621F

TIER III
Wheel Loader

Service Manual

Print No. 47417752A

 621F
Wheel Loader

47417752A

July, 2012

Use for Repair Manual

 621F Wheel Loader
Repair Manual
47417752A
Table of Contents
Description Section No.
General Tab 1
Section Index - General
General Torque Specifications 1001
Fluids and Lubricants 1002
Metric Conversion Chart 1003

Engines Tab 2
Section Index - Engines
Engine and Radiator Removal and Installation 2000
Stall Tests 2002
After Cooler 2003
Engine Intake Air Filtration 2010
For Engine Repair, See the Engine Service Manual (sold separately) 84392428

Fuel System Tab 3

Section Index - Fuel System
For Fuel System Repair, See the Engine Service Manual (sold separately) 84392428

Electrical Tab 4
Section Index - Electrical
Removal and Installation of Starter and Alternator 4001
Electrical Specifications and Troubleshooting 4002
Batteries 4003
Jump Post Option 4003a
Instrument Cluster 4005

Steering Tab 5
Section Index - Steering
Removal and Installation of Steering Components 5001
Steering Specifications, Pressure Checks, and Troubleshooting 5002
Steering Cylinders 5005
Center Pivot 5006
Auxiliary Steering Motor and Pump 5008
Joystick Steering System (JSS) 5009
 621F Wheel Loader
Repair Manual
47417752A
Table of Contents
Description Section No.

Power Train Tab 6

Section Index - Power Train
Removal and Installation of Power Train Components 6001
Transmission Specifications, Pressure Checks, and Troubleshooting 6002
4 Speed Transmission 6003
Front Axle 6004
Rear Axle 6004
Drive Shafts, Center Bearing, and Universal Joints 6005
Wheels and Tires 6006

Brakes Tab 7
Section Index - Brakes
Removal and Installation of Brake Components 7001
Hydraulic Brake Troubleshooting 7002
Brake Pump 7003
Brake Accumulators 7004
Parking Brake 7008

Hydraulics Tab 8
Section Index - Hydraulics
How to Read Hydraulic Schematics 8000
Removal and Installation of Hydraulic Components 8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002
Cleaning the Hydraulic System 8003
Loader Control Valve 8005
Cylinders 8006
Coupler Solenoid Locking Valve 8007
Ride Control Accumulator 8013
Ride Control Valve 8014

Mounted Equipment Tab 9

Section Index - Mounted Equipment
 621F Wheel Loader
Repair Manual
47417752A
Table of Contents
Description Section No.
Air Conditioning Troubleshooting and System Checks For System Checks For System with HFC-134a
9002
Refrigerant
Air Conditioner System Service 9003
Removal And Installation Of Air Conditioning And Heater Components 9004
Loader 9006
Roll Over Protective Structure (ROPS), Cab Structural Frame (CSF) 9007
Cab Glass Installation 9010
Rear View Camera Installation and Removal 9020

Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket

 SECTION INDEX

GENERAL

Section Title Section Number

Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
 1001
Section
1001

GENERAL TORQUE SPECIFICATIONS

1001-2

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

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
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
5/16 inch 204 to 252 23 to 28 1/2 inch 110 to 132 149 to 179
3/8 inch 420 to 504 48 to 57 9/16 inch 160 to 192 217 to 260
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
5/16 inch 1/2-20 96 to 192 11 to 22 5/16 inch 1/2-20 192 to 300 22 to 34
7.9 mm 7.9 mm
3/8 inch 9/16-18 120 to 300 14 to 34 3/8 inch 9/16-18 300 to 480 34 to 54
9.5 mm 9.5 mm
1/2 inch 3/4-16 180 to 504 20 to 57 1/2 inch 3/4-16 540 to 804 57 to 91
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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
 1002-3

CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. quarts)
Total system capacity ................................................................................................... 15.1 liters (16 U.S. quarts)
Type of oil ............................... Case Akcela Unitek CJ-4 engine oil - see engine oil recommendations on page 4
Engine Cooling System
Capacity........................................................................................................................ 28.4 liters (30 U.S. quarts)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ................................................................................................................... 246 liters (65.0 U.S. Gallons)
Type of Fuel............................................................................................. See Diesel fuel specifications on page 5
Hydraulic System
Hydraulic Reservoir Refill Capacity .............................................................................90.8 liters (24 U.S. Gallons)
Total System Capacity...............................................................................................147.6 liters (39 U.S. Gallons)
Type of Oil ...................................................................................................Case Akcela Hydraulic excavator fluid
Transmission
Refill Capacity with Filter Change .............................................................................. 26.7 litres (28.2 U.S. quarts)
Type of Oil ........................................................................................................... Case Akcela NEXPLORE™ fluid
Axles
Capacity
Standard Front ......................................................................................................... 22 litres (23.2 U.S. Quarts)
Standard Rear.......................................................................................................... 22 litres (23.2 U.S. Quarts)
Optional Front .......................................................................................................... 22 litres (23.2 U.S. Quarts)
Optional Rear........................................................................................................... 22 litres (23.2 U.S. Quarts)
Type of Lubricant ................................................................................................. Case Akcela NEXPLORE™ 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 Hydraulic excavator fluid
1002-4

ENGINE OIL RECOMMENDATIONS

Case Akcela Unitek CJ-4 engine oil is
See the char t below for
recommended for use in your Case engine. Case
recommended viscosity at
Akcela Unitek CJ-4 engine oil will lubricate your
ambient air temperature
engine correctly under all operating conditions.
ranges.
If Case Akcela Unitek CJ-4 engine oil is not available,
NOTE: Do not put performance
use only oil meeting API engine oil service category
additives or other oil additive
CH-4 (preferred) or CG-4.
products in the engine
crankcase. The oil change
RH99K130
intervals given in this manual
are according to tests with Case
AKCELA lubricants.

WHL201210

.
 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.

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
FREQUENCY IN HOURS

CHANGE FLUID
DRAIN FLUID
SERVICE

LUBRICATE

CLEANING
SERVICE POINTS

REPLACE
INTERVAL

GREASE

ADJUST
CHECK
Daily
General X
Inspection)
Every 10 Hours Check Engine Oil Level X
Bucket/attachment grease fittings X
Grease machine and attachments X
Every 50 Hours Hydraulic oil level X
Transmission oil level X
Engine coolant X
Wheel Torque X
Fuel prefilter (Initial) X
Initial 100 Hours
Fuel filter (Initial) X
Replace hydraulic oil filter (Initial) X
Grease fittings X
Every 100 Hours
Grease lift arms X
Grease drive shaft slip joints X
Cab air filter X
Every 250 Hours
Wheels and Tires X
Drive belt X
Engine oil filter X
Replace fuel filter X
Fuel filter X
Every 500 Hours
Fuel tank sediment X
Axle oil level X
Battery fluid level X
Pivot points X
Articulation fittings X
Every 1000 Hydraulic oil filter X
Hours Drive belt X
Cab air filter X
Replacing the engine breather filter X
Every 1500 Front and rear axle X
Hours Transmission fluid and filter X
Hydraulic oil and filters X
Engine coolant X
Every 2000
Engine air filters X
Hours
Frame and cab - lubricate X
Engine valve clearance X
Fuel pre-filter X
Air conditioning condenser X
Height control and return to travel X
Return to dig X
As required Calibrating the gear box X
Transmission declutch pressure adjustment X
Parking breake X
Secondary steering X
Cab service X

.
 1002-7
Battery service X
Battery electrolyte level X
Auxiliary battery connections X
Electrical Battery removal and installation X
System Fuses and realys X
Work lights X
Driving lights X
Additional features X
1002-8

.
 Section
1003

1003
METRIC CONVERSION CHART
1003-2

TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
 1003-3

CONVERSION FACTORS

Metric to U.S.
MULTIPLY BY TO OBTAIN

Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre

Force: newton 3.596 942 ounce force

newton 0.224 809 pound force

Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

bar 14.50385 lb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

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

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)
1003-4

U.S. to Metric
MULTIPLY BY TO OBTAIN

Area: square foot 0.092 903 square meter

acre 0.404 686 hectare

Force: ounce force 0.278 014 newton

pound force 4.448 222 newton

Length: inch 25.4 * millimeter

foot 0.304 8 * meter
mile 1.609 344 * kilometer

Mass: pound 0.453 592 kilogram

ounce 28.35 gram

Mass/Area: ton/acre 2241 702 kilogram/hectare

Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr

Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter

Power: horsepower 0.745 700 kilowatt

Pressure: lbs/sq. in. 6.894 757 kilopascal

lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm

Temperature: degree F 1.8 F - 32 degree C

Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter

Velocity: miles/hr. 1.609 344 * kilometer/hr.

Volume: cubic inch 16.387 06 cubic centimeter

cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre

Volume/Time: gallon/min. 3.785 412 litre/min.

* = exact
 SECTION INDEX

ENGINES

Section Title Section Number

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000

Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002
After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003
Engine Intake Air Filtration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2010

FOR ENGINE REPAIR, SEE THE ENGINE REPAIR MANUAL

84392428
 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 28.4 liter (30 U.S. quart) container below

BD03A040
radiator drain. Remove radiator cap. Remove cap
Park machine on a level surface and lower bucket to and drain coolant into container. Install cap after
ground. Put articulation lock in LOCKED position. coolant has 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 15.1 liter (16 U.S. quart) 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 by the

battery 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.
STEP 7 STEP 10

BD06F109

Tag and disconnect hood wiring harness connector

from rear chassis wiring harness connector.

STEP 8 STEP 11

1
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

BD06F111 BD06F112

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

Tag and remove the wires from the starter solenoid

(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

NOTE: Lifting up on the lever will release the

connector from the controller.

STEP 34

STEP 31

1
 2000-9
STEP 35 STEP 38

BD06F124 BD06F127

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

W130R0032

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
clamp on air cleaner intake hose.

STEP 73

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

BD03A228 BD03A221

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 13.25 Put articulation lock in OPERATING position.
liters (14 U.S. quarts) of Case Akcela Unitek CJ-4
engine oil.

STEP 81
If hydraulic reservoir was drained, fill reservoir with
90.8 liters (24.0 U.S. gallons) of Case Akcela
Hydraulic excavator fluid.

STEP 82
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 28.4 liters (30.0 U.S. quarts). 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 28.4 liter (30.0 U.S. quart) 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
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 28.4 liters (30.0 U.S. quarts). 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,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
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
621F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
 2002-3

621F SPECIFICATIONS
Engine with 4 Speed Transmission
A. Low idle ..........................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................670 to 730 rpm
Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm
B. Maximum No Load RPM .............................................................................................................2094 to 2224 rpm
C. Converter Stall ............................................................................................................................1975 to 2125 rpm
D. Hydraulic Stall .............................................................................................................................1895 to 2205 rpm
E. Converter & Hydraulic Stall .........................................................................................................1455 to 1765 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: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd
gear.

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.
2002-4

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.

BD06F027

4. Info 2 will be displayed next. The Info 2 screen

will display coolant temperature, engine oil
temperature in either Fahrenheit or Celsius, as
well as oil pressure.

BD06F188

2. From the driving screen push the down arrow, as

shown.

BD06F184

5. Push the down button again for the Info 3 screen.

T h i s s c r e e n d i s p l ay s t h e t e m p e ra t u r e i n
Fahrenheit or Celsius of the transmission oil,
hydraulic oil, sump oil.
BD06F183

3. Info 1 is the first information screen using the

down arrow from the driving screen. It displays
engine RPM’s, speed, and fuel level.
 2002-5

BD06F169

6. Press the down button again and the Trip 1

screen will display. The LCD provides two trip
computers. These will display since last reset the
total time in hours, the total fuel, and the average
fuel consumption per hour.

BD06F170

7. By continuing to scroll down, the fifth screen will

display the Trip 2 screen. Trip 1 and Trip 2
screens can be reset independently. The
previous screen can be accessed by using the
up arrow key.
2002-6

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).
 2002-7

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.
2002-8

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.
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: parking brake.
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.
 2002-9

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
2. Start the engine and run the engine at low idle.
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:
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.
7. Decrease the engine speed to low idle.
8. Lower the bucket to the ground.
9. Stop the engine.
2002-10

NOTE
Section
2003

2003
AFTER COOLER
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.

 Section
2010

ENGINE INTAKE AIR FILTRATION

2010
2010-2

TABLE OF CONTENTS
Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pre-cleaner Disassembly & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
 2010-3

AIR FILTRATION

Pre-cleaner Disassembly & STEP 3

Reassembly
STEP 1

IMG_1682.AI.TIF

Disassemble and remove precleaner from machine.

RCPH10WHL902AAH.PNG

Access pre-cleaner located on top of engine

STEP 4
compartment hood.

STEP 2

IMG_1680.AI.TIF

Empty debris and clean wipe precleaner with a damp

clean cloth. Reassemble/install unit on machine.

IMG_1683.AI.TIF

Loosen wing nut.

2010-4

Primary/Secondary Fillter Element STEP 3

Disassembly
STEP 1
1 2

IMG_0115.PNGD

Release all clips securing air filter element housing

cover.

STEP 4
RCPH10WHL902AAH.PNG

Raise engine compartment hood using controls

located behind access cover (1). Air filter
housing/element (2) is located in main engine
compartment on left hand side of engine.

STEP 2

IMG_0142.PNG

Remove cover from air filter element housing.

STEP 5

IMG_0099.PNG

Turn master electric switch “off”.

IMG_0143A.PNG

Remove primary filter element by lifting up on handle

 2010-5
STEP 6 STEP 2

IMG_0144A.PNG

Remove secondary filter element from right side of

housing. Remove debris from inside filter element
housing before installing new filter elements.
NOTE: Make sure primary and secondary filter
NOTE: Do not clean the seconday filter element. It elements form an effective seal.
must be replaced if damaged or clogged.
STEP 3
Primary/Secondary Element
Reassembly
STEP 1

STEP 4

Install new secondary filter element by inserting it

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

721F-8508.PNG

Lock clips to secure filter housing cover.

NOTE: If cover does not fit properly, recheck filter
element installation. Cover will be difficult to install if
filter elements are not properly installed.
2010-6
STEP 5

IMG_0099.PNG

Turn master electric power switch “on”. Clear any

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

Section Title Section Number

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE REPAIR MANUAL

84392428
 SECTION INDEX

ELECTRICAL

Section Title Section Number

Removal and Installation of Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4001

Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003a
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005
 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.
Remove and discard tags.

STEP 8
Place the master disconnect switch in the ON
BC05G047
1. STUDS position. Lower the engine compartment with lifting
2. NUTS motor.
Apply Loctite 747 primer to studs and holes, apply 2
drops of Loctite 271 to each hole and stud.
Immediately install and torque studs to 19 to 29 Nm
(14 to 21 pound-feet). Allow adhesive to cure for 20
minutes before installing starter.

STEP 6

BD06F135

Position the 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
Park machine on a level surface and lower bucket to
ground.

STEP 2

BD06F137

BD06F133

Raise the engine compartment with lifting motor.

Place the master disconnect switch in the OFF
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

Place the master disconnect switch in the ON

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Power Relay Module A, Power converter F1, Secondary steering F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Power Relay Module B, ACC Power F1                 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  52
Power Relay Module C, Ignition Power F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Power Relay Module D, Fuel Filter Heater F1, Engine ECM F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fan Control Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fan Reverse Relay (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
 4002-3
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for
Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Warning (AIC) Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4002-4
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
 4002-5
Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
HOOD RAISE AND LOWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
STARTING / ignition SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Ignition Power Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Ignition Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Start Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
JOYSTIC STEER ING / MISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Rear View Camera / Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Differential Lock Switch (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Differential Lock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Lockup Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Joystick PVRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Transmission Kick Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ARM POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FNR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FNR Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Pilot Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
JSS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Load Sense Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Pilot Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
JSS Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Joystick STR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
JSS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4002-6
 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 High Pressure Switch
Closed With Pressure .................................................................................. Above 27.6 ± 0.7 bar (400.3 ± 10.1 psi)
Opens With Pressure ..................................................................................Below 20.7 ± 0.7 bar (300.22 ± 10.1 psi)
A/C Low Pressure Switch
Closed With Pressure .......................................................................................Below 0.3 ± 0.1 bar (4.35 ± 1.45 psi)
Opens With Pressure ......................................................................................... Above 1.4 ± 0.2 bar (20.3 ± 2.9 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.....................................................4.13 bar (60 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
Water Separator Heater 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) .................................................................. 29.3 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 Cav Connector Cav
and Material
W 0.8 GXL
1 JMP1, JSS Load Sense A JMP2, JSS Load Sense C
Twist
Bk 0.8 GXL
2 JMP1, JSS Load Sense B JMP2, JSS Load Sense A
Twist
14 Alternator D+ Lg 1.0 SXL AD, Alternator D+ 1 ENG, Engine Cab1 26
30 Battery Sensing R 1.0 SXL Alt_5 Alternator D+ 2 AB_5 Alternator B+ 1
31 EDC Relay Control OR 0.8 GXL EDC7, Engine Controller 13 SPL_EDC4, Ultrasonic A
42 Work Lights Switched Fused Pwr R 2.0 GXL SPL-WL, Ultrasonic A ECC, Elect Center C A2
44 Brake Lt Control Power T 1.0 SXL BTM_C, Cab bottom bulkhd J PBL, Brake Light Press Switch 2
49 Back Lt Power DU1.0 GXL D-OR, Diode OR C SPL-BCK-LGT, Spl Back Lgt Pwr A
52 Fan Reverse LSD W 0.8 TXL AIC-1, Adv Instr Clust 1 23 ECB, Electrical Center B B8
56 Fan Control PWM W 0.8 TXL CAB-E, Cab Engine 23 AIC-1, Adv Instr Clust 1 26
57 Pin Engage Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 17 YPE, Pin Engage Jumper A
58 Ride Control Sol Pwr W 1.0 SXL PRBF, Rollback Press Sw A YRC, Ride Control Option 1
64 Horn Power Or 1.0 SXL FRONT, Cab Front Chassis 13 HN1, Horn Power 1
460 Fan Speed Sensor Signal Y 1.0 SXL Eng, Engine-Cab1 16 FSS, Fan Speed Sens 1
016B Pedal Sensor Grnd DU 0.8 GXL BTM_C, Cab Bottom Bulkhd D BPP, Pedal Position 6

