Repair system leak as necessary.
B. Discharge air from heater/evaporator 4. Replace receiver-drier.
only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.

9002-20
LOW LO W
476L7
Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator 3. Repair system leaks as needed.

cool or warm - not cold.
4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace

Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section

9003.
High Side Restriction - Indications:

A. Discharge air from heater/evaporator
1. Discharge refrigerant from system-restriction in
only a little cool.
receiver-drier or liquid line must be removed.
B. Condensation or frost on
2. Remove and replace part with restriction.
receiver-drier.
3. Remove air and moisture from the system. See
C. Liquid line to receiver-drier cool, with
Section 9003.
frost or condensation.
4. Charge system with new refrigerant. See Section
NOTE: The frost will form downstream from
9003.
or at the point of the restriction

9002-21
Expansion Valve Not Operating - Indications:

1. Expansion valve outlet with condensation or frost is
A. Discharge air from evaporator warm an indication of a restriction in the expansion valve.
or cool - not cold. Replace expansion valve. See Section 9004.
B. Condensation or frost on expansion 2. Inlet end of expansion valve is warm (not hot),
valve outlet. indicating expansion valve is not completely open.
C. Inlet end of expansion valve is If the valve is stuck closed, there will be little or no
warm. flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.

9002-22
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
Compressor Turning But Not Pumping Properly - Indications:

1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged. 4. Replace compressor.
B. Cool discharge air from evaporator. 5. Replace receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.
Expansion Valve Stuck Open

Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.

9002-23
HIGH HIGH
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
B. Add refrigerant until gauge pressures are
A. Liquid line very hot.
normal. See Section 9003.
B. Discharge air from evaporator warm.
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System - Indications:

1. Discharge refrigerant from system. See
Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the
Section 9003.

9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL NORMAL
476L7
Moisture in the System - Indications:

1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the freezing of this
moisture can stop refrigerant flow. See
Section 9003.
2. Replace receiver-drier. The moisture

removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day.
3. Remove air and moisture from the
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

Section 9003.

9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
HIGH
TO HIGH
476L7
Too Much Refrigerant in System - Indications:

1. Remove refrigerant from system until gauge
readings are below normal. See Section
A. Cool discharge air from heater/evaporator.
9003.
B. Compressor makes noise.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.

9002-26
TUBE CONNECTIONS TORQUE CHART
TUBING SIZE 3/8 inch 1/2 inch 5/8 inch

THREAD SIZE M10 -1.25 5/8-18 3/4-18 7/8-18 1-14
OR OR
3/4-16 7/8-14
STEEL TO STEEL 31-36 Nm 31-36 Nm 40-46 Nm 45-52 Nm 45-52 Nm
ALUMINUM TO BRASS 10-14 Nm 10-14 Nm 24-30 Nm 30-37 Nm 45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.

Section
9003
9003
AIR CONDITIONER SYSTEM SERVICE

9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

9003-4
SAFETY PROCEDURES

4. Always reclaim refrigerant from the system, if you
Refrigerant HFC-134a is the most stable and easiest conditioner system.
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFC’s) which are
harmful to the Earth’s ozone layer.
with refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.

9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refr igerant passes through an oil STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD03A213
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
BD03B001
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the por t on the discharge hose. Tur n in valve
depressor.

9003-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.
BD03A213
Remove the hoses from the service ports and install

the caps.

9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or Air and moisture are removed from the system by a
more of the following conditions occurs before you va c u u m p u m p. A v a c u u m p u m p i s t h e o n l y
remove the air and moisture from the system. equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
A. The system has been opened for service
from the system.
before.
NOTE: Refer to the vacuum pump manufacturer’s
B. Receiver-drier has operated two or more
user manual for additional information.
years.
C. Disassembly of compressor shows small STEP 11
particles of moisture removing material (gold
or brown particles).
D. Large system leak (broken hose, break in
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
A22113
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum of
45 minutes and press the Enter key. The display will
flash once indicating the programmed data has been
accepted.
STEP 12
BD03B001
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
A22115
Removal of air and moisture from the system is
necessary after the refrigerant has been removed Press the Charge key. “Program” and “Charge” will
after the system has been opened for maintenance. appear on the display.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.
NOTE: The pump on the reclamation unit will not pull
a sufficient vacuum to remove air and moisture.

9003-8
STEP 13 STEP 16
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. “Automatic” will appear on the
will flash once indicating the programmed data has display. Vacuum will appear on the display and after
been accepted. a slight delay, the vacuum pump will star t. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
l e a k - f r e e s y s t e m w i l l l e a c h r e f r i g e ra n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
Fully open the low and high pressure valves.

STEP 17
STEP 15
A22113
Press the charge key to begin refrigerant charging.

A22107
“Automatic” and “Charge” will appear on the display.
Open the red (vapor) and blue (liquid) valves on the The display shows the programmed amount and
tank. counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.

9003-9
STEP 18 STEP 21
A22114 BD03B001
Completely close the high and low pressure manifold Stop the engine, close any open valves and carefully
valves. remove the manifold gauge hoses.
ATTENTION: Check the OEM equipment manual
before performing Step 19 to avoid damaging the STEP 22
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure BD03B213
indicator lamp will illuminate when the relay is Install the caps on the service ports on the suction
actuated by a low or high pressure and the and discharge hoses.
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.
STEP 20
A22117
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
and pressure variations.

9003-10
PRESSURE - TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.5)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.1 to 14.5)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.5 to 15.8)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.6)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.9 to 19.3)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position and all
9. Measurements taken 15 minutes after start-up.
louvers open.
4. Cab temperature control set to maximum
cooling.