GND_ENG7, Tranny, Cool

017A Fan Speed Sensor GND BK 1.0 SXL 1 FSS, Fan Speed Sens 2
Temp
GND_CAB_SPL, Cab Grnd
0D_C DIAG2 GRND BK 0.8 GXL DIA_2, Diagnostic A D
Splice
SPL_BCK_LT_GD2, SPL_BACK
0_29 RTT/Float GND BK 0.8 GXL SFL, Return to Travel SW 4 K
LGT GRND
SPL-BCK-LT-GD2, Spl Back Lgt
0 29 RTT/Float Ground Bk 0.8 GXL SFL, Return To Travel Sw 4 K
Gnd
0 AA Proximity Switch Grnd Bk 1.0 SXL PXH, Height Control RTT B SPL-A2, Ultrasonic A
0 AB Proximity Switch Grnd Bk 1.0 SXL SPL-A2, Ultrasonic A GND-FC, Ground A 1
0 AC Proximity Switch Grnd Bk 1.0 SXL PXF, RTD B SPL-A2, Ultrasonic A
0 AD Ride Control Ground Bk 1.0 SXL YRC, Ride Control Option 2 SPL-A1, Ultrasonic A
0 AE Pin Engage Ground Bk 1.0 SXL SPL-A1, Ultrasonic A YPE, Pin Engage Jumper B
0 AF Horn Ground Bk 1.0 SXL HN2, Horn Ground 1 SPL-A1, Ultrasonic A
0 AG Front Chassis Ground Bk 2.0 SXL SPL-A1, Ultrasonic A GND-FC, Ground A 1
 4002-9

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 Cav Connector Cav
and Material
0 AH RH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LRF, Lights RH 1
0 AJ LH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LLF, Lights LH 1
0 AK Park Brake/Warning Ground Bk 1.0 SXL SPL-A4, Ultrasonic A BTM_E, CAB BTTOM 2
0 AL Brake Warning Press Sw Gnd Bk 1.0 SXL PBW, Brake Warn Press Sw 2 SPL-A4, Ultrasonic A
0 AM RTD Grnd Bk 1.0 SXL PXM, RTD B PXT, RTD B
0 AN Park Brake Solenoid Ground Bk 1.0 SXL YPB, Park Brake Solenoid 2 SPL-A4, Ultrasonic A
0 AP Front To Rear Chassis Ground Bk 5.0 SXL GND-S1, Ground A 1 GND-S2, Ground A 1

JSS_FRM, JSS Frame to

0 AS GRND, JOYSTICK Bk 1.0 GXL G SPL_JSS_17, Ultrasonic A
CAB
0 AT GRND, JSS VLV Bk 1.0 GXL JSS_Valve, JSS HYD Valve 3 SPL_JSS_17, Ultrasonic A
0 AU GRND, Pilot Dump Bk 1.0 GXL SPL_JSS_17, Ultrasonic A JSS_PIL_DUMP, JSS Pilot Dump 2
0 AV GRND Bk 1.0 GXL SPL_JSS_17, Ultrasonic A GND_JSS, Ground_A 1
0 AW Pin Engage GND Bk 1.0 SXL YPE1, Pin Engage Jumper B YPE2, Pin_Engage_OPT B
0B Front Washer Ground Bk 1.0 SXL FWW, Front Washer 2 SPL-ENG-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
SPL-BCK-LT-GD2, Spl Bk Lt
0 B2 Back Light Ground Bk 0.8 GXL SFL, Return To Travel Switch 7 B
Grnd
SPL-BCK-LT-GD2, Spl Bk Lt
0 B3 Back Light Ground Bk 0.8 GXL SHC, Height Control Switch 7 C
Grnd
SPL-BCK-LT-GD2, Spl Bk Lt
0 B4 Back Light Ground Bk 0.8 GXL SRTD, Detent Switch 7 D
Grnd
SPL-BCK-LT-GD2, Spl Bk Lt
0 B5 Back Light Ground Bk 0.8 GXL SPE, Pin Engage Switch 9 E
Grnd
SPL_BCK_LT_GD, SPL Back SPL-BCK-LT-GD2, Spl Bk Lt
0 B6 Cab2 Ground Bk 1.0 GXL D F
Lght GRND Grnd
SPL-BCK-LT-GD2, Spl Bk Lt
0 B7 Back Light Ground Bk 0.8 GXL SFC, Fan Control Switch 7 M
Grnd
0 B8 Front Wiper Motor Ground Bk 0.8 GXL GND_CAB2, Ground_A 1 FWMG, Wiper Ground A

SPL-HOOD-GRND, Hood
0 B10 Hood Ground Bk 1.0 GXL E GND-CAB2, Ground A 1
Grnd 6 Pck
SPL-BCK-LT-GD2, Spl Bk 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, Elect Center C C4
Grnd 6 Pck
4002-10

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 Cav Connector Cav
and Material
SPL-BCK-LT-GD, Spl Bk Lt
0 B13 Back Light Ground Bk 1.0 GXL A SPL_WL1, Ultrasonic A
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, Elect CNTR C B4
Grnd 6 Pck
0 B17 Back Light Ground Bk 0.8 GXL STA, Trans Auto Switch 7 SPL-BCK-LT-GD, Spl Bk 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

SPL-BCK-LT-GD2, Spl Bk Lt
0 B20 Back Light Ground Bk 0.8 GXL SRC, Ride Control Switch 7 J
Grnd
0 B21 Back Light Ground Bk 0.8 GXL SBU, Backup Alarm Disc Sw 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd J

SPL-HOOD-GRND, Hood
0 B22 Hood Up Relay Ground Bk 1.0 GXL C ECC, Elect CNTR C C2
Gnd 6 Pck
0 B23 Back Light Ground Bk 0.8 GXL SRWP, Rear Wiper Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd L

SPL-PED-BL-GD, Spl Bk Lt Grnd

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, Elect CNTR C B2
Gnd 6 Pck
0 B26 Buzzer/Switch Pad Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A GND_CAB2, Ground A 1
0 B27 Buzzer Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A BUZ, AIC Buzzer 2
0 B28 Switch Pad Ground Bk 0.8 TXL SW-PD, Switch Pad 10 SPL-BUZ, Ultrasonic A

SPL-PED-BL-GD, Spl Bk Lt Grnd

0 B29 RTT/Float Ground Bk 0.8 GXL SPB, Parking Brake Switch 7 E
6 Pck
SPL_BCK_LT_GD2,
0 B31 SDA GND Bk 0.8 GXL A SDA, Diff Lock Switch 7
SPL_BACK LGT GRND

0 B32 Back Light GND SPL_BCK_LT_GD, SPL Back

Bk 0.8 GXL SRP, Work Lights SW 7 M
Lght GD
0 BA Pedestal Gnd Strap Bk 5.0 SXL. GND-PDST, Ground A 1 GND-PDST2, Ground A 1
0 BAC EDC7 Ground Bk 2.0 SXL SPL-EDC1, Ultrasonic A GND-ENG2, WIF, EDC 1
0 BAE EDC7 Sender Ground Bk 1.0 SXL RECT, Engine Coolant Temp 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
 4002-11

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 Cav Connector Cav
and Material
GND-WIF, Gnd WIF Ring
0 BAR WIF Body Ground Bk 1.0 SXL 1 GND-ENG6, Dedicated 1
Term
0 BAT Crank Request FGND Bk 1.0 SXL Eng, Engine-CAB1 6 GND_ENG2, WIF, EDC 1
0 BAU EVGT_2 GND Bk 1.0 SXL Turbo, Eng Dash_Turbo 5 GND_ENG2, WIF, EDC 1
0 BB Fan Reverse Solenoid Ground Bk 1.0 SXL YFR, Fan Reverse Sol Opt 2 SPL-FAN, Ultrasonic A
0 BBA JOYSTICK GROUND Bk 0.8 GXL SPL_JSS_1, Ultrasonic A SJS, Joystick_Control_SW 4
0 BBB JOYSTICK GROUND Bk 0.8 GXL SJS, Joystick_Control_SW 7 SPL_JSS_1, Ultrasonic A

GND_CAB_SPL2, SPL Back

0 BBC JOYSTICK GROUND Bk 0.8 GXL F SPL_JSS_1, Ultrasonic A
LGHT GD
0 BBD JOYSTICK GROUND Bk 0.8 GXL JSS_CAB, JSS CAB 8 SPL_JSS_1, Ultrasonic A
0 BBE JOYSTICK GROUND Bk 0.8 GXL SJS_Joystick_Control_SW 9 SPL_JSS_1, Ultrasonic A

GND_ENG3, SPLC_PK, WSHR

0 BBR Ground Bk 1.0 SXL ENG_B, CAB BTTOM 2 1
MTR
0 BC EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 11
0 BD EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 10
0 BE EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 5
0 BF EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 6
0 BG AIC Power Ground Bk 0.8 GXL ENG, Engine Cab1 19 GND-ENG6, Dedicated 1
0 BH AIC Power Ground Red Bk 0.8 GXL ENG, Engine Cab1 20 GND-ENG6, Dedicated 1
0 BJ AIC Sensor Ground Bk 0.8 GXL ENG, Engine Cab1 17 GND-ENG6, Dedicated 1
0 BL Rear Washer Ground Bk 1.0 SXL RWW, Rear Washer 2 SPL-ENG, Ultrasonic A

GND-ENG3, SPLC-PK, Washer

0 BM Engine Splice Grounds Bk 1.0 SXL SPL_ENG, Ultrasonic A 1
Motor
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, LH Rear Comb Lamp 1 SPL-J1, Ultrasonic A
0 BS Fan Control Ground Bk 1.0 SXL SPL-FAN, Ultrasonic A SPL-ENG, Ultrasonic A
0 BT LH Rear Light Ground (EURO) Bk 1.0 SXL LLR-E, LH Rear Comb Lamp 5 GND-ENG4, Rear Lighting 1
0 BT N RH Rear Light Ground (NA) Bk 1.0 SXL LRR, RH Rear Comb Lamp 1 SPL-J1, Ultrasonic A
0 BU Fuel Level Sender Ground Bk 1.0 SXL RFLG, Fuel Send Ground 1 GND-ENG7, Tranny, Cool Temp 1
0 BV Grid Heater Control Grnd Bk 0.8 TXL GHC, Grid Heater Relay 2 EDC7, Engine Controller 75
4002-12

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 Cav Connector Cav
and Material
GND-ENG1, Start, FFH,
0 BW Water Separator Htr Ground Bk 2.0 SXL 1 WSH, Water Separator Heater A
WAT_SEP_HTR
GND-ENG1, Start, FFH,
0 BX Fuel Filter Heater Ground Bk 2.0 SXL FFH, Fuel Filter Heater B 1
WAT_SEP_HTR
0 BY Air Filter Restriction Sw Grd Bk 1.0 SXL SPL_ENG, Ultrasonic A PAF, Air Filter Restriction Sw 2
0 BZ Fuel Level Sender GND Bk 1.0 SXL RFL_23, Fuel_Level_Send B GND_ENG7, Tranny, Cool Temp 1
0 CA Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 11 SPL-SEC Ultrasonic A
0 CB Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 12 SPL-SEC Ultrasonic A

PSS, Sec. Steer Press

0 CC Sec. Steering Press Sw Ground Bk 1.0 SXL B SPL-SEC Ultrasonic A
Switch
0 CD Sec. Steering Splice Ground Bk 1.0 SXL SPL_SEC, Ultrasonic A GND-SSMOD, Sec Str Chas Gnd 1
0 CE Sec. Steering Chassis Ground Bk 1.0 SXL SSM, Sec. Steering Mod 4 GND-SSMOD, Sec. Str Chas Gnd 1
0 CF Sec. Steering Sol Ground Bk 1.0 SXL YSS, Sec. Strg Sol 2 SPL-SEC, Ultrasonic A
0 CG Sec STR Flyback GND Bk 1.0 SXL 245F, SEC_STR_FLYBACK 1 SSD, SEC_STR_Diode B
0 CH Sec STR Flyback GND Bk 1.0 SXL 245F, SEC_STR_FLYBACK 1 SSD, SEC_STR_Diode A
0 DA AIC Chassis Ground Bk 0.8 TXL GND-PDST1, Ground A 1 AIC-2, Advanced Inst Cluster 2 22

SPL-BCK-LT-GD, Splice Back

0 DAP Back Light Ground Bk 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, ADV Instr Cluster 2 15
0 DD Work Lights Grnd Bk 2.0 GXL SPL_WL1, Ultrasonic A GND_CAB1, Ground A 1

GND_CAB_SPL2, SPL Back

0 DE Neutral Start Relay Control Grd Bk 0.8 GXL G ECB, Elect Center B B4
Light GD
Crank Request Relay Control
0 DF Bk 0.8 GXL CAB_E, CAB-Engine 6 ECB, Elect Center B B6
Ground
0 DG Cab Splice Grounds Bk 1.0 GXL GND-CAB-SPL, Cab Grd Spl F GND-CAB3, Ground C 1
0 DH Diagnostic Connector Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl M DIA, Diagnostic A
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 J SC, Seat Comp Motor B
0 DM Speed Sensor Grounds Bk 0.8 TXL CAB-T, Cab Transmission 11 TECM, Trans 3
0 DN Output Speed Sensor Ground Bk 0.8 TXL CAB-T, Cab Transmission 28 TECM, Trans 4
0 DP DIAG TECM Ground Bk 0.8 TXL GND-CAB3D, Ground A 1 TECM, Trans 1
0 DQ DIAG TECM Ground Bk 0.8 TXL GND-CAB3D, Ground A 1 TECM, Trans 2
 4002-13

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 Cav Connector Cav
and Material
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

CAB_RF, CAB to Roof

0 DY Roof Splice GNDs Bk 1.0 GXL SPL_WL1, Ultrasonic A B
Connection
CAB_RF, CAB to Roof
0 DZ Work Lights GRND Bk 2.0 GXL SPL_WL1, Ultrasonic A A
Connection
0 EA PWR Relay GND Bk 0.8 GXL ECB, Elect CNTR B C2 SPL_SD3, Ultrasonic A
0 EB Ignition Relay Control Ground Bk 0.8 GXL SPL_SD3, Ultrasonic A PRM-C1, PRM Signal B
0 EC ACC Relay Control Ground Bk 0.8 GXL SPL_SD3, Ultrasonic A PRM-B1, PRM Signal B
0 ED HVAC Grounds Bk 3.0 SXL HVAC2, HVAC2 2 GND-CAB4, Ground C 1

GND-CAB-SPL, Cab Grnd

0 EE DIODE Suppression Grounds Bk 0.8 GXL A 140M, DIODE Module C
Spl
GND-CAB-SPL2, Spl Back
0 EF Brake Lights Relay Ctrl Grnd Bk 0.8 GXL M ECC, Elec CNTR D A1
Light Ground
GND-CAB-SPL2, Spl Back Light
0 EG Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 4 L
Ground
GND-CAB-SPL2, Spl Back Light
0 EH Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 3 K
Ground
CNV, 24V to 12V Pwr
0 EJ Power Converter Ground Bk 1.0 GXL 3 GND-CAB4, Ground C 1
Convert
0 EK AUX Power Outlet 1 Grnd Bk 1.0 GXL PO1, Power Outlet C GND-CAB5, Ground C 1
0 EL AUX Power Outlet 2 Grnd Bk 1.0 GXL PO2, Power Outlet C GND-CAB5, Ground C 1
0 EM Radio Ground Bk 0.8 GXL CAB-RF, Cab to Roof Conn. M GND-CAB-SPL, Cab Grnd Spl B
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
4002-14

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 Cav Connector Cav
and Material
GND-GH1, STRT, FFH, Water
0 ES Grid Heater Ground Bk 19.0 SXL GH-1, Grid Heater 1 1
Sep Htr
0 ET Power Relay GND Bk 0.8 GXL ECB, Elect CNTR B D2 SPL_SDL, Ultrasonic A
0 EU PWR Converter RLY CTRL GND Bk 0.8 GXL SPL_SD3, Ultrasonic A PRM_A2, PRM Signal B
0 EV IGN Latch GND Bk 0.8 GXL ECB, Elect CNTR B B2 SPL_SD1, Ultrasonic A

GND_CAB_SPL2, SPL Back

0 EW Power Relay GND Bk 0.8 GXL ECB, Elect CNTR B B1 E
LGHT GD
0 EY Power Relay GND Bk 0.8 GXL ECD, Elec CNTR D A4 SPl_SD1, Ultrasonic A
0 EZ Power Relay Control W 0.8 GXL ECD, Elec CNTR D A3 AIC_1, ADV Instr Cluster 1 22

GND_CB, Ground, On
0G Bk 2.0 SXL 1 GND_GL, Ground, Rear Grill 1
Cooling Box
GND-ENG1, STRT, FFH, Water
0 GB Starter Relay Control Ground Bk 1.0 SXL SRC-1, Relay 2 1
Sep Htr
0 HD Speed Sensor Grounds Bk 1.0 SXL TRANS, Cab Transmission 11 SPL-H2, Ultrasonic A
0 HE Output Speed Sensor Grnd Bk 1.0 SXL TRANS, Cab Transmission 28 OSS, Out Speed Sensor 1

Bk 0.8 GXL
0 HF Engine Speed Sensor Grnd ESS, Engine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
Bk 0.8 GXL
0 HG Inter Speed Sensor Grnd ISS, Inter Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
Bk 0.8 GXL
0 HH Turbine Speed Sensor Grnd TSS, Turbine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
0 HL Redundant Brake Switch Grnd Bk 1.0 SXL PRB2, Redundant Brake Sw B GND_TRANS, Ground_Trans 1
0 HM Redundant Brake Switch Grnd Bk 1.0 SXL PRB1, Redundant Brake Sw B GND_TRANS, Ground_Trans 1
0 HR HYD FLTR SW Grnd Bk 1.0 SXL PHF9, HYD_FLTR_RES_SW 1 GND_TRANS, Ground_Trans 1

HOT, Hydraulic Oil Temp

0 HW Hot Ground Bk 1.0 SXL B GND_TRANS, Ground_Trans 1
Send
GND_CAB_SPL2, SPL Back
0J Start Lockout RLY GND Bk 0.8 GXL ECC, Elect CNTR C B10 A
LGHT GD
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

GND_CAB_SPL2, SPL Back

0K Camera GND BK 0.8 GXL C Mon, Camera/Monitor 2
LGHT GD
 4002-15

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 Cav Connector Cav
and Material
GND_CAB_SPL2, SPL Back
0 KA IGN PWR Control GND Bk 0.8 GXL ECD, Elec CNTR D AA3 B
LGHT GD
0L Telematics GRND BK 2.0 GXL TEL, Telematics H CABE2, CAB to ENG2 Bulkhd G
0 MA Rear Wiper Motor Grnd Bk 1.0 GXL SPL-ROOF, Spl Rood Grnd C RWMG, Rear Wiper Motor Grnd 1
0 MB Dome Light Grnd Bk 0.8 GXL LDM3, Dome Light Grnd 1 SPL-ROOF, Spl Rood Grnd B
0 MC Beacon Light Grnd Bk 1.0 GXL LBEGRD, Light Beacon Grnd 1 SPL-ROOF, Spl Rood Grnd A
0 ME LH Rear Work Light Grnd Bk 1.0 GXL LLRW, LH Rear Work Light 2 SPL_WR, Ultrasonic A
0 MF RH Rear Work Light Grnd Bk 1.0 GXL LRRW, RH Rear Work Light 2 SPL_WR, Ultrasonic A
0 MG RH Front Work Light Grnd Bk 1.0 GXL LRFS, Front_WK_LT_OPT 2 SPL_WRK2, Ultrasonic A

Roof, Roof to CAB

0 MH Rear Work Light Grnd Bk 1.0 GXL B SPL_WR, Ultrasonic A
Connection
0 MJ RH Front Work Light Grnd Bk 1.0 GXL LRFW, RH Front Work Light 2 SPL_WK, Ultrasonic A
0 MK Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. G SPL-ROOF, Spl Rood Grnd E
0 ML RH Front Work Light Grnd Bk 1.0 GXL SPL_WRK2, Ultrasonic A LRFR, Front_EWK_LT_OPT 2
0 MN Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. F SPL-ROOF, Spl Rood Grnd D
0 MP RH Front Work Light Grnd Bk 1.0 GXL SPL_WRK2, Ultrasonic A LRFO, Front_WK_LT_OPT 2
0 MU LH Front Work Light Grnd Bk 1.0 GXL LLFW, LH Front Work Light 2 SPL_WK, Ultrasonic A
Roof, Roof to CAB
0 MV RH Front Work Light Grnd Bk 2.0 SXL A SPL_WK, Ultrasonic A
Connection
0 NA Hood Grounds (EU) Bk 1.0 SXL HD_9, Hood to ENG 1 SPL_B1 A
0 NB Master Disconnect Grnd Bk 62.0 SGR DC2, Discon Black Grnd 1 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
0 NE Hood Grounds (EU) Bk 1.0 SXL SPL_B1 A LLR_9, LH_Rear_Comb_LT 5
0 NF Hood Grounds (EU) Bk 1.0 SXL SPL_B1 A LLR_9, RH_Rear_Comb_LT 5
0 NG Hood Grounds (EU) Bk 1.0 SXL SPL_B1 A SPL_J1, Ultrasonic A
0 PA Left Speaker Grnd Bk 0.8 GXL LSPK, Left Speaker B SPK, Speaker 8
0 PB Right Speaker Grnd Bk 0.8 GXL RSPK, Right Speaker B SPK, Speaker 2

YRC_J, Ride
0 RD Ride Control Grnd Bk 1.0 SXL 2 YRC_J2, Ride_Control_OPT 2
CNTRL_Jumper
JSS_ARM, JSS Armrest to
0 SC GRND, Joystick Bk 0.8 GXL 7 PVRES, JSS Joystick V
CAB
4002-16

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 Cav Connector Cav
and Material
0 SD GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A CAB_ARM, CAB to Armrest 7
0 SE GRND Bk 0.8 TXL SPL_JSS_10, Ultrasonic A CAN_MOD_2, JSS can mod 10
0 SF GRND Bk 0.8 GXL SPL_JSS_14, Ultrasonic A Cab to JSS Frame G
0 SG Common Bk 0.8 GXL SPL_JSS_10, Ultrasonic A Arm_Pos, Arm position 1

JSS_ARM, JSS Armrest to

0 SH GRND, CAN MOD Bk 0.8 GXL 2 SPL_JSS_10, Ultrasonic A
cab
0 SJ GRND, CAN MOD Bk 0.8 GXL SPL_JSS_9, Ultrasonic A CAB_ARM, Cab to Armrest 2

CAB_ARM_FRM, Cab to Arm

0 SK GRND, CAN MOD Bk 0.8 GXL 8 SPL_JSS_9, Ultrasonic A
to Frm
0 SL Ground Bk 0.8 GXL JSS_RLY, Relay K2 87A SPL_JSS_9, Ultrasonic A
0 SM GRND, Joystick Bk 0.8 GXL JSS_CNT, JSS Controller 10 SPL_JSS_20, Ultrasonic A
0 SN GRND, Joystick Bk 0.8 GXL SPL_JSS_20, Ultrasonic A JSS_CNT, JSS Controller 11
0 SP GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A R1, Resistor CS0
0 SR GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A JSS_CNT, JSS Controller 15
0 SS GRND, Joystick Bk 0.8 GXL JSS_197F, Main_CAB_FNR 1 FNR_RLY, Relay K2 87A
0 ST GRND, Joystick Bk 0.8 GXL FNR_RLY, Relay K2 85 SPL_JSS_9, Ultrasonic A
0 SU GRND, Joystick Bk 0.8 GXL SPL_JSS_20, Ultrasonic A SPL_JSS_9, Ultrasonic A
12ACC Ignition Switch ACC Power W 0.8 GXL S-KEY, Ignition Switch 4 SPL-ACC, Ultrasonic A
12ACC
ACC PRM Control Power W 0.8 GXL SPL-ACC, Ultrasonic A PRM-B1, PRM Signal A
B
12ACC Power Converter PRM Control
W 0.8 GXL SPL-ACC, Ultrasonic A PRM-A2, PRM Signal A
C Power
12V 12V Pwr To Outlet 1 Or 1.0 GXL PO1, Power Outlet A ECB, Elect Center B AA1
12V A 12V Pwr To Outlet 2 Or 1.0 GXL PO2, Power Outlet A ECB, Elect Center B AA2
12V B 12V Fused Pwr to Radio Or 1.0 GXL CAB-RF, Cab to Roof Conn. N ECB, Elect Center B AA9
12V C 12V Switched Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 5 SPL-12V, Ultrasonic A
12V D Plug 1 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A1
12V E Plug 2 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A2
12V F Radio 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A9
12V G 2 Way Radio 12V Switched Pwr Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A10
12V H 12V Fused Power to Radio Or 0.8 GXL ROOF, Roof to Cab Conn. N SPL-RAD, Ultrasonic A
 4002-17

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 Cav Connector Cav
and Material
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 7
HA
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 4
HB
13A EVGT Relay Or 0.8 TXL Evgt_4, EVGT C EDC7, Engine Controller 51
13B EVGT Relay PWR Or 1.0 GXL Turbo, ENG Dash_Turbo 6 EVGT_4, EVGT A
13C Fuel Shutoff Fused Power Or 1.0 SXL DC3, Fuel Solenoid Disc 1 DISC, Disconnect Engine A
13C A Fuel Shutoff Fused Power Or 1.0 SXL ENG-D, Disc Harness A ENG, Engine Cab1 21
13C B Fuel Shutoff Fused Power Or 1.0 SXL CAB-E, Cab Engine 21 ECA, Elect Center A A9
13K Ignition Switch Pwr Or 1.0 GXL S-KEY, Ignition Switch 3 SPL-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
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
14 5 Alternator D+ LG 1.0 SXL ENG, Engine-CAB1 26 ALT_5, Alternator D+ 3
14 A Alternator D+ LG 0.8 GXL SPL_ALT, Ultrasonic A 215F, Alternator Resistor 1
14 AB Alternator D+ LG 0.8 GXL SPL_ALT, Ultrasonic A CAB_E, CAB-Engine 26
14 AC Alternator Running LG 0.8 GXL SPL_ALT, Ultrasonic A TEL, Telematics D
16R C FNR Reverse Signal LU 0.8 GXL JSS_197M, FNR-Main_CAB 4 RVS_DIODE, Diode ASSY C
17P A Switch Pad Power From AIC Pwr Or 0.8 TXL SW-PD, Switch Pad 9 SPL_SW_PD, Ultrasonic A
17P B SW Pad PWR from AIC PWR Or 0.8 TXL SPL_SW_PD, Ultrasonic A AIC_1, ADV Instr Cluster 1 25
17P C B+ CAN MOD Or 0.8 GXL SPL_SW_PD,Ultrasonic A JSS_CAB, JSS CAB 2
17P D B+ CAN MOD Or 0.8 GXL SPL_JSS_18, Ultrasonic A CAB_ARM, Cab to Armrest 4

JSS_ARM, JSS Armrest to

17P E B+ CAN MOD Bk 0.8 TXL 4 CAN_MOD_2, JSS CAN MOD 9
CAB
17P F B+ JSS Controller Or 0.8 GXL SPL_JSS_18, Ultrasonic A JSS_CNT, JSS Controller 3

CAB_ARM_FRM, Cab to Arm to

17P G B+ Joystick Or 0.8 GXL SPL_JSS_18, Ultrasonic A 2
Frm
18B LH High Beam Fused Power Or 2.0 SXL FRONT, Cab Front Chassis 6 LLF, Lights LH 3
18B A LH High Beam Fused Power Or 2.0 GXL CAB-F, Cab Front Chassis 6 ECB, Elect Center B AA3
18C RH High Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 16 LRF, Lights RH 3
4002-18

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 Cav Connector Cav
and Material
18C A RH High Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 16 ECB, Elect Center B AA4
18D LH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 14 LLF, Lights LH 2
18D A LH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 14 ECB, Elect Center B AA6
18E RH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 15 LRF, Lights RH 2
18E A RH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 15 ECB, Elect Center B AA5
18F LH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 10 LLF, Lights LH 4
18F A LH Position/Tail Fused Power Or 0.8 GXL CABE2, CAB to ENG2 Bulkhd M SPL-POS-L, Ultrasonic A
18F
LH Position/Tail Fused Power Or 1.0 SXL ENG2, ENG Bulkhd 2 M ENG-H, Engine to Hood 6
AN
18F B LH Position/Tail Fused Power Or 1.0 SXL ENG2, ENG Bulkhd 2 M LLR-E, LH Rear Comb Light 3
18F LLR-N LH Rear Combination
LH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 6 3
BN Light
18F C LH Position/Tail Fused Power Or 1.0 GXL SPL-POS-L, Ultrasonic A ECB, Electric Center B AA7
18F E LH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 10 SPL-POS-L, Ultrasonic A
18F F LH Position/Tail Fused Power Or 1.0 SXL HD-9, Hood to Engine 6 LLR-9, LH Rear Comb Light 3
18G RH Position/Tail Fused Power Or 1.0 GXL SPL-POS-R, Ultrasonic A ECB, Elect Center B AA8
18G A RH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 5 LRF, Lights RH 4
18G
RH Position/Tail Fused Power Or 1.0 SXL SPL-POS-NA, Ultrasonic A LRR, RH Rear Combination Light 3
CN
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
18G F RH Position/Tail Fused Power Or 0.8 GXL CABE2, CAB to ENG2 Bulkhd N SPL-POS-R, Ultrasonic A
18G G RH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 5 SPL-POS-R, Ultrasonic A
18G H RH Position/Tail Fused Power Or 1.0 SXL ENG2, Engine Bulkhd 2 N SPL-POS, Ultrasonic A
18G
RH Position/Tail Fused Power Or 1.0 SXL ENG2, Engine Bulkhd 2 N ENG-H, Engine to Hood 5
HN

LRR-E, RH Rear
18G J RH Position/Tail Fused Power Or 1.0 SXL 3 SPL-POS, Ultrasonic A
Combination Light
18G
RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-POS-NA, Ultrasonic A
JN
18G K RH Position/Tail Fused Power Or 1.0 SXL HD-9, Hood to Engine 5 SPL-P9, A
 4002-19

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 Cav Connector Cav
and Material
18G L LIC Plate Fused Power Or 1.0 SXL SPL-P9, A LPL, LIC_PLATE_LIGHT A

LRR-9, RH Rear Combination

18G M RH Position/Tail Fused Power Or 1.0 SXL SPL-P9, A 3
Light
18J B EDC7 Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 3
18J C EDC7 Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 2
18J D EDC7 Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 8
18J E EDC7 Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 9
18J F EDC7 Fused Power Or 3.0 GXL PRM_D1, PRM Output A SPL-EDC4, Ultrasonic A
18J H Water In Fuel Sensor Fused Pwr Or 1.0 GXL SPL-EDC2, Ultrasonic A WIF, Water In Fuel Sensor 3
18K A Diagnostic Fused Power Or 0.8 GXL ECC, Elect CNTR C A9 SPL_PK1, Splice 3-4 way K
18K B Diag Fused B+ Or 0.8 GXL SPL_PK1, Splice 3-4 way L DIA_2, Diagnostic B
18K C Telematics FSD Power Or 0.8 GXL SPL_PK1, Splice 3-4 way M TEL, Telematics A
18K D Diag Fused B+ Or 0.8 GXL SPL_PK1, Splice 3-4 way J DIA, Diagnostic B
18N Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A ECA, Elect Center A C1
18N A Blower Motor Fused Power Or 0.8 GXL SPL-BLWR, Ultrasonic A HVAC1, HVAC1 2
18N B Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A HVAC2, HVAC2 1
18S A B+, JSS Fused Or 0.8 GXL ECA, Elect CNTR A A2 SPL_JSS_3, Ultrasonic A
18S B B+, JSS Fused Or 0.8 GXL SPL_JSS_3, Ultrasonic A SJS, Joystick_Control_SW 2
18S C B+, JSS Fused Or 0.8 GXL JSS_CAB, JSS CAB 11 SPL_JSS_3, Ultrasonic A

CAB_FRM, CAB to JSS CAB_ARM_FRM, CAB to ARM to

18S D B+, JSS Fused Or 0.8 GXL J 11
Frame FRM
JSS_PIL_PR, JSS Pilot J
18S E B+, JSS Fused Or 1.0 SXL A JSS_FRM, JSS Frame to Cab
Pressure
19A Output Speed Sensor Fused Pwr Or 1.0 SXL TRANS, Transmisson-CAB 29 OSS, Out Speed Sensor 3
19A A Brake Declutch Sw Fused Pwr Or 1.0 SXL TRANS, Transmisson-CAB 24 PBD, Dec. Pressure Switch A
19A B FNR Switched Fused Power Or 0.8 GXL 197M, FNR Main Cab 1 SPL-FNR, Ultrasonic A
19A C FNR Switched Fused Power Or 0.8 GXL 197F, Main Cab FNR 1 SPL-TRNS-PWR, Trans Pwr F
19A D Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 2 SPL-D15, Ultrasonic A
19A E AIC Fused Power 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
4002-20

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 Cav Connector Cav
and Material
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-PBS, Ultrasonic A
19A M Output Speed Sensor Fused Pwr Or 0.8 TXL CAB-T, Cab Transmission 29 SPL-TRNS-PWR, Trans Power K

SPL-TRANS-PWR, Trans
19A N Trans Fused Power Or 1.0 GXL A ECA, Elect Center A A1
Pwr

19A P Backup Alarm Relay Control Or 1.0 GXL

SPL-TRANS-PWR, Trans 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 T Brake Declutch Switch Fused Or 0.8 GXL CAB-T, Cab-Transmission 24 SPL-TRANS-PWR, Trans Pwr D
Power

19A U Trans Kick Down Switch Fused Or 0.8 GXL SPL-FNR, Ultrasonic A 20M, Trans Kick Down 1
Power
19A V FNR Switch Fused Power Or 0.8 GXL SFNR, FNR Switch 5 SPL-FNR, Ultrasonic A
19A W Diagnostic Conn. Fused Power Or 0.8 GXL 108F, Diagnostic Connector 1 SPL-TRANS-PWR, Trans Pwr E
19B Turn Signal Fused Power Or 0.8 GXL SRHSTLK, RH Stalk Switch 49a ECA, Elect Center A A8
19B A FNR SW Fused PWR W 0.8 GXL FNR_RLY, Relay K2 30 JSS_197M, FNR-MAIN_CAB 1
19B B FNR SW Fused PWR Or 0.8 GXL CAB_FNR, MAIN_CAB_FNR 1 FNR_RLY, Relay K2 87
19B C FNR SW Fused PWR Or 0.8 GXL ARM_FNR, FNR-MAIN_CAB 1 SPL_AJ, Ultrasonic A
19B D FNR SW Fused PWR Or 0.8 GXL 21M, Trans_KICK-DOWN 1 SPL_AJ, Ultrasonic A
19B E FNR SW Fused PWR Or 0.8 GXL SAJ, FNR_SWITCH 5 SPL_AJ, Ultrasonic A
19B F FNR SW Fused PWR Or 0.8 GXL SAJ, FNR_SWITCH 8 SPL_AJ, Ultrasonic A
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 SW Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A SRC, Ride Control Switch 2
19C E Pilot Control SW FSD Pwr Or 0.8 GXL SPL-D24, Ultrasonic A TEL, Telematics C
19C F Pilot Control SW Fused Pwr Or 0.8 GXL SPL-D24, Ultrasonic A SPC, Pilot_Control_Switch 2
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
 4002-21