Section
9004
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING
AND HEATER COMPONENTS

9004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXPANSION VALVE, EVAPORATOR/HEATER CORE,
HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9004-3
SAFETY PROCEDURES

4. Always reclaim refrigerant from the system if you
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFC’s) which are
harmful to the earth’s ozone layer.
with Refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.

9004-4
SPECIAL TOOLS
A22094 BS03H012
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

9004-5
COMPRESSOR
Removal STEP 4
STEP 1
position.
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD06F116
Remove the fan belt.
STEP 5
BD06F113
BD06F117
Disconnect the low pressure line from the suction

port and the high pressure line from the discharge
p o r t o n t h e c o m p r e s s o r. I m m e d i a t e l y i n s t a l l
protective caps on the open ports and lines.
BD06F114
Loosen and remove the four bolts holding the

protective shield. Remove the shield.

9004-6
STEP 6 Installation
STEP 9
Place the compressor into position on the machine.
STEP 10
BD06F117
Disconnect the compressor clutch wire from the

engine harness assembly.
STEP 7
BD06F117
Install the three bolts to mount the compressor.
STEP 11
BD06F117
Loosen and remove the three compressor mounting

bolts.
STEP 8 BD06F117
Remove the compressor from the machine. Connect the compressor clutch wire to the engine
harness assembly.

9004-7
STEP 12 STEP 13
Carefully remove the protective cap, install a new
O-ring, and connect the low pressure line to the
suction port on the compressor.
STEP 14
Install the belt.
STEP 15
Install the protective shield.
STEP 16
Charge the air conditioning system according to the
BD06F117 instructions in Section 9003.
Slowly remove the protective cap, install a new
O-ring, and connect the high pressure line to the
discharge port on the compressor.
IMPORTANT: Use caution when removing cap as
new compressors have internal pressure when
shipped.

9004-8
EXPANSION VALVE, EVAPORATOR/HEATER CORE,

HEATER VALVE, BLOWERS
3 6
5
7
8
9
18 10
17
12 11
14
13
16
15
BS06G118
1. EVAPORATOR 7. WASHER 13. LOWER BOX PPE

2. UPPER BOX PPE 8. GROMMET 14. EXPANSION VALVE
3. COVER PPE 9. HEATER CORE 15. BLOWER
4. SOLENOID DRIVER 10. HEATER VALVE 24V 16. RECIRCULATING VAIN
5. UPPER BOX 11. THERMOSTAT 17. RECIRCULATING MOTOR
6. BOLT 12. LOWER BOX 18. RESISTOR BLOWER MOTOR

9004-9
Removal STEP 23
STEP 17
bucket to the floor.
STEP 18
If changing any air conditioning components,
discharge the air conditioning system according to
STEP 19
BD06G212
Open the cover on the cooler.
STEP 24
BD02N160
If changing the heater core, put a 37 liter (10 gallon)

container below radiator drain. Remove radiator cap.
Remove cap and drain coolant into container. Install
cap after coolant has drained. Install radiator cap. BD06G213
Remove the four screws securing the air vent,

STEP 20 remove the vent cover.
Place the master disconnect in the OFF position.
STEP 25
STEP 21
Disconnect the wiring harness from the operator’s
seat (if equipped with air seat option).
STEP 22
BD06G214
Remove the three screws securing the cooler to the

cab, remove the cooler.
STEP 26
Fold the rubber mat over to gain access to the upper
BD06G202
box mounting bolts.
Remove the four bolts that fasten the operator’s seat
to the upper box, remove the seat from the machine.

9004-10
STEP 27 STEP 30
BD06G215 BD06G217
Remove the six bolts securing the upper box. G o i n g t h r o u g h th e i n s i d e f i l t e r a r e a fe e l th e

recirculating vain to make sure is is in the outside air,
STEP 28 “closed”, position.
STEP 31
BD06G216
Remove two screws, one on each side of the upper

box, securing the upper box to the lower box. BD06G218
The above photo shows that the recirculating vain is

STEP 29 not in the outside air “closed” position.
Place the air selector on the control panel to outside
air. STEP 32
NOTE: In step 30 and 33 the upper box is shown
removed for clarity only, these steps must be done
prior to removing the upper box.
BD06G240
Use a screw driver and disconnect the linkage.

9004-11
STEP 33 STEP 36
BD06G219
Close the vain so the upper cover can be removed. BD06G203
Disconnect the solenoid driver.

STEP 34
Remove the upper box up and rest it against the STEP 37
console.
NOTE: The wiring harness for the HVAC system
goes through the upper cover, by resting the cover
against the console the wiring harness will not need
to be removed.
STEP 35
BD06G236
Remove the upper PPE from the heater and air

conditioning cores.
NOTE: If testing on the electrical components are
required the solenoid driver can be reconnected
once the upper PPE is removed.
BD06G220
Pull the wiring harness loose from the upper PPE.

9004-12
NOTE: If replacing the heater control valve, heater STEP 40
core, air conditioning expansion valve, air
conditioning evaporator core do steps 38 through 47,
if replacing electrical components go to step 48.
STEP 38
BD06G206
Remove the thermostat probe and clamp from the

evaporator core.
STEP 41
BD06G204
Remove the right side cab skirt.
STEP 39
2 3
1 BD06G237
Disconnect the electrical connectors from the

thermostat control.
STEP 42
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
Fasten identification tags on the hoses. Disconnect

the hoses for the heater core and evaporator core,
install plugs in the hoses and caps on the fittings.
BD06G236
Disconnect the electrical connectors from the heater

control valve.