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 Cav Connector Cav
and Material
19E A AIC Wake Up Ignition Or 0.8 TXL SPL_AP, Ultrasonic A ECA, Elect Center A A3
19H Backup Alarm B+ Or 1.0 GXL 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 Fused Power Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D D1
19J E Front Wiper Relay Fused Power Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D B1

Front Wiper Relay LS Control

19J F Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D D3
Fused Power
19J G Wiper Cutout Relay Fused Pwr Or 0.8 GXL SPL-FW, Ultrasonic A K-WCO, Wiper Cutout 86
19K Rear Wiper Fused Pwr Or 1.0 GXL SPL-RWW, Ultrasonic A ECA, Elect Center A C3
19K A Rear Wiper Sw Fused Pwr Or 1.0 GXL SRWP, Rear Wiper Sw 3 SPL-RWW, Ultrasonic A
19K B Rear Wip Wash Fused Pwr Or 0.8 GXL SRWP, Rear Wiper Sw 5 SPL-RWW, Ultrasonic A

CAB-RF, Cab to Roof

19K C Rear Wiper Motor Fused Pwr Or 1.0 GXL J SPL-RWW, Ultrasonic A
Connect
19K D Rear Wiper Motor Fused Pwr Or 1.0 SXL ROOF, Roof to Cab Connect J RWM, rear Wiper Motor C
19L Pwr Converter Fused Power Or 3.0 GXL PRM-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
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
Steering Accessory Fused
19M A Sec. 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
4002-22

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 Cav Connector Cav
and Material
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 3.0 GXL PRM_A1, PRM Output A SPL_19S, Ultrasonic A
19S2 Sec. Steering Fused Pw Or 1.0 GXL SPL_19S, Ultrasonic A CAB_T, Cab-Transmission 26
19S1 E Sec. Steering Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 26 TR-SS, Sec. Steering Module Opt E

SS-TR, Sec. Steering Module

19S1 X Sec. Steering Fused Pwr Or 1.0 SXL SSM, Sec. Steering Module 3 E
Trans
19S B AIC Delay Fused Power Or 0.8 GXL SPL-DKY3, Ultrasonic A ECC, Elect Center C A8
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
19S E AIC BATT B+ Or 1.0 GXL SPL_AP, Ultrasonic A AIC_1, ADV Instr Cluster 1 1
19S F AIC BATT B+ Or 1.0 GXL SPL_AP, Ultrasonic A AIC_2, ADV Instr Cluster 2 21
19T A Fused_Batt_Pwr Or 0.8 TXL TECM, Trans 23 SPL_D17, Ultrasonic A
19T B Fused_Batt_Pwr Or 0.8 TXL TECM, Trans 68 SPL_D17, Ultrasonic A
19T C Fused_Batt_Pwr Or 0.8 TXL ECC, Elect CNTR C A10 SPL_D17, Ultrasonic A
19U Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Elect CNTR C A6
19U A Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Elect CNTR C B7
19U B Beacon Dome Lt Fused Pwr Or 1.0 GXL SPL-LT, Ultrasonic A ECC, Elect CNTR C A1

ROOF, Roof to Cab

19U C Dome Lt Fused Pwr Or 0.8 GXL D LDM1, Dome Light B+ 1
Connection
CAB-RF, Cab to Roof
19U D Dome Lt Fused Pwr Or 0.8 GXL D SPL-LT, Ultrasonic A
Connection
19U E Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Elect CNTR C D7

ROOF, Roof to Cab

19U F Door Sw Fused Power Or 0.8 GXL P DS, Door Switch A
Connection
CAB-RF, Cab to Roof
19U G Door Sw Fused Power Or 0.8 GXL P SPL-LT, Ultrasonic A
Connection
19U H Beacon Switch Fused Power Or 1.0 GXL SBE, Beacon Switch 2 SPL-LT, Ultrasonic A
 4002-23

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 Cav Connector Cav
and Material
19W Cigar Lighter Pwr Or 3.0 GXL CL, Cigar Lighter 1 ECC, Elect CNTR A C8
19Y Hood control Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect CNTR C A7
19Y A Hood Up Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect CNTR C D2
19Y B Hood Down Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect CNTR C D4
19Y C Hood Switch Fused Power Or 1.0 GXL CABE2, Cab to Eng2 Bulkhd T SPL-HOOD, Ultrasonic A
19Y D Hood Switch Fused Power Or 1.0 GXL ENG2, Engine Bulkhd 2 T HD, Hood Switch B
19Z Driving Lights Sw Fused Power Or 1.0 GXL SPL_DR, Ultrasonic A ECC, Elect CNTR C A3
19Z A Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 2 SPL_DR, Ultrasonic A
19Z B Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 5 SPL_DR, Ultrasonic A
19Z C High Beam Flash Fused Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56d SPL_DR, Ultrasonic A
1CB Cab CB Protected Power R 19.0 SXL P_C3, B+ Pwr FRM PRMD 1 CBPW, Cab Power 1
1CB A Cab CB Protected Power R 19.0 SXL P-A3, B+ Power 1 CAB-PW, Cab Power 1
1DM Time Delay/Ign Sw Fused Pwr R 1.0 GXL ECC, Elect CNTR C A5 S_Key, Ignition_Switch 1
1 AA Brake Lt Sw Pwr R 1.0 SXL BTM_C, Cab Bottom Bulkhd K PBL, Brake Light Press Switch 1
1B EVGT Relay PWR R 1.0 GXL EVGT_3, EVGT_Fuse B EVGT_4, EVGT D
1 BA Alternator B+ R 13.0 SXL AB+, Alternator B+ 1 B2 Starter Power 1
1 BB Starter Solenoid Pwr R 8.0 SXL 193 Starter Relay 1 194 Starter Signal 1
1 BE Grid Htr Pwr R 19.0 SXL 115 Grid Htr Pwr 1 GH, Grid Htr 1
1 BF Alternator B+ R 13.0 SXL AB_5, Alternator B+ 1 B6, Starter Power 1
1 BG B+ PWR PRMC R 19.0 SXL B5, Starter PWR Stud 1 P_C1, B+ PWR FRM PRMD 1
1C ECC Bat Power R 8.0 GXL P-A1, B+ Power 1 L1-ECC, ECC Battery Power 1
1 DR Brake Light Switch Power R 1.0 GXL CAB-B, Cab Front Chassis K SPL-FLSHR-PWR, Ultrasonic A
1 DU Flasher Module Pwr R 1.0 GXL FLSHR, Flasher Module 1 SPL-FLSHR-PWR, Ultrasonic A

SPL-FLSHR-PWR,
1 DV Brake Lights/Flasher Bat Pwr R 2.0 GXL A ECC, Elec CNTR C A4
Ultrasonic
SPL-FLSHR-PWR,
1 DW Brake Lt Relay Bat Pwr R 1.0 GXL A ECD, Elec CNTR D A2
Ultrasonic
1E Grid heater Fuse Bat Power R 19.0 SXL P-C2, B+ Power from PRMD 1 GHF1, Grid Heater Fuse 1
1 GA Filter Htr Pwr R 3.0 SXL PRM-D1, PRM Output C SPL-HTR, Ultrasonic A
1 GB Fuel Filter Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A FFH, Fuel Filter Heater A
1 GC Water Sep Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A WSH, Water Separator Heater B
4002-24

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 Cav Connector Cav
and Material
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
1 NE Battery STRTR R 62.0 SGR B7, Starter-Battery 1 BT1, Battery_Starter 1
1 NF SSM PWR R 62.0 SGR B8, Starter_Power 1 244F, Starter-sec_STRG_MTR 1
1T EVGT_3 PWR R 1.0 SXL P_C6, B+ PWR FRM PRMD 1 EVGT_3, EVGT_FUSE A
1Y Grid Heater Fused Power R 19.0 SXL GHF3, Grid heater Fuse 1 GHF4, Grid Heater 1
1Z Starter Relay Battery Power R 8.0 SXL P-C4, B+, Power From PRMC 1 195, Starter Relay Power 1
20G A EDC7 ESO-K Interface W 0.8 TXL ENG, Engine Cab1 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 ECD, Elect Center D A6
21D Starter Relay Signal W 1.0 SXL SRC-1, Relay 1 ENG, Engine Cab1 15
21D A Starter Relay Signal W 0.8 GXL CAB_E, Cab-Engine 15 ECD, Elect Center D AA5
21E Key Switch Crank W 0.8 GXL ECB, Elect CNTR B D6 ECC, Elect Center C B9
21E A Key Switch Crank W 0.8 TXL ENG, Engine Cab1 27 EDC7, Engine Controller 32
21E B Key Switch Crank W 0.8 GXL ECC, Elect CNTR C C10 CAB_E, Cab-Engine 27
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
21F B EDC7 Digital Ground W 0.8 TXL SPL-EDC3, Ultrasonic A EDC7, Engine Controller 29
21F C EDC7 Digital Ground W 0.8 TXL ENG_B, CAB BTTOM 1 SPL-EDC3, Ultrasonic A
21F D EDC7 Digital Ground W 0.8 TXL RTHP, Throttle Pedal 1 BTM_E, CAB BTTOM 1
21G EDC7 Crank Control relay W 0.8 GXL CAB-E, Cab Engine 3 ECD, Elect Center D AA6
21G A EDC7 Crank Control relay W 0.8 TXL ENG, Engine Cab1 3 EDC7, Engine Controller 37
21H Crank control relay LSD W 0.8 GXL CAB-E, Cab Engine 4 ECD, Elect Center D A5
21H A Crank control relay LSD W 0.8 TXL ENG, Engine Cab1 4 EDC7, Engine Controller 17
21J Restart Prevent W 0.8 GXL ECC, Elect CNTR C D9 TEL, Telematics S
21K Ign Sw Start Signal W 0.8 GXL S-KEY, Ignition Switch 2 SPL-CRK, Ultrasonic A
 4002-25

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 Cav Connector Cav
and Material
21K A Ign Sw Start Signal W 0.8 TXL SPL-CRK, Ultrasonic A AIC-2, Adv Instrument Cluster 2 17
21K B Ign Sw Start Signal W 0.8 GXL SPL-CRK, Ultrasonic A ECB, Elect Center B B3
22A Declutch SW DU 0.8 TXL SDC, Declutch_Switch 3 TECM, Trans 21
22B Pedal Sensor +5V K 0.8 TXL TECM, Trans 37 CAB_B, Cab BTM Bulkhd B
22C Pedal POS Signal Y 0.8 TXL TECM, Trans 38 CAB_B, Cab BTM Bulkhd C
22D Pedal Sensor Grnd LU 0.8 TXL TECM, Trans 24 CAB_B, Cab BTM Bulkhd A
22E Pedal Sensor +5V K 0.8 TXL BTM_C, Cab Bottom Bulkhd B BPP, Pedal Position 2
22F Pedal POS Signal Y 0.8 GXL BTM_C, Cab Bottom Bulkhd C BPP, Pedal Position 3
22G Pedal Sensor Grnd LU 0.8 GXL BTM_C, Cab Bottom Bulkhd A BPP, Pedal Position 1
24B Throttle Signal W 0.8 TXL ENG_B, Cab BTTOM 3 EDC7, Engine Controller 79
24B A Throttle Signal W 0.8 TXL RTHP, Throttle Pedal 3 BTM+E, Cab BTTOM 3
24L Low Idle Sw W 0.8 TXL ENG_B, Cab BTTOM 6 EDC7, Engine Controller 48
24L A Low Idle Sw W 0.8 TXL RTHP, Throttle Pedal 6 BTM_E, Cab BTTOM 6
24R Throttle Grnd W 0.8 TXL ENG_B, Cab BTTOM 4 EDC7, Engine Controller 78
24R A Throttle Grnd W 0.8 TXL RTHP, Throttle Pedal 4 BTM_E, Cab BTTOM 4
24S Throttle Supply W 0.8 TXL ENG_B, Cab BTTOM 5 EDC7, Engine Controller 77
24S A Throttle Supply W 0.8 TXL RTHP, Throttle Pedal 5 BTM_E, Cab BTTOM 5
24T B TC Lockup SOL GND LU 1.0 SXL TRANS, Cab Transmission 25 YLS, TC_Lockup_Valve 2
255E Pedal Sensor +5V K 0.8 TXL BTM_C, Cab Bottom Bulkhd E BPP, Pedal Position 5

LU 0.8 GXL
25A Eng Speed Sig TRANS, Cab Transmission 7 ESS, Engine speed Sensor 1
Twist
25A A Eng Speed Sig LU 0.8 TXL TECM, Trans 19 Cab+T, Cab-Transmission 7

LU 0.8 GXL
25B Int Speed Sig TRANS, Cab Transmission 9 ISS, Int Speed Sensor 1
Twist
25B A Int Speed Sig LU 0.8 TXL TECM, Trans 42 Cab+T, Cab-Transmission 9

LU 0.8 GXL
25C Turbine Speed Sig TRANS, Cab Transmission 8 TSS, Turbine Speed Sensor 1
Twist
25C A Turbine Speed Sig LU 0.8 TXL TECM, Trans 41 Cab+T, Cab-Transmission 8
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 TECM, Trans 62 Cab+T, Cab-Transmission 10
25F Forward Signal LU 0.8 TXL TS1, Transmission Shifter B TECM, Trans 43
25G Brake Declutch Switch LU 1.0 SXL Trans, Transmission-Cab 14 PBD, Declutch Pressure Switch B
4002-26

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 Cav Connector Cav
and Material
25G A Brake Declutch Switch CTRL LU 0.8 GXL CAB-T, Cab Transmission 14 SPL-DC, Ultrasonic A
25G B Brake Declutch Switch CTRL LU 0.8 GXL SDC, Declutch Switch 1 SPL-DC, Ultrasonic A
25G C Brake Declutch Switch CTRL LU 0.8 TXL SPL-DC, Ultrasonic A TECM, Trans 66
25H Trans Auto Signal LU 0.8 TXL STA, Trans Auto Switch 3 TECM, Trans 29
25J Trans Sol Valve Y6 LU 0.8 TXL TRANS, Cab Transmission 21 TRC, Trans Control 6
25J A Trans Sol Valve Y6 LU 0.8 TXL CAB-T, Cab Transmission 21 TECM, Trans 51
25K Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 1
25K 9 Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 2
25K A Trans Sol Valve Y1 LU 0.8 TXL CAB-T, Cab Transmission 16 TECM, Trans 56
25L Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 2
25L 9 Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 1
25L A Trans Sol Valve Y2 LU 0.8 TXL CAB-T, Cab Transmission 17 TECM, Trans 10
25M Trans Sol Valve Y3 LU 0.8 TXL TRANS, Cab Transmission 18 TRC, Trans Control 3
25M A Trans Sol Valve Y3 LU 0.8 TXL CAB-T, Cab Transmission 18 TECM, Trans 32
25N Trans Sol Valve Y4 LU 0.8 TXL TRANS, Cab Transmission 19 TRC, Trans Control 4
25N A Trans Sol Valve Y4 LU 0.8 TXL CAB-T, Cab Transmission 19 TECM, Trans 55
25P Trans Sol Valve Y5 LU 0.8 TXL TRANS, Cab Transmission 20 TRC, Trans Control 5
25P A Trans Sol Valve Y5 LU 0.8 TXL CAB-T, Cab Transmission 20 TECM, Trans 9
25R Reverse Signal LU 0.8 TXL TS1, Transmission Shifter C TECM, Trans 64
25R A TC Lockup SOL Power LU 0.8 TXL TECM, Trans 50 CAB_T, Cab-Transmission 15
25R B TC Lockup SOL Power LU 1.0 SXL Trans, Transmission-CAB 15 YLS, TC_Lockup_Valve 1
25S Output Sw Power VPS1 LU 0.8 TXL TRANS, Cab Transmission 22 TRC, Transmission Control 7
25S A Output Sw Power VPS1 LU 0.8 TXL CAB-T, Cab Transmission 22 SPL D12, Ultrasonic A
25S B Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 12
25S C Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 13
25T Neutral Signal LU 0.8 GXL SPL-NEU, Ultrasonic A ECB, Elect Center B D3
25T A TC Lockup SOL GND W 0.8 TXL SPL_D19, Ultrasonic A CAB_T, Cab-Transmission 25
25T B Neutral Signal LU 0.8 GXL TS1, Transmission Shifter D SPL-NEU, Ultrasonic A
25T C Neutral Signal LU 0.8 TXL SPL-NEU, Ultrasonic A TECM, Trans 67
25W 3rd And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter B TECM, Trans 65
25Y Trans Kick Down Signal LU 0.8 GXL TS2, Transmission Shifter D SPL D11, Ultrasonic A
 4002-27