9004-13
STEP 43 STEP 49
Pull the heater core and evaporator core from the
lower box PPE.
STEP 44
Remove the expansion valve from the evaporator
core.
STEP 45
Remove and discard the O-rings from the openings
in the expansion valve.
STEP 46
Remove the screws from the heater core and remove BD06G208
the control valve. D i s c o n n e c t t h e e l e c t r i c a l c o n n e c t o r fo r t h e

recirculating vain motor, disconnect the linkage from
STEP 47 the vain. Remove the mounting screws and remove
the motor.
Remove and discard the O-rings from the heater
control valve.
STEP 50
STEP 48
1 2
3
BD06G209
1. FAN SPEED AND A/C SWITCH
BD06G207 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
1. RESISTORS
3. THERMOSTAT
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR R e m ove t h e sw i t c h p a n e l f r o m t h e c o n s o l e.
Disconnect the electrical connectors and remove
Remove the fans from the lower PPE, disconnect the
switches as required.
electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.

9004-14
STEP 51
1
1 2
3
BD06G207
1. RESISTORS
2. RESISTOR CONNECTOR
BD06G209 3. BLOWER MOTOR CONNECTOR
1. FAN SPEED SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH Install the resistor, install the two mounting screws
3. THERMOSTAT and tighten. Install the fans in the lower PPE, connect
Re place switches and connect the electr ical the electrical connectors.
connectors as required. Install the switch panel in the
console. STEP 54
Install new O-rings on the heater control valve.
STEP 52
STEP 55
Install the control valve, install and tighten the screws
to the heater core.
STEP 56
Install new O-rings on the openings of the expansion
valve.
STEP 57
Install the heater core and evaporator core into the
lower box PPE.
BD06G208 STEP 58
Install the motor and install the mounting screws and
tighten. Connect the electrical connector for the
recirculating vain motor, connect the linkage to the
vain.
BD06G236
Connect the electrical connectors to the heater

control valve.

9004-15
STEP 59 STEP 61
2 3
BD06G237
Connect the electrical connectors to the thermostat BD06G205

control.
3. HEATER HOSES
STEP 60
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings in the evaporator
fittings, connect the heater and evaporator hoses.
Remove and discard identification tags that were
used during disassemble.
STEP 62
BD06G206
Install the thermostat probe coil and clamp to the

evaporator core “cold” tube.
BD06G204
Install the right side cab skirt.
STEP 63
BD06G238
Install the upper PPE on the heater and air

conditioning cores.
9004-16
STEP 64 STEP 67
BD06G210.
BD06G203 Make sure that the recirculating vain is in the closed

Connect the solenoid driver. position.
IMPORTANT: This photo shows it in the open
STEP 65 position and the upper box will not go back into
position without damaging the recirculating vain.
STEP 68
BD06G239
Push the wiring harness into the preformed notches

in the upper PPE.
BD06G241
Set the upper box into position on the heater and

STEP 66 evaporator cores.
Place the air selector on the control panel to outside
air. STEP 69
BD06G216
Install two screws, one on each side of the upper box

securing the upper box to the lower box.

9004-17
STEP 70 STEP 74
BD06G242 BD06G214
Install the insolation panel in the center of the upper Install and tighten the three screws securing the
box. cooler to the cab.
STEP 71 STEP 75
BD06G215 BD06G213
Install and tighten the six bolts securing the upper Install the vent cover, install and tighten the four
box. screws securing the air vent.
STEP 72 STEP 76
BD06G243
Install the right rear floor mat into the cab, if machine BD06G202
is equipped with air ride seat make sure to pull the Install and torque the four bolts to 73 to 87 Nm (55 to
wiring up above the mat for the seat. 65 pound-feet).
STEP 73
Install the remainder of the floor mat.

9004-18
STEP 77 STEP 79
Connect the wiring connector to the operator’s seat Charge the air conditioning system according to the
(if equipped with air seat option). instructions in Section 9003.
STEP 78
Ethylene Glycol and 50% water. Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.

9004-19
CONDENSER AND RECIEVER DRIER
Removal STEP 85
STEP 80
bucket to the ground.
STEP 81
position.
STEP 82
Discharge the air conditioning system according to
BS03A107
STEP 83 Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the condenser.
1 STEP 86
Install plugs in the hoses and caps on the fittings.
2 STEP 87
BD01D142
1. COVER 2. CONDENSER
Open the cover (1) to gain access to the condenser
(2).
STEP 84
BS03A109
Loosen the bolts that fasten the condenser to the

bracket, pivot the condenser and remove the bolts
and condenser.
BD03A109
The condenser is connected to a bracket which

pivots on the cooling frame. Pivot the condenser to
gain access to the hoses.

9004-20
STEP 91
Put the condenser in position on the bracket.
STEP 92
BD06G211
Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the receiver drier.
STEP 89
Install plugs in the hoses and caps on the fittings. BS03A109
Install the bolts that fasten the condenser to the

STEP 90 bracket, pivot the condenser down and tighten the
Disconnect the trinary switch, remove the mounting bolts.
bolt, remove the receiver drier and bracket.
STEP 93
BS03A107
Pivot the condenser to gain access to the hoses.
STEP 94
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings and connect the
hoses to the fittings. Remove and discard
identification tags that were used during
disassemble.
STEP 95
Pivot the condenser down and close the cover.
STEP 96
Mount the receiver drier and bracket, install and
tighten the mounting bolt.

9004-21
STEP 97 STEP 98
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 99
position.
BD06G211
Remove plugs from the hoses and caps from the

fittings, install new O-rings and connect the hoses to
the fittings, connect the trinary switch. Remove and
discard identification tags that were used during
disassemble.