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 Cav Connector Cav
and Material
25Y A Trans Kick Down Signal LU 0.8 TXL SPL D11, Ultrasonic A TECM, Trans 22
25Y B Trans Kick Down Signal LU 0.8 GXL 197F, Main Cab FNR 6 SPL D11, Ultrasonic A
25Y C Trans Kick Down Signal LU 0.8 GXL 20M, Trans Kick Down 2 197M, FNR Main Cab 6
25Y D Trans Kick Down Signal LU 0.8 GXL KD_Diode, Diode ASSY C JSS_197M, FNR-Main_Cab 6
25Y E Trans Kick Down Signal LU 0.8 GXL CAB_FNR, Main_Cab_Fnr 6 KD_Diode, Diode ASSY B
25Y F Trans Kick Down Signal LU 0.8 GXL KD_Diode, Diode ASSY A JSS_197F, Main_Cab_Fnr 6
25Y G Trans Kick Down Signal LU 0.8 SXL 21M, Trans_Kick-Down 2 ARM_FNR, Fnr-Main_Cab 6
25Z 1st And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter C TECM, Trans 63
26E A Trans Enable Signal LU 0.8 TXL STE, Trans Enable Switch 3 TECM, Trans 31
26F A FNR Forward Signal LU 0.8 GXL 197M, FNR Main Cab 2 SFNR, FNR Switch 6
26F B FNR Forward Signal LU 0.8 TXL 197F, Main Cab FNR 2 TECM, Trans 20
26F C FNR Forward Signal LU 0.8 GXL FWD_DIODE, Diode ASSY C JSS_197M, FNR-Main_Cab 2
26F D FNR Forward Signal LU 0.8 GXL JSS_197F, Main_Cab_Fnr 2 FWD_DIODE, Diode ASSY A
26F E FNR Forward Signal LU 0.8 GXL CAB_FNR, Main_Cab_Fnr 2 FWD_DIODE, Diode ASSY B
26F F FNR Forward Signal LU 0.8 GXL SAJ, FNR_Switch 6 ARM_FNR, FNR-Main_Cab 2
26J FNR Switch Jumper LU 0.8 GXL SFNR, FNR Switch 2 SFNR, FNR Switch 4
26K FNR Switch Jumper LU 0.8 GXL SAJ, FNR_Switch 2 SAJ, FNR_Switch 4
26N A FNR Neutral Signal LU 0.8 GXL SFNR, FNR Switch 3 197M, FNR Main Cab 3
26N B FNR Neutral Signal LU 0.8 TXL 197F, Main Cab FNR 3 TECM, Trans 44
26N C FNR Neutral Signal LU 0.8 GXL JSS_197M, FNR-Main_Cab 3 NTRL_DIODE, Diode ASSY C
26N D FNR Neutral Signal LU 0.8 GXL JSS_197F, Main_Cab_Fnr 3 NTRL_DIODE, Diode ASSY A
26N E FNR Neutral Signal LU 0.8 GXL NTRL_DIODE, Diode Assy B CAB_FNR, Main_Cab_Fnr 3
26N F FNR Neutral Signal LU 0.8 GXL SAJ, FNR_Switch 3 ARM_FNR, FNR-Main_Cab 3
26R A FNR Reverse Signal LU 0.8 GXL SFNR, FNR Switch 1 197M, FNR Main Cab 4
26R B FNR Reverse Signal LU 0.8 TXL 197F, Main Cab FNR 4 TECM, Trans 30
26R D FNR Reverse Signal LU 0.8 GXL JSS_197F, Main_Cab_Fnr 4 RVS_DIODE, Diode ASSY A
26R E FNR Reverse Signal LU 0.8 GXL CAB_FNR, Main_Cab_Fnr 4 RVS_DIODE, Diode ASSY B
26R F FNR Reverse Signal LU 0.8 GXL SAJ, FNR_Switch 1 ARM_FNR, Fnr-Main_Cab 4
28F Fuel FLTR HTR RLY CTRL W 0.8 TXL PRM-D2,PRM Signal A EDC7, Engine Controller 36
28G Grid Heater Source Dr. W 1.0 GXL GHC, Grid Htr Relay 1 EDC7, Engine Controller 12
31A EVGT Relay B+ Or 0.8 GXL EVGT_4, EVGT B SPL_EDC4, Ultrasonic A
4002-28

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 Cav Connector Cav
and Material
31B Filter Heater Control Or 0.8 GXL PRM_D2, PRM Signal B SPL_EDC4, Ultrasonic A
31F Air Filter Rest Sw Signal Y 1.0 SXL ENG, Engine Cab1 28 PAF, Air Filter Rest Sw 1
31F A Air Filter Rest Sw Signal Y 0.8 TXL CAB-E, Cab Engine 28 SW-PD, Switch Pad 5
31H Hyd Filter Rest Sw Signal Y 1.0 SXL TRANS, Cab Transmission 23 PHF, Hyd Oil Filter Rest Sw 1
31H9 HYD FLTR RST SW 9 Y 1.0 SXL TRANS, Cab Transmission 23 PHF9, HYD_FLTR_RES_SW 2
31H A Hyd Filter Rest Sw Signal Y 0.8 TXL 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
32J F Trans Enable Indiction Y 0.8 GXL SPL_JSS_21, Ultrasonic A JSS_197M, FNR-Main_Cab 5
32J G Trans Enable Indiction Y 0.8 GXL JSS_197F, Main_Cab_Fnr 5 SPL_JSS_21, Ultrasonic A
32J H Trans Enable Indiction Y 0.8 GXL CAB_FNR, Main_Cab_Fnr 5 SPL_JSS_21, Ultrasonic A
32J J Trans Enable Indiction Y 0.8 GXL SAJ, FNR_Switch 7 ARM_FNR, Fnr-Main_Cab 5
33P Brake Warning Press Low Y 1.0 SXL BTM_C, Cab Bottom Bulkhd L PBW, Brake Warning Press Sw 1
33P A Brake Warning Press Low Y 0.8 TXL CAB_B, Cab BTM Bulkhd L AIC-2, Advance Instr Cluster 2 5

Redundant Brake Accumulator 4

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

33R A Redundant Brake Accumulator Y 1.0 SXL TRANS, Cab Transmission 1 SPL-RD, Ultrasonic A
Pressure Low

33R B Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB2, Redundant Brake Switch A
Pressure Low

33R C Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB1, Redundant Brake Switch A
Pressure Low
33U Parking Brake Switch Y 0.8 TXL SPB, Parking Brake Switch 3 AIC-2, Advance Instr Cluster 2 6
34A A Diff Lock SW B+ Or 0.8 GXL SDA, Diff Lock Switch 2 SPL_PBS, Ultrasonic A
34A B Diff Lock SW SIG B+ Or 0.8 GXL SDA, Diff Lock Switch 2 SPL_PBS, Ultrasonic A
34A C Diff Lock SOL B+ W 0.8 TXL SPL_D19, Ultrasonic A CAB_T, Cab-Transmission 2
34A D Diff Lock SOL B+ Or 1.0 SXL TRANS, Transmission-Cab 27 YDL, Diff Lock Solenoid 1
 4002-29

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 Cav Connector Cav
and Material
34A E Diff Lock SOL B+ Or 1.0 SXL YDL_1, Diff Lock Solenoid 1 YDL_2, Diff Lock Solenoid 1
34B Diff Lock SW SIG LU 0.8 TXL SDA, Diff Lock Switch 3 TECM, Trans 35
34C Diff Lock SOL GND LU 0.8 TXL TECM, Trans 11 CAB_T, Cab-Transmission 27
34C A Diff Lock SOL GND LU 1.0 SXL TRANS, Transmission-Cab 2 YDL, Diff Lock Solenoid 2
34C D Diff Lock SOL GND LU 1.0 SXL YDL_1, Diff Lock Solenoid 2 YDL_2, Diff Lock Solenoid 2
34D Diff Lock SW SIG LU 0.8 TXL TECM, Trans 59 SDM, Diff Lock Switch 1
35A 9 Backup Alarm RLY OUT Bk 1.0 SXL HD-9, Hood to Engine 7 BU2, Backup_Alarm 1
35A A Backup Alarm Y 0.8 GXL SPL_35A, Ultrasonic A ECD, Elect Control D AA9
35A B Backup Alarm Disable Switch Y 0.8 GXL SBU, Backup Alarm Dis Sw 2 SPL_35A, Ultrasonic A
35A C Backup Alarm Relay Out Y 0.8 GXL SPL_35A, Ultrasonic A CABE2, Cab to Eng2 Bulkhd L

209M, Backup Alarm Dis

35A D Backup Alarm Relay Out Y 0.8 GXL A SPL_35A, Ultrasonic A
Jump
209F, Backup Alarm Dis
35A E Backup Alarm Relay Out Y 0.8 SXL 1 SPL-D8-C1, Ultrasonic A
Jump
35A F Backup Alarm Relay Out Y 0.8 SXL CABE2, Cab to Eng2 Bulkhd K SPL-D8-C1, Ultrasonic A
35A G Backup Alarm Relay Out Y 0.8 SXL ENG2, Eng Bulkhd 2 K E-HD, Trans Hood B
35A
Backup Alarm Relay Out Y 1.0 SXL ENG2, Eng Bulkhd 2 K ENG-H, Engine to Hood 7
GN
35A H Backup Alarm Relay Out Y 1.0 SXL HD-E, Hood Trans B BU2, Backup Alarm 1
35A
Backup Alarm Relay Out Y 1.0 SXL HD-N, Hood to Engine 7 BU2, Backup Alarm 1
HN
35A J Reverse Light K 1.0 SXL ENG2, Eng Bulkhd 2 L SPL-A1A, Ultrasonic A
35A K Reverse Light K 1.0 SXL SPL-A1A, Ultrasonic A LRR-E, RH rear Comb Light 4
35A L Reverse Light K 1.0 SXL SPL-A1A, Ultrasonic A LLR-E, LH rear Comb Light 4
35A M Reverse Signal K 1.0 SXL SPL-35A, Ultrasonic A MON, Camera/Monitor 3
35A N Reverse Light K 1.0 SXL SPL-REV A LLR-9, LH Rear Comb Light 4
35A O Reverse Light K 1.0 SXL HD_9, Hood to Eng 8 SPL_REV A
35A P Reverse Light K 1.0 SXL LRR-9, RH rear Comb Light 4 SPL-REV A
35A R Backup Alarm Relay Out Y 1.0 SXL ENG2, Eng Bulkhd 2 L ENG-H, Engine to Hood 8
35B AIC Buzzer HSD W 0.8 TXL BUZ, AIC Buzzer 1 AIC-1, Advance Instr Cluster 1 13
35C Backup Alarm Relay Control Y 0.8 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
4002-30

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 Cav Connector Cav
and Material
35W Water In Fuel Indicator W 0.8 TXL WIF, Water In Fuel Sensor 1 EDC7, Engine Controller 42
35X Sec. Str Low Press Sig Y 0.8 TXL CAB-T, Cab Transmission 6 AIC-2, Advance Instr Cluster 2 11
35X A Sec. Str Low Press Sig Y 1.0 SXL SPL-C3, Ultrasonic A PSS, Sec. Steering Press Sw C
35X B Sec. Str Low Press Sig Y 1.0 SXL TRANS, Cab Transmission 6 TR-SS, Sec. Steering Mod Option C
35X C Sec. Str Low Press Sig Y 1.0 SXL SPL-C3, Ultrasonic A SS-TR, SS Module Trans C
35X D Sec. Str Low Press Sig Y 1.0 SXL SSM, Sec. Steering Module 8 SPL-C3, Ultrasonic A
36C Radiator Cool Temp Signal P 1.0 SXL ENG, Engine Cab1 5 RECT, Engine Coolant Temp A
36C A Radiator Cool Temp Signal P 0.8 TXL CAB-E, Cab Engine 5 AIC-1, Advance Instr Cluster 1 11
36F Fuel Level Analog P 1.0 SXL ENG, Engine Cab1 1 RFL, Fuel Sender 1
36F A Fuel Level Analog P 0.8 TXL CAB-E, Cab Engine 1 AIC-1, Advance Instr Cluster 1 2

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 P 1.0 SXL TRANS, Cab Transmission 30 HOT, Hydraulic Oil Temp Sender A
36H A Hydraulic Oil Temp P 0.8 TXL CAB-T, Cab Transmission 30 AIC-1, Advance Instr Cluster 1 9
36J Fuel Level Analog P 1.0 SXL ENG, Engine-Cab1 1 RFL_23, Fuel_Level_Send A
36R A Trans Temps/Filter Return P 1.0 SXL TRANS, Cab Transmission 12 SPL H1, Ultrasonic A
36R B Trans Filter Maint Sw Return P 1.0 SXL SPL H1, Ultrasonic A FM, Filter Maint Switch 2
36R C Valve Body Temp Return P 0.8 TXL SPL H1, Ultrasonic A TRC, Trans Control 9
36R D TCO Temp Return P 1.0 SXL SPL H1, Ultrasonic A TCOT, TCO Sender 2
36R E Trans Temps/Filter Return P 0.8 TXL CAB-T, Cab Transmission 12 TECM, Trans 46
36T Valve Body Temp Sig P 0.8 TXL TRANS, Cab Transmission 5 TRC, Trans Control 8
36T A Valve Body Temp Sig P 0.8 TXL CAB-T, Cab Transmission 5 TECM, Trans 39
37D A Diagnostic Signal P 0.8 TXL 108F, Diagnostic Connector 2 TECM, Trans 15
37E Diagnostic Signal Switched P 0.8 TXL 108F, Diagnostic Connector 4 TECM, Trans 18
401B Pedal POS Signal Y 0.8 GXL BTM_C, Cab Bottom Bulkhd F BPP, Pedal Position 4
41H A High Beam Pwr Or 1.0 GXL SRHSTLK, RH Stalk Switch 56a SPL_HB, Ultrasonic A
41H B High Beam LH Pwr Or 0.8 GXL SPL_HB, Ultrasonic A ECB, Elect Center B A3
41H C High Beam RH Pwr Or 0.8 GXL SPL_HB, Ultrasonic A ECB, Elect Center B A4
41H D High Beam Pwr Or 0.8 TXL SW-PD, Switch Pad 1 SPL_HB, Ultrasonic A
 4002-31

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 Cav Connector Cav
and Material
41H D High Beam Pwr Or 0.8 TXL SW-PD, Switch Pad 1 SPL_HB, Ultrasonic A
41J Driving Light Power Or 1.0 GXL SDR, Driving Lights Switch 6 SRHSTLK, RH Stalk Switch 56
41L A Low Beam Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56b SPL-LB, Ultrasonic A
41L B Low Beam LH Power Or 0.8 GXL SPL-LB, Ultrasonic A ECB, Elect Center B A6
41L C Low Beam RH Power Or 0.8 GXL SPL-LB, Ultrasonic A ECB, Elect Center B A5
41T Position Lights Switched Pwr K 1.0 GXL SDR, Driving Lights Switch 3 SPL_PR, Ultrasonic A
41T A Position Lights RH Switched Pwr K 1.0 GXL SPL_PR, Ultrasonic A ECB, Elect Center B A8
41T B Position Lights LH Switched Pwr K 1.0 GXL SPL_PR, Ultrasonic A ECB, Elect Center B A7
41T C Position Lights Switched Pwr K 1.0 GXL D-OR, Diode OR B SPL_PR, Ultrasonic A
42C A Front Work Lights Fused Pwr DU 2.0 GXL CAB-RF, Cab to Roof Conn. H SPL_42C, Ultrasonic A
42C C Front Work Lights Fused Pwr DU 2.0 GXL SPL_42C, Ultrasonic A SWL, Work Lights SW 3
42C D Front Work Lights Fused Pwr DU 1.0 GXL SPL_42C, Ultrasonic A D-OR, Diode OR A
42C F Front Work Lights Fused Pwr DU 2.0 GXL ROOF, Roof to Cab Conn. H SPL-WRKF, Ultrasonic A
42C G RH Front Work Lights Fused Pwr DU 1.0 GXL SPL-WRKF, Ultrasonic A LRFW, RH Front Work Light 1
42C H LH Front Work Lights Fused Pwr DU 1.0 GXL SPL-WRKF, Ultrasonic A LLFW, LH Front Work Light 1
42R A RH Front Work Lights Fuse Pwr DU 1.0 GXL LRFS, Front_WK_LT_OPT 1 SPL_WRK1, Ultrasonic A
42R B RH Front Work Lights Fuse Pwr DU 1.0 GXL SPL_WRK1, Ultrasonic A LRFR, Front_WK_LT_OPT 1
42R C Rear Work Lights Fused Pwr DU 2.0 GXL CAB-RF, Cab to Roof Conn. S SWL, Work Lights SW 6
42R F Rear Work Lights Fused Pwr DU 2.0 GXL ROOF, Roof to Cab Conn. S SPL-WRKR, Ultrasonic A
42R G RH Rear Work Lt Fused Pwr DU 1.0 GXL SPL-WRKR, Ultrasonic A LRRW, RH Rear Work Light 1
42R H LH Rear Work Lt Fused Pwr DU 1.0 GXL SPL-WRKR, Ultrasonic A LLRW, LH Rear Work Light 1
42R K RH Front Work Lights Fuse Pwr DU 1.0 GXL SPL_WRK1, Ultrasonic A LRFO, Front_WK_LT_OPT 1
42 A Work Lights Fused Power R 2.0 GXL SWL, Work Lights Switch 2 SPL-WL, Ultrasonic A
42 B Work Lights Fused Power R 1.0 GXL SWL, Work Lights Switch 5 SPL-WL, Ultrasonic A
43S A Door Open Signal W 0.8 GXL CAB-RF, Cab to Roof Conn. R AIC_2, ADV Instr Cluster 2 2
43S B Door Open Signal W 0.8 GXL ROOF, Roof to Cab Conn. R DS, Door Switch B
43 A Dome Light Auto Mode DU 0.8 TXL CAB-RF, Cab to Roof Conn. C AIC-1, Adv Instrument Cluster 1 7
43 B Dome Light Auto Mode DU 0.8 GXL ROOF, Roof to Cab Conn. C LDM2, Dome Light Auto 1
44A A Brake Light Relay Out T 0.8 GXL CABE2, Cab to Eng2 Bulkhd S ECD, Elect CNTR D AA1
44A D Brake Light Relay Out T 1.0 SXL ENG2, Eng Bulkhd2 S SPL-B8, Ultrasonic A
4002-32