9004-22
NOTES

Section
9006
LOADER
9006

9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth ........................................................................1315 to 1480 Nm (970 to 1090 pound-feet)
BUCKET TEETH
Replacement of the Tooth Points

1. Use a hammer and punch to drive the retaining 3 5
pin (1) for the tooth point (2) out of the tooth
4
shank (3), refer to the illustration on this page. 2 1
2. Remove the tooth point (2).
3. Install a new tooth point (2) on the tooth shank
(3).
4. Install the retaining pin (1) into the tooth point (2)
7
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
6
8 10
a hammer to hit the retaining pin (1) until the 3
retaining pin (1) is even with the outside of the
tooth shank (3).
2 1
Replacement of the Bucket Teeth
1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth. 9
NOTE: If wear of the bolt or nut makes removal 7
difficult, the bolt or nut can be cut off.
2. Remove the tooth.
B0740A88J
3. Install the new tooth on the bucket cutting edge 1. RETAINING RING 6. BOLT
(7). 2. TOOTH POINT 7. CUTTING EDGE
3. TOOTH SHANK 8. PLOW BOLT
4. Use new nuts (4), hardened washers (5), and
4. NUT 9. NUT
bolts (6) for the tooth being installed.
5. HARDENED WASHER 10. CORNER TOOTH
5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to
1090 pound-feet). BUCKET TEETH ILLUSTRATION
Replacement of the Bucket Corner

Teeth
1. Loosen and remove the nuts (9) and bolts (8)
from the bucket corner teeth (10).
NOTE: If wear of the bolt or nut makes removal
difficult, the bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket
cutting edge (7).
4. Use new nuts (9) and bolts (8) for the corner
tooth being installed.
5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to
1090 pound-feet).
9006-4
RETURN TO DIG ADJUSTMENT
6
1
3
4
5
BS01C083
1. TARGET MOUNTING BRACKET 3. TARGET BAR 5. PROXIMITY SWITCH

2. BUCKET CYLINDER 4. PROXIMITY SWITCH MOUNTING BRACKET 6. PROXIMITY SWITCH GUARD
RETURN TO DIG ADJUSTMENT ILLUSTRATION
IMPORTANT: Before adjusting the return-to-dig, 7. Loosen the bolts holding the target bar (3) to the
make sure that the target bar on the bucket linkage is target mounting bracket (1). Slide the target bar
not damaged. Slowly roll back and dump the bucket (3) towards the proximity switch (5) until the face
and make sure that the target bar stays the same of the proximity switch (5) is completely covered.
distance from the switch. The switch mounting 8. Align the target bar (3) parallel to the tilt cylinder
bracket protects the switch. Make sure the target bar (2) and tighten the bolts.
cannot touch the switch when the bucket is dumped.
9. Turn the ignition switch to the ON position. Do
1. Park the machine on a level surface. Raise the lift NOT start the engine.
arms until they are approximately horizontal and
dump the bucket. Lower the bucket until the 10. Place the bucket control lever in the ROLLBACK
bucket edge is on the ground. position.
2. Apply the parking brake and stop the engine. 11. Loosen the bolts holding the target bar (3) to the
target mounting bracket (1).
3. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target 12. Slide the target bar (3) slowly away from the
mounting bracket (1) parallel to the tilt cylinder proximity switch (5), until the control lever returns
(2). Tighten the bolts, refer to the illustration on to the center position. Tighten the bolts holding
this page. the target bar (3).
4. Loosen the bolts holding the proximity switch 13. Check to make sure that the 3.2 to 5.0 mm (1/8
mounting bracket (4) to the tilt cylinder (2). to 3/16 inch) gap is still maintained.
Position the proximity switch (5) parallel to the 14. Start the engine.
target bar (3) and tighten the bolts. 15. Place the detent switch in the ON position and
5. Adjust the proximity switch (5) out towards the place the return to travel/float detent switch to the
target bar (3), until an air gap of 3.2 to 5.0 mm TRAVEL position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 16. Raise the lift arms approximately horizontal, and
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). put the bucket in the fully dumped position.
NOTE: The proximity switch (5) must not protrude 17. Place the loader control lever in the ROLLBACK
past the proximity switch guard (6). position, and verify that the electromagnet holds
6. Start the engine, position the bucket to the it in that position until the end of the target bar (3)
correct digging angle and stop the engine. passes in front of the proximity switch (5).
18. Lower the lift arms and verify that the bucket is at
the correct digging angle.
9006-5
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
5
6
3
2
1
BS01C081
1. TARGET MOUNTING PLATE 3. PROXIMITY SWITCH 5. RETURN TO TRAVEL TARGET

2. HEIGHT CONTROL TARGET 4. LIFT ARM 6. FRONT CHASSIS (TOP LEFT HAND SIDE)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
1. Park the machine on a level surface. 6. Adjust the proximity switch (3) out towards the
return to travel target (5) until an air gap of 3.2 to
2. Start the engine and apply the parking brake.
5.0 mm (1/8 to 3/16 inch) is obtained.
3. Lower the lift arms and place the bucket flat on
7. Lock the proximity switch (3) in this position with
the ground.
the jam nut. Torque the jam nut to 6 to 7.5 Nm
4. Stop the engine. (4.5 to 5.5 pound-feet).
NOTE: To avoid damage to the proximity switch (3),
it must be adjusted back to clear everything on the lift
arm as it passes. Refer to the illustration on this
page.
WARNING: Raised equipment on the machine

without an operator can cause injury or death.
Before you leave the operators compar tment,
always suppor t or lower the equipment
(backhoe, blade, boom, bucket, etc.) to the
ground and stop the engine.
CSM105
5. Position the return to travel target (5) opposite

the proximity switch (3) and tighten it to the target
mounting plate (1).