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 Cav Connector Cav
and Material
44A
Brake Light Relay Out T 1.0 SXL ENG2, Eng Bulkhd2 S ENG-H, Engine to Hood 2
DN
44A E Brake Light Relay Out T 1.0 SXL LLR-E, LH Rear Comb Light 1 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL HD-N, Hood to Engine 2 SPL-J2-N, Ultrasonic A
EN
44A F Brake Light Relay Out T 1.0 SXL LRR-E, RH Rear Comb Light 1 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL LLR-N, LH Rear Comb Light 2 SPL-J2-N, Ultrasonic A
FN
44A
Brake Light Relay Out T 1.0 SXL LRR-N, RH Rear Comb Light 2 SPL-J2-N, Ultrasonic A
GN
44A J Brake Light Relay Out T 1.0 SXL SPL-L1 A HD-9, Hood to Engine 2
44A K Brake Light Relay Out T 1.0 SXL SPL-L1 A LRR-9, RH Rear Comb Light 1
44A L Brake Light Relay Out T 1.0 SXL LLR-9, LH Rear Comb Light 1 SPL-L1 A
44 A Brake Light Control Power T 0.8 GXL CAB-B, Cab BTM Bulkhd J ECD, Elec CNTR D AA2
45A A Left Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 9 SRHSTLK, RH Stalk Switch L
45B A Right Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 10 SRHSTLK, RH Stalk Switch R
45H Hazard Switch Power N 0.8 GXL FLSHR, Flasher Module 11 SHZ, Hazard Switch 3
45L Left Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 2 LLF, Lights LH 5
45L A Left Turn Signal N 1.0 SXL ENG2, Eng Bulkhd 2 R LLR-E, LH Rear Comb Light 2
45L AN Left Turn Signal N 1.0 SXL ENG2, Eng Bulkhd 2 R ENG-H, Engine to Hood 3
45L B Left Turn Signal N 0.8 GXL CABE2, Cab to Eng2 Bulkhd R SPL-PK3, Splice 3-4 Way D
45L BN Left Turn Signal N 1.0 SXL HD-N, Hood to Engine 3 LLR, LH Rear Comb Light 4
45L C Left Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 2 SPL-PK3, Splice 3-4 Way C
45L D Left Turn Signal N 0.8 GXL FLSHR, Flasher Module 8 SPL-PK3, Splice 3-4 Way B
45L E Left Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way A AIC-2, Adv Instrument Cluster 2 9
45L N Left Turn Signal N 1.0 SXL HD_9, Hood to Eng 3 LLR_9, LH_Rear_Comb_LT 2
45N A Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 2 64F, Flasher Connector 1
45N B Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 12 64M, Flasher Connector 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 ENG2, Eng Bulkhd 2 P LRR-E, RH Rear Comb Light 2
 4002-33

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 Cav Connector Cav
and Material
45R
Right Turn Signal N 1.0 SXL ENG2, Eng Bulkhd 2 P ENG-H, Engine to Hood 4
AN
45R B Right Turn Signal N 0.8 GXL CABE2, Cab to Eng2 Bulkhd P SPL-PK3, Splice 3-4 Way H
45R
Right Turn Signal N 1.0 SXL HD-N, Hood to Engine 4 LRR, RH Rear Comb Light 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
49A Back Light Power S 0.8 GXL HVAC1, HVAC1 3 SPL-BCK-LGT, Spl Back Lgt Pwr F
49S Back Light Power S 0.8 GXL STA, Trans Auto Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr J
49 A Back Light Power S 0.8 GXL SWL, Work Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr M
49 B Back Light Power S 0.8 GXL SBE, Beacon Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr L
49 C Back Light Power S 0.8 GXL SRWP, Rear Wiper Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr C

SPL-PED-BL, Spl Back Lgt Pwr 6

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

SPL-BCK-LGT2, Spl Back Lgt

49 J Back Light Power S 0.8 GXL SRTD, Detent Switch 8 C
Pwr
SPL-BCK-LGT2, Spl Back Lgt
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

SPL-BCK-LGT2, Spl Back Lgt

49 M Back Light Power S 0.8 GXL SHC, Height Control Switch 8 D
Pwr
SPL-PED-BL, Spl Back Lgt Pwr 6
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
4002-34

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 Cav Connector Cav
and Material
SPL-BCK-LGT2, Spl Back Lgt
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
SPL-BCK-LGT2, Spl Back Lgt
49 T Back Light Power S 0.8 GXL SFWW, Front Wiper/Washer 8 H
Pwr
SPL-PED-BL, Spl Back Lgt Pwr 6
49 V Back Light Power S 0.8 GXL SPB, Parking Brake Switch 8 E
Pck
SPL-PED-BL, Spl Back Lgt Pwr 6
49 W JSS Backlight S 0.8 GXL SJS, Joystick_Control_SW 8 Pck A

SPL-PED-BL, Spl Back Lgt Pwr 6

49 X Back Light AIC S 0.8 TXL SW_PD, Switch Pad 3 Pck D

SPL_BCK_LGT2, Spl_Back
49 Z Back Light Power S 0.8 GXL J SDA, Diff Lock Switch 8
Lgt Pwr
51B A JSS ACT SW W 0.8 GXL SPL_JSS_2, Ultrasonic A SJS, Joystick_Control_SW 3
51B B JSS ACT SW W 0.8 GXL SJS, Joystick_Control_SW 6 SPL_JSS_2, Ultrasonic A
51B C JSS ACT SW W 0.8 GXL JSS_CAB, JSS Cab 5 SPL_JSS_2, Ultrasonic A

CAB_ARM_FRM, Cab to Arm

51B D JSS ACT SW W 1.0 SXL 5 SPL_JSS_7, Ultrasonic A
to Frm
51B E B+, JSS W 0.8 GXL JSS_RLY, Relay K2 86 SPL_JSS_7, Ultrasonic A
51B G B+, JSS W 0.8 GXL SPL_JSS_7, Ultrasonic A JSS_RLY, Relay K2 87
51B H JSS ACT SW W 0.8 GXL SPL_JSS_7, Ultrasonic A CAB_ARM, Cab to Armrest 6

JSS_ARM, JSS Armrest to

51B J JSS ACT SW Bk 0.8 TXL 6 CAN_MOD_2, JSS Can Mod 1
Cab
51B K JSS Power W 0.8 GXL FNR_RLY, Relay K2 86 SPL_JSS_4, Ultrasonic A
51C A JSS ACT BTN Y 0.8 GXL JSS_VAB, JSS Cab 10 SJS, Joystick_Control_SW 5

CAB_ARM_FRM, Cab to Arm

51C B JSS ACT BTN Y 0.8 GXL 10 JSS_CNT, JSS Controller 13
to Frm
51D A GRND, Relay CTRL Bk 0.8 GXL JSS_CAB, JSS Cab 4 AIC_1, ADV Instr Cluster 1 21

CAB_ARM_FRM, Cab to Arm

51D B GRND, Relay CTRL Bk 0.8 GXL 4 JSS_RLY, Relay K2 85
to Frm
51E A Armrest Lower Or 0.8 GXL JSS_CNT, JSS Controller 6 CAB_ARM, Cab to Armrest 3
 4002-35

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 Cav Connector Cav
and Material
JSS_ARM, JSS Armrest to
51E B Armrest Lower Or 0.8 GXL 3 ARM_POS, Arm Position 3
Cab
51F A LS Press Sw SIG G 1.0 GXL JSS_LS, JSS Load Sense B JSS_FRM, JSS Frame to Cab A

CAB_FRM, Cab to JSS

51F B LS Press Sw G 0.8 GXL A JSS_CNT, JSS Controller 16
Frame
51H B Joystick Signal Y 0.8 GXL JSS_CNT, JSS Controller 4 CAB_ARM, Cab to Armrest 10

JSS_ARM, JSS Armrest to

51H C Joystick Signal Y 0.8 GXL 10 PVRES, JSS Joystick T
Cab
51J A Valve Alarm P 0.8 GXL SPL_JSS_11, Ultrasonic A CAB_FRM, Cab to JSS Frame B
51J B Valve Alarm P 0.8 GXL JSS_CNT, JSS Controller 12 SPL_JSS_11, Ultrasonic A
51J C JSS Alarm P 1.0 GXL JSS_VALVE, JSS HYD Valve 2 JSS_FRM, JSS Frame to Cab B
51J D Valve Alarm P 0.8 GXL SPL_JSS_11, Ultrasonic A R1, Resistor CS0

CAB_FRM, Cab to JSS

51K B Pilot Press SW G 0.8 GXL C JSS_CNT, JSS Controller 8
Frame
JSS_PIL_PR, JSS Pilot
51K C Pilot Press SW SIG G 1.0 GXL B JSS_FRM, JSS Frame to Cab C
Pressure
51L Joystick Signal Y 1.0 GXL JSS_VALVE, JSS HYD Valve 1 JSS_FRM, JSS Frame to Cab D
51L A Joystick Signal Y 0.8 GXL JSS_CNT, JSS Controller 7 CAB_FRM, Cab to JSS Frame D
51NC NC Neutral SW Bk 0.8 TXL PVRES, JSS Joystick W CAN_MOD_2, JSS Can Mod 3

JSS_ARM, JSS Armrest to

51NO NO Neutral SW Y 0.8 GXL 11 PVRES, JSS Joystick U
Cab
51NO
NO Neutral SW P 0.8 GXL CAB_ARM, Cab to Armrest 11 JSS_CNT, JSS Controller 14
A
51PW
JSS Power W 1.0 SXL SPL_JSS_16, Ultrasonic A JSS_FRM, JSS Frame to Cab H
H
51PW
JSS Power W 1.0 SXL JSS_LS, JSS Load Sense A SPL_JSS_16, Ultrasonic A
J
51PW
JSS Power W 1.0 SXL SPL_JSS_16, Ultrasonic A JSS_PIL_DUMP, JSS Pilot Dump 1
K
51PW CAB_ARM_FRM, Cab to Arm to
JSS Power W 0.8 GXL SPL_JSS_6, Ultrasonic A 9
M Frm
51PW
JSS Power W 0.8 GXL JSS_CAB, JSS Cab 9 SJS, Joystick_Control_SW 10
N
51PW
JSS Power W 0.8 GXL JSS_RLY, Relay K2 30 SPL_JSS_4, Ultrasonic A
P
4002-36

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 Cav Connector Cav
and Material
51PW
JSS Power W 0.8 GXL JSS_CNT, JSS Controller 9 SPL_JSS_4, Ultrasonic A
Q
51PW
JSS Power W 0.8 GXL SPL_JSS_6, Ultrasonic A CAB_ARM, Cab to Armrest 8
R
51PW
JSS Power W 0.8 GXL SPL_JSS_13, Ultrasonic A JSS_ARM, JSS Armrest to Cab 8
S
51PW
JSS Power W 0.8 GXL SPL_JSS_6, Ultrasonic A CAB_FRM, Cab to JSS Frame H
T
51PW
JSS Power Bk 0.8 TXL SPL_JSS_13, Ultrasonic A CAN_MOD_2, JSS Can Mod 2
U
51PW
JSS Power W 0.8 GXL SPL_JSS_13, Ultrasonic A PVRES, JSS Joystick S
V
51PW
JSS Power W 0.8 GXL SPL_JSS_6, Ultrasonic A SPL_JSS_4, Ultrasonic A
W
51P A SEC STR High Press W 1.0 SXL SSM, SEC STR MOD 9 PSS, Sec Str Press Switch A
51R Armrest Raise Bk 0.8 TXL ARM_POS, Arm Position 2 CAN_MOD_2, JSS Can Mod 5
51S A JSS Okay PWR W 0.8 GXL JSS_CNT, JSS Controller 5 SPL_JSS_5, Ultrasonic A
51S B JSS Okay PWR W 0.8 GXL CAB_ARM, Cab to Armrest 9 SPL_JSS_5, Ultrasonic A
51S C JSS Okay PWR W 0.8 GXL SPL_JSS_15, Ultrasonic A JSS_ARM, JSS Armrest to Cab 9
51S D JSS Okay PWR Bk 0.8 TXL CAN_MOD_2, JSS Can Mod 4 SPL_JSS_15, Ultrasonic A
51S E JSS Okay PWR W 0.8 GXL PVRES, JSS Joystick R SPL_JSS_15, Ultrasonic A

CAB_FRM, Cab to JSS

51S F JSS Okay PWR W 0.8 GXL F SPL_JSS_5, Ultrasonic A
Frame
51S J JSS Okay PWR W 1.0 SXL JSS_VALVE, JSS HYD Valve 4 JSS_FRM, JSS Frame to Cab F
51 A Sec. Str Motor Control W 1.0 SXL SSM, Sec. Steer Module 2 SPL-SS, Ultrasonic A
51 B Sec. Str Motor Control W 1.0 SXL SPL-SS, Ultrasonic A SSS, SS Mag Switch 1
51 C Sec. Str Sol Control W 1.0 SXL SPL-SS, Ultrasonic A YSS, Sec. Steering Solenoid 1
51 D Sec. Str Flyback W 1.0 SXL SSS, SS Mag Switch 1 SSD, SEC_STR_Diode C
52AU Fan Reverse Auto W 0.8 TXL SFC, Fan Control Switch 3 AIC-2, Adv Instrument Cluster 2 8
52A A Fan Reverse Relay Out W 1.0 GXL CAB-E, Cab Engine 22 ECB, Elect Center B D8
52A B Fan Reverse Relay Out W 1.0 SXL ENG, Engine Cab1 22 YFR, Fan Rev Solenoid Option 1

AIC-1, Adv Instrument

52C Parking Brake Solenoid LSD W 0.8 TXL 14 ECB, Elect Center B B10
Cluster 1
52J Fan Control Switch Jumper W 0.8 GXL SFC, Fan Control Switch 4 SFC, Fan Control Switch 2
 4002-37

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 Cav Connector Cav
and Material
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 BTM_C, Cab Bottom Bulkhd M YPB, Park Brake Solenoid 1
52P A Parking Brk Relay Out W 0.8 GXL CAB-B, Cab BTM Bulkhd M SPL-PTM, Ultrasonic A
52P B Parking Brk Relay Out W 0.8 GXL SPL-PB, Ultrasonic A ECB, Elect Center B D10
53A RTD Switch Power W 0.8 GXL SRTD, Detent Switch 3 EM, RTD Height Control RTT 3
53B RTD Signal W 1.0 SXL FRONT, Cab Front Chassis 12 PXF, RTD A
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

AIC-1, Adv Instrument

53C A Pilot Control Solenoid LSD W 0.8 TXL 20 ECD, Elect Center D B6
Cluster 1
53P A Pilot Control Relay Out W 0.8 GXL SPL-D25, Ultrasonic A YPP, Pilot Pressure Solenoid A
53P B Pilot Control Relay Out W 0.8 GXL SFL, Return to Travel Switch 2 SPL-D25, Ultrasonic A
53P C Pilot Control Relay Out W 1.0 GXL SPL-D25, Ultrasonic A ECD, Elect Center D D6
53P D Pilot Control Relay Out W 0.8 GXL SHC, Height Control Switch 2 SPL-D25, Ultrasonic A
53P E Pilot Control Relay Out W 0.8 GXL SRTD, Detent Switch 2 SPL-D25, Ultrasonic A
53P F Pilot Control Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 9 SPL-D25, Ultrasonic A
53P G Pilot Control Relay Out W 1.0 SXL FRONT, Cab Front Chassis 9 SPL-A3, Ultrasonic A
53P H Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXF, RTD C
53P I Pilot Control Relay Out W 1.0 SXL PXM, RTD C PXT, RTD C
53P J Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXH, Height Control RTT C
54A Height Control Switch Power W 0.8 GXL SHC, Height Control Switch 6 EM, RTD Height Control RTT 2
54B HC RTT Control Signal W 1.0 SXL FRONT, Cab Front Chassis 11 PXH, Height Control RTT A
54B A HC RTT Control Signal W 0.8 GXL CAB-F, Cab Front Chassis 11 SPL-D1, Ultrasonic A
54B B HC RTT Control Signal W 0.8 GXL EM, RTD Height Control RTT 5 SPL-D1, Ultrasonic A
54B C HC RTT Control Signal W 0.8 GXL SFL, Return to Travel Switch 6 SPL-D1, Ultrasonic A
55A A RTT Float Sw Power W 0.8 GXL EM, RTD Height Control RTT 1 SPL-RTT, Ultrasonic A
55A B RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 1 SPL-RTT, Ultrasonic A
55A C RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 3 SPL-RTT, Ultrasonic A
55B RTT Float Switch Control W 0.8 GXL SFL, Return to Travel Switch 5 EM, RTD Height Control RTT 6
56 A Fan Control PWM W 1.0 SXL ENG, Engine Cab1 23 YFN, Fan PWM Solenoid A
57 A Pin Engage Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 17 SPL-PINE, Ultrasonic A
4002-38