9006-6
2
A
B
1
BS01C082
1. HEIGHT CONTROL TARGET 2. RETURN TO TRAVEL TARGET 3. TARGET MOUNTING PLATE
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
821E 56 mm (2.2 inches) 414 mm (16.3 inches) 42 mm (1.6 inches) 3302 mm (130 inches)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
8. Refer to the table and the illustration on this 14. Place the loader control lever in the raise position
page. Position the height control target (1) on the and verify that the electromagnet holds it in that
target mounting plate (3) using the table above. position until the height control target (2) passes
in front of the proximity switch (3). Refer to the
NOTE: The higher the height control target (1) is
positioned in its slot in the target mounting plate (3),
the lower the lift arms will stop as they are raised. 15. With the lift arms still raised, place the loader
control lever in the lower position and verify that
9. Tighten the height control target (1).
the electromagnet holds it in that position until
10. Position the return to travel target (2) using the the return to travel target (5) passes in front of
table above. the proximity switch (3). Refer to the illustration
on page 5.
NOTE: The higher the return to travel target (2) is
positioned in its slot in the target mounting plate (3), 16. Repeat steps 8 through 15 until the desired
the lower the lift arms will stop as they are lowered. heights are reached.
11. Check to make sure the proximity switch (3) and 17. Lower the bucket to the ground and stop the
all of the mounting bolts are tight. Refer to the engine.
12. Start the engine.
13. Place the detent switch in the ON position, and
set the return to travel/float detent switch to the
return to travel position.

9006-7
REMOVING THE LOADER FRAME

1. Park the machine on a level surface and apply 17. Loosen and remove the bolt (19), flat washer
the parking brake. Roll the bucket all the way (20) and spacer (21) that fasten the pivot pin (9
forward and lower the bucket to the floor. Stop or 10) to the front frame.
the engine.
18. Raise the loader frame slightly. Use an
2. Loosen the filler plug in the reservoir to release acceptable driver and drive the pivot pin (9 or 10)
the air in the reservoir. out of the front frame. Do not lose the washers
(18) and wipers (22) between the front frame and
3. Fasten a chain hoist to the cross member (1) of
the loader frame (2).
the loader frame (2), refer to the illustration on
page 8.
4. Loosen and remove the bolt (12), flat washer
(13), and spacer (14) that fasten the pivot pin (3)
to the piston rod yoke of the right lift cylinder (4).
5. Use an acceptable driver and drive the pivot pin
(3) out of the piston rod yoke of the right lift
cylinder (4). Do not remove the driver.
6. Repeat Steps 4 and 5 for the left lift cylinder (6).
7. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor
and fasten the chain hoist to a lift cylinder (4 or
6). BD01G009
19. Remove the proximity switch cover. Left-hand

8. Raise the lift cylinder (4 or 6) slightly and remove side of the machine only.
the driver.
9. Repeat steps 7 and 8 for the other lift cylinder (4
or 6).
10. Connect the chain hoist to the bucket cylinder
(8).
11. Loosen and remove the bolt (15), flat washer 1
(16), and spacer (17) that fasten the pivot pin (7)
for the piston rod eye of the bucket cylinder (8) to
the bell crank (11).
2
12. Use an acceptable driver and drive the pivot pin
(7) out of the piston rod eye of the bucket cylinder
(8).
BD01G010
13. Raise the bucket cylinder (8) and use a chain or 1. ELECTRICAL CONNECTION 2. PROXIMITY SWITCH
other acceptable holding equipment to hold the
20. Disconnect the electrical connector (1), remove
bucket cylinder (8) in place.
the lock nut from the proximity switch (2) and
14. If the machine is equipped with auxiliary remove the proximity sw itch (2) fr om the
hydraulics, disconnect the two hoses from the machine. Left-hand side of the machine only.
tubes at the bracket on the right side of the
21. Repeat Steps 17 and 18 for the other pivot pin (9
loader frame (2). Install caps on the hoses and
or 10).
plugs in the tube fittings.
22. Raise the loader frame (2) out of the front frame.
15. If the machine is equipped with front lamps,
Carefully move the machine out of the loader
loosen and remove the cap screws and lock
frame (2).
washers that fasten the lamp brackets to the front
frame. Put the lamp brackets on the fenders.
16. Connect the chain hoist to the loader frame (2).

9006-8
10
18 8
20 18 22
16
17 15
19 9 6 7
2
1 11
21
5
5 4
14
12 5
3
13
23
BS01G022
1. CROSS MEMBER 7. PIVOT PIN 13. WASHER 19. BOLT

2. LOADER FRAME 8. BUCKET CYLINDER 14. SPACER 20. WASHER
3. PIVOT PIN 9. PIVOT PIN 15. BOLT 21. SPACER
4. LIFT CYLINDER 10. PIVOT PIN 16. WASHER 22. WIPER
5. PIVOT PIN 11. BELL CRANK 17. SPACER 23. DUMP LINK
6. LIFT CYLINDER 12. BOLT 18. WASHER
LOADER FRAME ILLUSTRATION