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 Cav Connector Cav
and Material
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
57 D Pin Engage Sol Pwr W 1.0 SXL YPE1, PIN Engage Jumper A YPE2, Pin_Engage_OPT A
58C Ride Control Switch Jumper W 0.8 GXL SRC, Ride Control Switch 5 SRC, Ride Control Switch 3
58H A Power VPS2 W 0.8 TXL TECM, Trans 8 SPL_D19, Ultrasonic A
58H B Power VPSL W 0.8 TXL SPL_D19, Ultrasonic A TECM, Trans 53
58H C Power W 0.8 GXL ECD,Elec CNTR D D7 SPL_D19, Ultrasonic A
58L Ride Control Relay LSD Bk 0.8 TXL TECM, Trans 57 ECD, Elect Center D B8
58T Ride Control Relay Sw Pwr W 0.8 GXL SRC, Ride Control Switch 4 ECD, Elect Center D B7
58 A Ride Control Sol Pwr W 1.0 SXL 202M, Rollback Jumper A 202M, Rollback Jumper B
58 B Ride Control Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 18 PRBF, Rollback Pressure Switch B
58 C Ride Control Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 18 SPL-D26, Ultrasonic A
58 D Ride Control Sol Pwr W 0.8 GXL 140M, Diode Module D SPL-D26, Ultrasonic A
58 E Ride Control Sol Pwr W 0.8 GXL SPL-D26, Ultrasonic A ECD, Elect Center D D8
58 F Ride Control Sol Pwr W 0.8 GXL SRC, Ride Control Switch 6 SPL-D26, Ultrasonic A
58 G Ride Control Sol Pwr W 1.0 SXL Front, FRNT_CHAS_CAB 18 YRC, Ride_Control_OPT 1
58 H Ride Control Signal W 1.0 SXL YRC_J, Ride CNTR_Jumper 1 YRC_J2, Ride_Control_OPT 1
59D Hood Relay Control Down W 1.0 GXL CABE2, Cab to Eng2 Bulkhd V ECC, Elect CNTR C D3
59D A Hood Relay Control Down W 1.0 SXL ENG2, Eng Bulkhd 2 V HD, Hood Switch A
59U Hood Relay Control Up W 1.0 GXL CABE2, Cab to Eng2 Bulkhd X ECC, Elect CNTR C D1
59U A Hood Relay Control Up W 1.0 SXL ENG2, Eng Bulkhd 2 X HD, Hood Switch C
60D Hood Down Relay Out W 1.0 GXL CABE2, Cab to Eng2 Bulkhd U ECC, Elect CNTR C B3
60D A Hood Down Relay Out W 1.0 SXL ENG2, Eng Bulkhd 2 U HDM, Hood Lift Motor 2
60U Hood Up Relay Out W 1.0 GXL CABE2, Cab to Eng2 Bulkhd W ECC, Elect CNTR C B1
60U A Hood Up Relay Out W 1.0 SXL ENG2, Eng Bulkhd 2 W HDM, Hood Lift Motor 1
61A AC Press SW input W 1.0 SXL ENG, Engine Cab1 30 SPL_ACP, Ultrasonic A
61A B Trinary Press Sw Input W 0.8 GXL SPL_AC, Ultrasonic A CAB_E, Cab-Engine 30
61A C AC Switch Input W 1.0 SXL SPL_ACP, Ultrasonic A ENG_B, Cab Bttom 8
61A D AC Switch Input W 1.0 SXL SPL_ACP, Ultrasonic A PRH, AC High Press SW A
61A E AC Switch Input W 1.0 SXL PRL, AC Low Press SW A BTM_E, Cab Bttom 8
61A F Trinary Press Sw Input W 0.8 GXL HVAC1, HVAC1 1 SPL_AC Ultrasonic A
 4002-39

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 Cav Connector Cav
and Material
61A G Trinary Press Sw Input W 0.8 GXL ECD, Elec CNTR D B9 SPL_AC Ultrasonic A
61B A AC Signal W 0.8 GXL HVAC1, HVAC1 4 AIC_2, ADV Instr Cluster2 12
61C AC Relay Out Or 0.8 GXL CAB-E, Cab Engine 2 ECD, Elect Center D C10
61C A AC Relay Out Or 1.0 SXL ENG, Engine Cab1 2 ACT, AC Comp Clutch 1
61R AC Relay Control W 1.0 SXL ENG, Engine Cab1 29 SPL_ACS Ultrasonic A
61R B AC Relay Control W 0.8 GXL CAB-E, Cab Engine 29 ECD, Elect Center D D9
61R C AC Switch Output W 1.0 SXL SPL_ACS, Ultrasonic A ENG_B, Cab Bttom 7
61R D AC Switch Output W 1.0 SXL SPL_ACS, Ultrasonic A PRH, AC High Press SW B
61R E AC Switch Output W 1.0 SXL PRL, AC Low Press SW B BTM_E, Cab Bttom 7
63C Front Wiper Park Control W 0.8 GXL FWM, Front Wiper Motor D ECD, Elect Center D C4
63C2 Front Wiper Park Control W 0.8 GXL ECD, Elect Center D 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 Rly High Speed 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 Rly High Speed 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 Cab1 25 FWW, Front Washer 1
64C Horn Relay Control Or 0.8 GXL SRHSTLK, RH Stalk Switch 31b ECC, Elect CNTR C B8
64 A Horn Power Or 0.8 GXL CAB-F, Cab Front Chassis 13 ECC, Elect CNTR C D8
65L Left Speaker Or 0.8 GXL LSPK, Left Speaker A SPK, Speaker 7
65R Right Speaker Or 0.8 GXL RSPK, Right Speaker A SPK, Speaker 1
66A RR Camera PWR OR 0.8 GXL ECA, Elect CNTR A C9 MON, Camera/Monitor 1
4002-40

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 Cav Connector Cav
and Material
67A Park Brake Signl OR 0.8 GXL TEL, Telematics E SPL_PTM, Ultrasonic A
67B Start Lockout OR 0.8 GXL ECC, Elect CNTR C D10 SRP, Work Lights SW 8
68C Rear Wiper Park Control Or 1.0 GXL CAB-RF, Cab to Roof Conn. K SRWP, Rear Wiper Switch 1
68C A Rear Wiper Park Control Or 1.0 GXL ROOF, Roof to Cab Conn. K RWM, Rear Wiper Motor D
68L Rear Wiper Switch Power Or 1.0 GXL SRWP, Rear Wiper Switch 2 SPL-3, Ultrasonic A
68L A Rear Wiper Switch Power Or 1.0 GXL ROOF, Roof to Cab Conn. L RWM, Rear Wiper Motor B
68L B Rear Wiper Switch Power Or 1.0 GXL CAB-RF, Cab to Roof Conn. L SPL-3, Ultrasonic A
68L C Rear Wiper Switch Power Or 1.0 GXL 140M, Diode Module F SPL-3, Ultrasonic A
68W Rear Washer Pump W 0.8 GXL CAB-E, Cab Engine 24 SRWP, Rear Wiper Switch 6
68W A Rear Washer Pump W 1.0 SXL ENG, Engine Cab 24 RWW, Rear Washer 1
CAN1 Y 0.8 TXL
CAN HI ENG, Engine-Cab1 14 EDC7, Engine Controller 35
H twist
CAN1
G 0.8 TXL
L CAN LO ENG, Engine-Cab1 13 EDC7, Engine Controller 34
twist

CANS Y 0.8 TXL

JSS_ARM, Jss Armrest to
HA CAN HI, CAN MOD2 twist 1 CAN_MOD_2, JSS Can Mod 7
Cab

CANS Y 0.8 TXL

CAB_ARM_FRM, Cab to Arm
HB CAN HI, CAN MOD2 twist 12 CAB_ARM, Cab to Armrest 1
to Frm

CANS Y 0.8 TXL CAB_ARM_FRM, Cab to Arm

HD CAN HI, CAN MOD3 twist to Frm 7 JSS_CNT, JSS Controller 1

CANS
G 0.8 TXL JSS_ARM, JSS Armrest to
LA CAN LO, CAN MOD2 12 CAN_MOD_2, Jss Can Mod 8
twist Cab

CANS
G 0.8 TXL CAB_ARM_FRM, Cab to Arm to
LB CAN LO, CAN MOD2 CAB_ARM, Cab to Armrest 12 1
twist Frm

CANS CAB_ARM_FRM, Cab to Arm

G 0.8 TXL
LD CAN LO, CAN MOD3 to Frm 6 JSS_CNT, Jss Controller 2
twist

Y 0.8 TXL
CAN H CAN High ENG, Engine-Cab1 14 SPL_CAN_DH, Ultrasonic A
TWIST
CAN Y 0.8 GXL TERM_CAN_2, Can Bulk
CAN2 HI, Term B SPL_CAN_HV, Ultrasonic A
H2 twist Head
 4002-41

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 Cav Connector Cav
and Material
CAN Y 0.8 TXL
CAN High SPL-CAN-JS_HI, Ultrasonic A SPL_CAN_GH, Ultrasonic A
HA TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-DIAG, Ultrasonic A DIA, Diagnostic C
HB TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A SPL-CAN-DIAG, Ultrasonic A
HC TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A TECM, Trans 25
HD TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A SPL-CAN-TRANS, Ultrasonic A
HE TWIST
CAN Y 0.8 TXL
CAN High SW-PD, Switch Pad 7 SPL-CAN, Ultrasonic A
HF TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A AIC-1, Adv Instrument Cluster 1 3
HG TWIST
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A TEL, Telematics M
HH TWIST
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A SPL_CAN_JS_H2, Ultrasonic A
HJ TWIST
CAN Y 0.8 GXL
CAN HI, EDC SPL-CAN-DH, Ultrasonic A EDC7, Engine Controller 35
HK twist
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A SPL_CAN_DIAG, Ultrasonic A
HL TWIST
CAN Y 0.8 GXL
CAN2 HI, EDC SPL-CAN-GH, Ultrasonic A CAB_E, Cab-Engine 14
HM TWIST
CAN Y 0.8 TXL
CAN High SPL_CAN_JS_HI, Ultrasonic A SPL_CAN_JS_H2, Ultrasonic A
HN TWIST
CAN Y 0.8 GXL
CAN2 HI, Diag2 SPL_CAN_GH, Ultrasonic A DIA_2, Diagnostic C
HO TWIST
CAN Y 0.8 GXL
CAN HI, Can Mod2 SPL_CAN_JS_HI, Ultrasonic A JSS_CAB, JSS Cab 12
HP TWIST
CAN Y 0.8 GXL SPL_CAN_JS_H2,
CAN HI, Can Mod3 A JSS_CAB, JSS Cab 7
HR TWIST Ultrasonic
CAN Y 0.8 GXL
CAN2 HI, TERM SPL_CAN_HT, Ultrasonic A Term_VAN_2, CAN Bulk Head B
HV TWIST
CAN Y 0.8 TXL
CAN2 HI, EVGT SPL_CAN_HV, Ultrasonic A Turbo, ENG Dash_Turbo 7
HW TWIST
4002-42

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 Cav Connector Cav
and Material
CAN Y 0.8 GXL
CAN2 HI SPL_CAN_HV, Ultrasonic A SPL_CAN_HT, Ultrasonic A
HZ TWIST
G 0.8 TXL
CAN L CAN Low ENG, Engine-CAB1 13 SPL_CAN_DL, Ultrasonic A
TWIST
CAN G 0.8 GXL Term_CAN_2, CAN Bluk
CAN 2 LO, TERM A SPL_CAN_LV, Ultrasonic A
L2 TWIST Head
CAN G 0.8 TXL
CAN Low SPL-CAN-JS-L1, Ultrasonic A SPL_CAN_GL, Ultrasonic A
LA TWIST
CAN G 0.8 TXL
CAN Low SPL-CAN-DIAG-L, Ultrasonic A DIA, Diagnostic D
LB TWIST
CAN G 0.8 TXL SPL-CAN-TRANS-L,
CAN Low A SPL-CAN-DIAG-L, Ultrasonic A
LC TWIST Ultrasonic
CAN G 0.8 TXL
CAN Low TECM, Trans 26 SPL-CAN-TRANS-L, Ultrasonic A
LD TWIST
CAN G 0.8 TXL
CAN Low SPL-CAN-L, Ultrasonic A SPL-CAN-TRANS-L, Ultrasonic A
LE TWIST
CAN G 0.8 TXL
CAN Low SW-PD, Switch Pad 8 SPL-CAN-L, Ultrasonic A
LF TWIST
CAN G 0.8 TXL
CAN Low SPL-CAN-L, Ultrasonic A AIC-1, Adv Instrument Cluster 1 4
LG TWIST
CAN G 0.8 TXL
CAN Low SPL_CAN_TEL2, Ultrasonic A SPL_CAN_JS_L2, Ultrasonic A
LH TWIST
CAN G 0.8 GXL
CAN LO, EDC EDC7, Engine Controller 34 SPL_CAN_DL, Ultrasonic A
LJ TWIST
CAN G 0.8 GXL
CAN2 LO, EDC SPL-CAN-GL, Ultrasonic A CAB_E, Cab-Engine 13
LL TWIST
CAN G 0.8 TXL
CAN Low SPL_CAN_TEL2, Ultrasonic A TEL, Telematics N
LM TWIST
CAN G 0.8 GXL
CAN Low, Can Mod3 SPL_CAN_JS_L1, Ultrasonic A JSS_CAB, JSS Cab 1
LP TWIST
CAN G 0.8 TXL
CAN Low SPL_CAN_JS_L1, Ultrasonic A SPL_CAN_JS_L2, Ultrasonic A
LQ TWIST
CAN G 0.8 GXL
CAN Low, Can Mod2 SPL_CAN_JS_L2, Ultrasonic A JSS_CAB, JSS Cab 6
LR TWIST
CAN G 0.8 GXL TERM_CAN_2, Can Bulk
CAN2 LO, TERM A SPL_CAN_LT, Ultrasonic A
LV TWIST Head
 4002-43

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 Cav Connector Cav
and Material
CAN G 0.8 TXL
CAN LO, EVGT SPL_CAN_LV, Ultrasonic A Turbo, Eng Dash_Turbo 1
LW TWIST
CAN G 0.8 GXL
CAN2 LO, Diag2 SPL_CAN_GL, Ultrasonic A DIA_2, Diagnostic D
LX TWIST
CAN G 0.8 TXL
CAN Low SPL_CAN_TEL2, Ultrasonic A SPL_CAN_DIAG_L, Ultrasonic A
LY TWIST
CAN G 0.8 GXL
CAN 2 LO SPL_CAN_LV, Ultrasonic A SPL_CAN_LT, Ultrasonic A
LZ TWIST
ECC
Beacon/Dome Light L1 ECC BUSS L1-ECC, ECC Batt Power 1 ECC, Elect CNTR C L1-1
L1
J1 Trans ECM Power ECA-BUSS ECA-L1, B+ Power cs01 ECA, Elect Center A L1
J2 Trans ECM Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J3 Emergency 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 Plt EM 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, Elect Center A L2 PRMB_L1, B+ Power cs01

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
J17 Seat Comp EMG Strtr ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J18 Diagnostic Power ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J19 ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J10
BUSS ECC, Elect Center C L1-9 ECC, Elect Center C L1-10
ECC
J2
Beacon/Dome Lt Work Lights ECC-BUSS ECC, Elect Center C L1-1 ECC, Elect Center C L1-2
ECC
J3
Work Lights Driving Lights ECC-BUSS ECC, Elect Center C L1-2 ECC, Elect Center C L1-3
ECC
4002-44

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 Cav Connector Cav
and Material
J4
Driving Lights Brake Lights ECC-BUSS ECC, Elect Center C L1-3 ECC, Elect Center C L1-4
ECC
J5
Brake Lights Delay Power ECC-BUSS ECC, Elect Center C L1-4 ECC, Elect Center C L1-5
ECC
J6
Delay Power Horn ECC-BUSS ECC, Elect Center C L1-5 ECC, Elect Center C L1-6
ECC
J7
Horn HOD Control ECC-BUSS ECC, Elect Center C L1-6 ECC, Elect Center C L1-7
ECC
J9
ECC-BUSS ECC, Elect Center C L1-8 ECC, Elect Center C L1-9
ECC
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
RAD7 Not Used W 0.8 GXL RAD-J3, Radio Jumper 11 RAD-J2, Speaker 5
RAD8 Not Used W 0.8 GXL RAD-J3, Radio Jumper 2 RAD-J2, Speaker 4
RAD9 Not Used W 0.8 GXL RAD-J3, Radio Jumper 9 RAD-J2, Speaker 3
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
 4002-45

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.
4002-46

STARTING AND CHARGING SYSTEMS

9
3

8
5

10

2
4 11
1
6
RCPH10WHL094FAH

1. STARTING RELAY 7.
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.
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.
 4002-47

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
Check Points Possible Cause of Bad Reading
Reading

Between terminals of resistor 75 ohms Bad resistor.

3 – Alternator
Located on left side of engine, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading

Between housing of alternator and Continuity Bad ground connection.

ground

NOTE: Put the master disconnect switch in the ON position.

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.

4002-48

4 – Crank Control Relay

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
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

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
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.

7 –
 4002-49

8 – Master Disconnect Switch

Located on right side battery box cover, remove battery box cover to gain access.
Correct
Check Points Possible Cause of Bad Reading
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).

9 – Starter Motor
Located on left side of engine, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading

Between housing of starter and Continuity Bad ground connection.

ground

NOTE: Put the master disconnect switch in the ON position.

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.

4002-50

10 – Ignition Switch
Located on steering column.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put the master disconnect switch in the ON position.

Terminal for wire 1DM to ground 24 volts Check circuit 1DM 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.

11 – Neutral Start Relay

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
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 –
 4002-51

POWER RELAY MODULES AND COLD STARTING SYSTEMS

13 14
20
18 15
21 16
17
RCPH10WHL094

13. POWER RLEAY MODULE A 18. POWER RELAY MODULE D

14. POWER RELAY MODULE B 19.
15. POWER RELAY MODULE C 20. WATER SEPARATOR HEATER
16. GRID HEATER RELAY 21. FUEL FILTER HEATER
17. GRID HEATER
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.
4002-52

13 – Power Relay Module A, Power converter F1, Secondary steering F2

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Check fuse F1, F2 Continuity Bad fuse or circuit.

Terminal for wire 0-EU 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 1CB-A to ground 24 volts Check circuit 1CB.

Terminal for wire 12ACC-C to 24 volts Check circuit 12ACC and check ignition switch (10).
ground

Terminal for wire 19L to ground 24 volts Bad power relay module A.

14 – Power Relay Module B, ACC Power F1

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Check fuse F1, F2 Continuity Bad fuse or circuit.

Terminal for wire 0-EC 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 12ACC-B to 24 volts Check circuit 12ACC, check ignition switch (10).
ground

Terminal for wire 1CB-A to ground 24 volts Check circuit 1CB.