9006-9
INSTALLING THE LOADER FRAME

1. Apply antiseize compound to the inner bores and 17. Disconnect the chain hoist from the bucket
outer bores for the pivot pins of the front frame, cylinder (8).
refer to the illustration on page 8.
18. Fasten the chain hoist to one of the lift cylinders
2. Move the machine into alignment with the loader (4 or 6).
frame (2).
19. Raise the piston rod yoke of the lift cylinder (4 or
3. Lower the loader frame (2) into alignment with 6) so the piston rod yoke is aligned with the
the front frame. loader frame (2).
4. Apply antiseize compound to the pivot pins (9 20. Install a driver in the piston rod yoke and the
and 10) that fasten the loader frame (2) to the loader frame (2).
front frame.
21. Repeat Steps 18, 19, and 20 for the other lift
5. Start the pivot pins (9 and 10) into the front cylinder (4 or 6).
frame. Install the washers (18) and new wipers
22. Disconnect the chain hoist from the lift cylinder (4
(22) between the loader frame (2) and the front
or 6).
frame.
23. Start the engine. Raise the loader frame and roll
6. Install the pivot pins (9 and 10) all the way.
the bucket all the way forward. Lower the bucket
7. Install the bolt (19), washer (20) and spacer (21) to the floor. Stop the engine.
that fasten the pivot pins (9 and 10). Tighten the
24. Fasten the chain hoist to the cross member (1) of
bolt.
the loader frame (2).
8. Install the proximity switch and cover. Left-hand
side of the machine only.
26. Have another person help you at this time. Move
9. Disconnect the chain hoist from the loader frame
the lift control lever as required to align the piston
(2).
rod yoke of one of the lift cylinders (4 or 6) with
10. If the machine is equipped with front lamps, hold the loader frame (2).
the front lamps in place and install the cap
screws and lock washers that fasten the front IMPORTANT: D o n o t u s e yo u r f i n g e r s t o
lamps to the front frame. Tighten the cap screws. check the alignment of the cylinder rod.
11. If the machine is equipped with auxiliary Personal injury can be the result.
48-88
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses. Connect the 27. Remove the driver and install the pivot pin (3).
hoses to the tubes.
28. Install the bolt (12), washer (13), and spacer(14)
12. Connect the chain hoist to the bucket cylinder (8) that fasten the pivot pin (3). Tighten the bolt.
and lower the bucket cylinder (8).
29. Repeat Steps 26, 27, and 28 for the other lift
13. Start the engine and run the engine at low idle. cylinder (4 or 6). Stop the engine.
14. Have another person help you at this time. Move 30. Lubricate the pivot pins with molydisulfide
the bucket control lever as required to align the grease.
piston rod eye of the bucket cylinder (8) with the
bell crank (11). Stop the engine. 31. Disconnect the chain hoist from the cross
member (1) of the loader frame (2).
IMPORTANT: D o n o t u s e yo u r f i n g e r s t o 32. Tighten the filler plug in the reservoir.
check the alignment of the cylinder rod.
33. If the machine is equipped with auxiliary
Personal injury can be the result.
48-88
hydraulics, start the engine and run the engine at
low idle.
15. Install the pivot pin (7) in the bell crank (11) and
34. Slowly extend and retract the clam cylinders four
the piston rod eye of the bucket cylinder (8).
times to remove air from the auxiliary circuit.
16. Install the bolt (15), washer (16), and spacer (17)
35. Stop the engine, check the level of the oil in the
that fasten the pivot pin (7). Tighten the bolt.
reservoir, and check for leaks. Add oil to the
reservoir as required.

9006-10
NOTES

Section
9007
ROLLOVER PROTECTIVE STRUCTURE (ROPS)

CAB STRUCTURAL FRAME (CSF)
9007

9007-2
TABLE OF CONTENTS
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3
CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

9007-3

CAB STRUCTURAL FRAME (CSF)
After an accident, fire or rollover, the following MUST
be performed before returning the machine to field or
Attention
job site operation:
● The ROPS or CSF structure MUST be replaced.
The Rollover Protective Structure (ROPS) or Cab ● The ROPS or CSF mounting or suspension,
S t r u c t u r a l Fr a m e ( C S F ) i s a s p e c i a l s a fe t y operator seat and suspension, seat belts and
component of your machine. mounting components and wiring within the
DO NOT attach any device to the ROPS or CSF for operator’s protective system MUST be carefully
pulling purposes. inspected for damage.
● All damaged parts MUST be replaced.
The ROPS or CSF is a certified structural support
and any damage, fire, corrosion or modification will DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
weaken the structure and reduce your protection. If REPAIR THE ROPS OR CAB STRUCTURAL
this occurs, the ROPS or CSF MUST be replaced so FRAME.
that it will provide the same protection as a new
ROPS or CSF.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following: WARNING: Do not install attachments that
will make the total weight of the machine
1. Check the torque on the CSF cab or ROPS more than the weight shown in the maximum
canopy mounting bolts; torque should be 773 to gross vehicle weight section of the ROPS
854 Nm (570 to 630 lb-ft). If necessary, tighten serial number plate. 47-26
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight WARNING: Do not change the ROPS in any
and seat belt is not cut or frayed. Check the way. Changes made to the ROPS which are
torque on operators seat mounting bolts; torque not authorized, such as welding, drilling or
should be 73 to 87 Nm (54 to 64 lb-ft). If cutting will make the ROPS weaker and
necessary, tighten the bolts to the correct torque. decrease your protection. Replace the
Replace parts that are worn or damaged. ROPS if it becomes damaged in any way.
DO NOT TRY TO MAKE REPAIRS TO THE
WARNING: Grade 8 hardware is used to ROPS. 47-25
mount and anchor the ROPS. Parts used for
replacement must be those shown in the
parts catalog. 47-27A

9007-4
CSF CAB AND ROPS CANOPY
Removal STEP 5
NOTE: Procedures and photos in following steps
cover in detail removal and installation of CSF
structure. Removal and installation of ROPS is
similar to removal and installation of CSF structure.
STEP 1
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position. BD06G191
Remove skirting under each side and front of cab.

STEP 2
STEP 6
BD01F143
Put articulation lock in LOCKED position. BD06G186
Remove the ducts from the machine.

STEP 3
Put battery disconnect switch in OFF position. STEP 7
STEP 4
BD06G189
At RH rear, bottom of cab, disconnect ground strap

BD01F184 from rear chassis.
If machine is equipped with a heater, put a 40 liters
(10 Gallons) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.

9007-5
STEP 8 STEP 11
BD06G194 BD06G192
If machine is equipped with windshield washers, Identify, tag, and disconnect hoses from steering
identify, tag, and disconnect front and rear windshield control valve. Plug hoses and cap steering control
washer nozzle hoses from supply hoses. valve fittings to prevent entry of foreign matter into
hydraulic system.
STEP 9
STEP 12
2 3
BD06G205
2. AIR CONDITIONING HOSES BD06F207
3. HEATER HOSES
Unlatch and open the window on the right hand side.
If machine is equipped with a heater disconnect
heater hoses (3), if machine is equipped with air STEP 13
conditioning discharge the air conditioning system,
see section 9003, and disconnect the air conditioning
hoses (2), cap and plug lines and fittings.
STEP 10
BD06F208
Open and remove the access panel.
BD06G193
Disconnect throttle connector and the air duct.

9007-6
STEP 14 STEP 19
BD06F209 BD06G187
Remove the front access panel. Disconnect the electrical connectors, push
connectors out of the bottom of the cab with the
STEP 15 rubber gromment
STEP 20
BD06F210
Disconnect the electrical connectors for the remote

control valve.
BD06G188
Raise floor mat up and away from brake pedal to gain

STEP 16 access to mounting hardware.
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the STEP 21
STEP 17
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.
STEP 18
Push the hoses out of the bottom of the cab with the
rubber gromment.
BD06G185
Remove hardware securing brake valve to cab floor.

Let brake valve rest on the frame.

9007-7
STEP 22 STEP 25
Slowly raise cab from rear chassis. Check that all tie
straps and clamps have been removed and all hoses,
tubes, and wires are disconnected and free. Check
that brake valve with hoses attached are free and
clear of cab. Remove the ROPS or CSF from the
machine. Lower ROPS or CSF onto wooden blocks
to prevent damaging cab or canopy.
BD06G184
Install lifting eyes in threaded holes at top of the cab.
STEP 23
Connect lifting equipment to cab at lifting eyes. Take
up all slack in lifting equipment.
STEP 24
Remove nuts, bolts, and washers securing cab to
rear chassis.

9007-8
2 1
4
4
5
5
6
6
BC06G031
1. NUT 4. RUBBER MOUNT

2. WASHER 5. WASHER
3. RUBBER MOUNT 6. BOLT

9007-9
STEP 26
Check rubber mounts (3 an 4) for deterioration, tears,
defor mation, or other damage; replace rubber
mounts as necessary.
STEP 27
BD06G188
Position floor mat.
STEP 33
BD01D388
Position cab over rear chassis then put wood blocks

under brake valve. Slowly lower cab onto rear
chassis making sure that brake valve is positioned so
that brake pedal enters into cab. Remove wood
blocks as cab is lowered onto brake valve.
STEP 28
Install washers, bolts, and nuts to secure cab to rear BD06G192
chassis. Tighten bolts to a torque of 773 to 854 Nm
Remove plugs from hoses and caps from fittings.
(570 to 630 pound feet)
Connect hoses to steering control valve following
tags installed during removal. Remove and discard
STEP 29 tags.
Disconnect lifting equipment from cab.
STEP 34
STEP 30
Remove lifting eyes.
STEP 31
BD06G193
Connect throttle connector and mount air duct.
BD06G185
Align mounting holes in brake valve with associated

holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
9007-10
STEP 35 STEP 38
2 3
BD06G186 BD06G205
Install the ducts on the machine.
3. HEATER HOSES
STEP 36
If machine is equipped with a heater, remove plugs
from hoses and caps from fittings, connect heater
hoses (3), if machine is equipped with air
conditioning, remove plugs from hoses and caps
from fittings, connect air conditioning hoses (2),
charge the air conditioning system, see section 9003.
STEP 39
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
shown on pages 11, 12, and 13.
BD06G189
At RH rear, bottom of cab, connect ground strap to

rear chassis.
STEP 37
BD06G194
If machine is equipped with windshield washers,

connect front and rear windshield washer nozzle
hoses following tags installed during removal.

9007-11
3
8
6
7
1
5
7 8
7 5
1 2
8 3
6 4
BC05M092
1. PILOT TANK HOSE 4. ORANGE BLACK GREEN 7. GREEN WHITE GREEN

2. PILOT PRESSURE HOSE 5. GREEN BLACK GREEN 8. RED WHITE GREEN
3. YELLOW BLACK GREEN 6. RED BLACK GREEN
JOYSTICK AND 2 LEVER HOSE COLOR CODING

9007-12
5 5
7 1 4 7
3
4
6 3
2 1
6
2
7 7
7 7
1 1
2 2
6 6
3 3
4 5 4 5
BC05M091

7. RED WHITE GREEN 7. RED WHITE GREEN
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING

9007-13
1
5
4 5 4 6
6 3 2
3 1
2
2 1 2 1
6 6
3 3
4 5 4 5
BC05M090

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING

9007-14
STEP 40 STEP 43
BD06F210 BD06F208
Connect the electrical connectors for the remote Install and close the access panel.
control valve.
STEP 44
STEP 41
BD06F209 BD06F207
Place the access panel into position, install and Close the right hand window.
tighten the screw.
STEP 42 STEP 45
BD06G187
BD06G191
Connect wiring harness connectors.
Install skirting under each side and front of cab.

9007-15
STEP 46 STEP 49
Start engine and run engine at low idle. Run engine
at operating temperature for approximately five
minutes to completely mix Ethylene Glycol and
water. When coolant is at operating temperature,
stop engine. When engine has cooled, check coolant
level at reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: let system cool,
radiator cap.
BD01F184
STEP 50
If machine is equipped with a heater and coolant was
drained, check that coolant drain cap is tight.
STEP 47
capacity is 36.9 liters (9.75 U.S. Gallons). Install
radiator cap. Fill coolant reservoir up to FULL mark
on reservoir.
STEP 48
Put battery disconnect switch in ON position.

9007-16
NOTES

Section
9010
CAB GLASS INSTALLATION
9010

9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9010-3
PREPARATION FOR GLASS REPLACEMENT

1. Remove all of the damaged glass section and 5. Clean the new glass section. Apply a 25 mm (1
the silicone sealant from the window frame inch) wide band of glass primer (349-110) to the
black ceramic painted edges of the window.
2. Remove all the adhesive from the window frame.
6. When replacing a front window section, a
3. The window frame recesses must be free of oil
silicone forming tool is needed, refer to Figure 2.
and dust. Clean the frame with rubbing alcohol
Use the template and instructions provided to
with a clean rag. Do not reuse the rag.
make the tool.
4. Apply a 25 mm (1 inch) wide band of metal
primer (349-108) to the window recesses.
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must 3. For front glass installations install a glass spacer
be installed within 5 minutes. If the glass is not 12 mm (1/2 inch) from each corner on bottom
installed within the 5 minute period, the adhesive edge of each glass section, refer to Figure 3.
must be removed and applied again.
4. Install the glass. The glass edges must not
1. Apply a 10 mm (3/8 inch) diameter bead of contact the metal frame at any point.
adhesive (345-135) to the pr imed surface
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the
front glass apply extra adhesive in corners, refer to
Figure 3.
SILICONE SEALANT APPLICATION - FRONT WINDOWS

1. Clean the edges of the front center and front side 6. Fill the joint with the clear silicone sealant
windows. Use glass cleaning primer. (114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
2. Apply masking tape to the inside edge of each
glass sections. The sealant must extend at least
glass section next to the gap.
1.5 mm (1/16 inch) above the outside surface of
3. Apply the polyester tape on top of the masking the glass section for the length of the gap. Be
tape across the inside side gap. Do not push the sure the sealant fills against the adhesive at each
tape into the gap. end of the joint.
4. Apply masking tape to the outside edge of each 7. Remove the polyester tape from the inside joint.
glass section. Align the edge of the tape with
8. Remove the extra silicone from the outside joint
edge of glass on both sections.
by carefully sliding the forming tool down the
5. The tape must be smooth to get the best result length of the joint. The tool must remain in
when using the silicone forming tool. contact with the glass sections during this
process. Refer to Figure 2 for for ming tool
template.

9010-4
9. Remove all the silicone from the forming tool
1 2 immediately after use.
10. Remove the outside tape from the glass
sections.
11. Remove the extra silicone sealant from the inside
joint by carefully sliding the forming tool down the
length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.
3 13. Remove the inside joint masking tape.
4 14. If two or more glass sections are being replaced,

498L93
use the procedure on the second joint.
1. FRONT RH SIDE GLASS 3. SILICONE BEFORE 15. Apply the gray silicone sealant above the front
SMOOTHING center, front side or rear windows for additional
2. FRONT CENTER GLASS 4. SILICONE AFTER leak protection.
SMOOTHING
FIGURE 1. SILICONE APPLICATION 16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
NOTE: Make the forming tool from 10 mm (3/8 inch)
each front side window replaced, refer to Figure
plexiglass, or wood. Sand all radius and edges
3.
smooth.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.
6 MM 120°
(1/2 INCH) R
120°
4 MM
(3/16 INCH) R
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE

9010-5
2
1
3
4
2
1
497L93
1. SIDE GLASS ADHESIVE 4. RIGHT HAND SIDE GLASS SPACER LOCATIONS

2. CENTER GLASS ADHESIVE 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS CENTER GLASS
FIGURE 3 SILICONE APPLICATION
NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
9010-6
NOTES

Vended Schematic
5-3310
English
Part Number 84299244
CNH AMERICA LLC Printed in U.S.A. • Rac
700 STATE STREET © 2009 CNH America LLC. All Rights Reserved.
RACINE, WI 53404 U.S.A. Case is a registered trademark of CNH America

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SERVICE MANUAL

Revised December 2009

Section Title Section Number

Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Copyright © 2006 CNH Ameica LLC.

GENERAL TORQUE SPECIFICATIONS

Copyright © 2004 CNH America LLC.

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Pound- Newton Pound- Newton

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - METRIC HARDWARE

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

Pound- Newton M24 780 to 940 1050 to 1275

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-ring

Split Flange Mounting Bolts

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Boss End

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

Bur 8-71603 Revised 7-05 Printed in U.S.A.

FLUIDS AND LUBRICANTS

Copyright © 2006 CNH Ameica LLC.

Bur 5-3100 Issued 8-06 Printed in U.S.A.

CAPACITIES AND LUBRICANTS

Bur 5-3100 Issued 8-06 Printed in U.S.A.

ENGINE OIL RECOMMENDATIONS

Bur 5-3100 Issued 8-06 Printed in U.S.A.

TRANSMISSION TEMPERATURE CHART

DIESEL FUEL SYSTEM

The diesel fuel used in this machine must meet the

Specifications for Acceptable No. 2 Diesel Fuel

Bur 5-3100 Issued 8-06 Printed in U.S.A.

13 Radiator Coolant Level *

Bur 5-3100 Issued 8-06 Printed in U.S.A.

Bur 5-3100 Issued 8-06 Printed in U.S.A.

Bur 5-3100 Issued 8-06 Printed in U.S.A.

Copyright © 2003 CNH Ameica LLC.

Bur 7-52590 Issued 4-03 Printed in U.S.A.

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

Bur 7-52590 Issued 4-03 Printed in U.S.A.