Terminal for wire PRM-B J11 BUSS 24 volts Bad power relay module B
to ground

15 – Power Relay Module C, Ignition Power F1

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Check fuse F1 Continuity Bad fuse or circuit.

Terminal for wire 0-EB to ground Continuity Bad ground circuit.

NOTE: Put the ignition switch in the ON position.

Terminal for wire 13K-C to ground 24 volts Check 13K and check ignition switch (10).

Terminal for wires J1 BUSS to 24 volts Bad power relay module.

ground
 4002-53

16 – Grid Heater 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-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
Check Points Possible Cause of Bad Reading
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 – Power Relay Module D, Fuel Filter Heater F1, Engine ECM F2

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

Check fuse F1, F2 Continuity Bad fuse or circuit.

NOTE: Make sure engine

temperature is below 0 C (32 F).

Terminal for wire 31B to ground Continuity Bad ground circuit or bad EDC7 (24).

NOTE: Turn the ignition switch to the ON position.

Terminal for wire 1-NC to ground 24 volts Check circuit 1-NC.

Terminal for wire 28F to ground 24 volts Check EDC7 (24).

Terminal for wire 1-GA to ground 24 volts Bad power relay module

19 –
4002-54

20 – Water Separator Heater

Located in the right side of the engine compartment on water separator housing, open engine compartment to gain
access.
Correct
Check Points Possible Cause of Bad Reading
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-GA between water separator heater connector WSH and power
relay module D connector PRM-D1.

21 – Fuel Filter Heater

Located in the right side of the engine compartment on fuel filter housing, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
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 D connector PRM-D1.
 4002-55

ENGINE CONTROLLER

24 22 23
RCPH10WHL094FAH

22. WATER IN FUEL SENSOR

23. THROTTLE POTENTIOMETER
24. ENGINE CONTROLLER
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.
4002-56

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
Check Points Possible Cause of Bad Reading
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.

Terminal for wire 18J-H to ground 24 volts Check power EDC7, also check 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
Check Points Possible Cause of Bad Reading
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)
 4002-57

24 – Electronic Diesel Control

Located on right side of engine, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
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 ECM-F2, bad wire 18J.
ground

Terminal for wire 18J-B pin 3 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground

Terminal for wire 18J-D pin 8 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
Terminal for wire 18J-E pin 9 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground

NOTE: Use diagnostic service tool for additional tests on EDC7.

4002-58

RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE

28
30

25 26 31 32

27
29 33 34
RCPH10WHL094FAH

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)
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.
 4002-59

25 – Return-To-Travel/Float Switch
Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
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

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
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.
4002-60

27 – Electromagnetic Detents
Located under right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: For joystick controller.

74 ohms @
Between pins 3 and 4 Bad electromagnetic detent
20° C (68° F)

74 ohms @
Between pins 2 and 5 Bad electromagnetic detent
20° C (68° F)

74 ohms @
Between pins 1 and 6 Bad electromagnetic detent
20° C (68° F)

NOTE: For single axis controller.

328 ohms @
Between pins 3 and 4 Bad electromagnetic detent
20° C (68° F)

328 ohms @
Between pins 2 and 5 Bad electromagnetic detent
20° C (68° F)

328 ohms @
Between pins 1 and 6 Bad electromagnetic detent
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 (26). 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 (31). Also check wires 53A.
to ground

28 – Return-To-Dig Proximity Switch

Located on bucket cylinder.
Correct
Check Points Possible Cause of Bad Reading
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-AM 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-I 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.
 4002-61

29 – Pilot Control Relay

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
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
Check Points Possible Cause of Bad Reading
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

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
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.
4002-62

32 – Pin Engage Switch (Option)

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B5 to ground Continuity Bad ground circuit.

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 C. 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
Check Points Possible Cause of Bad Reading
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
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-AW 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-D to ground 24 volts Bad pin engage switch (32), also check circuit 57.

NOTE: If the readings are good, replace the pin engage solenoid.
 4002-63

PILOT CONTROL - RIDE CONTROL - FAN CONTROL

43 44

35 37 39

40
36 41
38 42
RCPH10WHL094FAH

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)
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.
4002-64

35 – Ride Control Switch

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
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 C. 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

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal 85 for wire 58L to

Continuity Check wire 58L.
connector TECM pin 57

Terminal 86 for wire 58H-C to Continuity Check wire 58H-C.

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.

 4002-65

37 – Fan Control Switch (Option)

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B7 to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Check fuse ECA-F7, power relay module C, also check circuit

Terminal for wire 19P-C to ground 24 volts
19P.

NOTE: Put fan control switch in position 1.

Terminal for wire 52AU to ground 24 volts Bad fan control switch.

NOTE: Put fan control switch in momentary position, hold rocker.

Terminal for wire 52M to ground 24 volts Bad fan control switch.

NOTE: Put driving lamp switch in position 3.

Check driving lamp switch. If LEDs in fan control switch are not
Terminal for wire 49-Q to ground 24 volts
ON with 24 volts at check point, replace fan control switch.

38 – Fan Reverse Relay (Option)

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
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 control switch in the manual reverse position.

Bad fan reverse solenoid, bad fan control switch (37), bad
Terminals for wire 52A-A to ground 24 volts
advanced instrument cluster (62).
4002-66

39 – Pilot Control Switch

Located on steering column pedestal.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0B1 to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Terminal for wire 19C-F to ground 24 volts Bad fuse ECA-F5, 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
Check Points Possible Cause of Bad Reading
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
Check Points Possible Cause of Bad Reading
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 58 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.)
 4002-67

42 – Rollback Jumper (Option)

Located inside of front frame.
Correct
Check Points Possible Cause of Bad Reading
Reading

Between terminals A and B on Continuity Bad rollback jumper.

switch

43 – Fan PWM Solenoid (Option)

Located on fan control valve.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector YFN from fan PWM solenoid.

Between pins A and B of fan PWM 26 to 32 ohms Bad fan reversing solenoid.
solenoid

Pin B 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 A 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
Check Points Possible Cause of Bad Reading
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 control switch. Also check wire 52-A.
YFR to ground
4002-68

TRANSMISSION

46 48

52

55 56 57 60

49 50 45 53 54
51 47 61 58
RCPH10WHL094FAH
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
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.
 4002-69

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
4002-70

WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE

66

62 63

68
67
69

65 64

RCPH10WHL094FAH

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
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.
 4002-71

62 – Instrument Cluster Connector 1

Located on instrument cluster.
Correct
Check Points Possible Cause of Bad Reading
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 11 to 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 9 to 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 or 17P-B.

connector terminal SW-PD 9

Connector terminal AIC-2 4 to Bad redundant brake switche(s) (75)(76). Also check circuit
Open Circuit
ground 33R.

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)

NOTE: Put the parking brake switch in the ON position.

Connector terminal AIC-1 14 to Bad parking brake switch (64). Also check fuse ECA-F6 and
24 volts
ground circuit 19D-B 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.

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 1 to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECB-F3 or F4. Also check circuit 41H-D.

NOTE: Press pilot control switch to turn ON switch LED.

Connector terminal AIC-1 14 to Bad parking brake relay or fuse ECA-F6. Also check circuits
24 volts
ground 52C and 19D-B.

Connector terminal AIC-1 20 to Bad pilot control relay or fuse ECA-F5. Also check circuits
24 volts
ground 53C-A and 19C-C.
4002-72

63 – Warning (AIC) Buzzer

Located on steering column under instrument cluster.
Correct
Check Points Possible Cause of Bad Reading
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

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
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.

65 – Fuel Level Sender

Located on the fuel tank top right side.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-BU to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

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
 4002-73

66 – Air Filter Restriction Switch

Located on the air filter left side.
Correct
Check Points Possible Cause of Bad Reading
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.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

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
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-AN to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF
position.

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.

68 – Radiator Coolant Temperature Sender

Located on the lower radiator hose to engine on left side of engine compartment.
Correct
Check Points Possible Cause of Bad Reading
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)

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Approximately
Terminal A for wire 36C to ground Check the instrument cluster (62).
5 volts
4002-74

69 – Brake Warning Pressure Switch

Located on the foot brake valve.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Brake warning pressure switch opens at 110.3 bar (1600 psi).

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

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.
 4002-75

SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE

70 71 74

75
76

72
73
RCPH10WHL094FAH

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.
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.
4002-76

70 – Switch Pad
Located on steering column.
Correct
Check Points Possible Cause of Bad Reading
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.

 4002-77

71 – Instrument Cluster Connector 2

Located on instrument cluster.
Correct
Check Points Possible Cause of Bad Reading
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 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-DA.
to ground.

Connector terminal AIC-2 4 to Bad redundant brake switche(s) (75)(76). Also check circuit
Open Circuit
ground 33R.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Connector terminal AIC-2 14 and 20 24 volts Bad fuse ECD-F8. Also check circuit 19S-C and 19S-D.
to ground

Connector terminal AIC-2 21 to Bad fuse ECA-F3. Also check circuit 19E-A. Also check power
24 volts
ground relay module C (15).

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 1 to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECB-F3 and F4. 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 9 to off every 1-2 Also check circuit 45A-A to flasher module, and circuit 45L-D
ground seconds 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 10 to off every 1-2 Also check circuit 45B-A to flasher module, and circuit 45R-E
ground seconds from flasher module to instrument cluster.

NOTE: Press pilot control switch to turn ON switch LED.

Connector terminal AIC-2 18 to Bad pilot control switch or fuse ECA-F5. Also check wire 31L
24 volts
ground and circuit 19A.
4002-78
]

72 – Hydraulic Filter Restriction Switch

Located on hydraulic filter block.
Correct
Check Points Possible Cause of Bad Reading
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

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

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
Check Points Possible Cause of Bad Reading
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)

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Approximately
Terminal A for wire 36H to ground Check the instrument cluster (62).
5 volts
 4002-79

74 – Parking Brake Switch

Located on steering column.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B29 to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Terminal for wire 19A-L to ground 24 volts Check fuse ECA-F6, 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
Check Points Possible Cause of Bad Reading
Reading

NOTE: Redundant brake switch close at 62 bar (900 psi).

Terminal for wires 0-HM to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

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
Check Points Possible Cause of Bad Reading
Reading

NOTE: Redundant brake switches close at 62 bar (900 psi).

Terminal for wireS 0-HL to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

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).
4002-80

77 –
 4002-81

BACK UP ALARM CONTROLS

79

78

RCPH10WHL094FAH
BS06H241 / BS06H242

78. BACK UP ALARM RELAY 79. BACK UP ALARM DISABLE SWITCH

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.
4002-82

78 – Back-up Alarm Relay

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
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

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Bad fuse ECA-F1, also check wires 19A-P, power relay module
Terminal for wire 19A-P to ground 24 volts
C, Ignition power (15).

Bad fuse ECA-F14, also check wires 19H, power relay module
Terminal for wire 19H to ground 24 volts
B, accessory power (14).

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

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B21 to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.

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.
 4002-83

LIGHTS - 01

87
82 85
81

83 86
88

80 84

89

RCPH10WHL094FAH

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
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.
4002-84

80 – Work Lamps Switch

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
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 42C-C to ground 24 volts Bad work lamps switch.

NOTE: Put the wok lamps switch in position 3 for rear work lamps.

Terminal for wire 42R-C to ground 24 volts Bad work lamps switch.

81 – Door Switch
Located above door in cab.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put the master disconnect switch in the ON position.

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
Check Points Possible Cause of Bad Reading
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.

 4002-85

83 – Dome Lamp
Located in top of cab.
Correct
Check Points Possible Cause of Bad Reading
Reading

Bulb Continuity Bad bulb.

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
Terminal for wire 43-B to ground Check circuit 43, also check advanced instrument cluster (62).
3 to 5 seconds

NOTE: If readings are good, replace dome lamp.

84 – Beacon Switch (Option)

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B15 to ground Continuity Bad ground circuit.

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
Check Points Possible Cause of Bad Reading
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 driving lamp switch (95). Also check circuit 42C from
Terminal for wire 42C-H to ground 24 volts
flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.
4002-86

86 – Right Hand Front Work Lamp

Located on right front side of cab.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector LRFW from RH front work lamp connector.

Flood lamp connector pin A to pin B Continuity Bad lamp bulb.

NOTE: Connect wiring harness connector LRFW to RH front work lamp connector.

Terminal for wire 0-MJ to ground Continuity Bad ground circuit. (O-MJ, O-MG, O-MP, O-ML)

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.

Check driving lamp switch (95). Also check circuit 42C from
Terminal for wire 42C-G to ground 24 volts
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
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector LLRW from LH rear work lamp connector.

Flood lamp connector pin A to pin B Continuity Bad lamp bulb.

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.

Check driving lamp switch (95). Also check circuit 42R from
Terminal for wire 42R-H to ground 24 volts
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
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector.

Flood lamp connector pin A to pin B Continuity Bad lamp bulb.

NOTE: Connect wiring harness connector LRRW to RH rear work lamp connector.

Terminal for wire 0-MF to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.

Check driving lamp switch (95). Also check circuit 42R from
Terminal for wire 42R-G to ground 24 volts
flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.
 4002-87

89 – Lights Diodes
Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector D-OR from diode connector.

Multimeter positive on pin A to pin C Continuity Bad diode.

Multimeter positive on pin B to pin C Continuity Bad diode.

Multimeter positive on pin C to pin A None Bad diode.

Multimeter positive on pin C to pin B None Bad diode.

4002-88

LIGHTS - 02

93 94

95

90
92 91
RCPH10WHL094FAH
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
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.
 4002-89

90 – Brake Lamp Pressure Switch

Located on the foot brake valve.
Correct
Check Points Possible Cause of Bad Reading
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

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-EF to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch in ON position.

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.
4002-90

92 – Flasher Module
Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Check Points Possible Cause of Bad Reading
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)

NOTE: Put master disconnect switch in ON position.

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) . Also check wire 45A-A.

Intermittent 24
Terminal for wire 45L-D to ground Bad flasher module.
volts
 4002-91

93 – Hazard Switch
Located on steering column.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B24 to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch in ON position.

Terminal for wire 1-KA to ground 24 volts Check fuse ECC-F4. Also check wires 1-KA and 1-DV.

NOTE: Put hazard switch in ON position.

Bad hazard switch. If hazard switch LED is not ON with 24 volts

Terminal for wire 45H to ground 24 volts
at check point, replace hazard switch.

NOTE: Put driving lamp switch (95) in position 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

Located on steering column.
Correct
Check Points Possible Cause of Bad Reading
Reading

HORN SWITCH

Terminal for wire 0-EP to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position.

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

NOTE: Put master disconnect switch and ignition switch in ON position.

Check fuse ECA-F8 and power relay module C(15). 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.

4002-92

95 – Driving Lamp Switch

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put the master disconnect switch in the ON position.

Terminal for wire 19Z-a to ground 24 volts Check fuse ECC-F3, also check circuit 19Z.

NOTE: Put the driving lamp switch in position 2.

Terminal for wire 41T to ground 24 volts Bad driving lamp switch.

NOTE: Put the driving lamp switch in position 3.

Terminal for wire 41J to ground 24 volts Bad driving lamp switch.
 4002-93

LIGHTS - 03 AND HORN

96 99

97

98
RCPH10WHL094FAH

96. LEFT HAND FRONT COMBINATION LAMPS 98. HORN RELAY

97. RIGHT HAND FRONT COMBINATION LAMPS 99. HORN
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.
4002-94

96 – Left Hand Front Combination Lamp

Located on the left front of the machine.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector LLF from LH front combination lamp connector.

Combination lamp connector pin 3 to Continuity Bad high beam lamp bulb.
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 LLF to LH front combination lamp connector.

Terminal for wire 0-AJ to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 2.

Check fuse ECB-F7 and driving lamp switch (95). Also check
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, driving lamp switch (95), and high/low

Terminal for wire 18B to ground 24 volts
beam switch (94). Also check circuit 18B and wire 41H-B.

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-B.

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.
 4002-95

97 – Right Hand Front Combination Lamp

Located on the right front of the machine.
Correct
Check Points Possible Cause of Bad Reading
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.

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3.

Check fuse ECB-F8 and driving lamp switch (95). Also check
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.

Check fuse ECB-F4, driving lamp switch (95), and high/low

Terminal for wire 18C to ground 24 volts
beam switch (94). Also check circuit 18C and wire 41H-C.

NOTE: Put high/low beam lever (94) in LOW beam position.

Check fuse ECB-F5, driving lamp switch (95), and high/low

Terminal for wire 18E to ground 24 volts
beam switch (94). Also check circuit 18E and wire 41L-C.

NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.

Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
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.
4002-96

98 – Horn Relay
Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
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 Fuse ECC-F6, also 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
Check Points Possible Cause of Bad Reading
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.

 4002-97

LIGHTS - 04 AND BACK UP ALARM

101
103

100
102

RCPH10WHL094FAH

100.RIGHT HAND REAR COMBINATION LAMPS 102.LICENSE PLATE LAMP

101.LEFT HAND REAR COMBINATION LAMPS 103.BACK UP ALARM
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.
4002-98

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

Located on the right rear of the machine.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector LRR 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-N 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.

Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
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.
 4002-99

100 – Right Hand Rear Combination Lamp (Europe Only)

Located on the right rear of the machine.
Correct
Check Points Possible Cause of Bad Reading
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.

NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.

Check brake lamps relay (91). Also check circuit 44 to brake

Terminal for wire 44A-F to ground 24 volts
lamps relay (91).

NOTE: Have assistant put transmission in reverse.

Check backup alarm relay (78). Also check circuit 35A to

Terminal for wire 35A-K to ground 24 volts
backup alarm relay (78).

NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.

Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
Terminal for wire 45R-A to ground volts check circuit 45R to flasher module.

NOTE: Put driving lamp switch (95) in position 2 or 3.

Check fuse ECB-F8 and lamp switch (95). Also check circuit
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.
4002-100

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

Located on the left rear of the machine.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector LLR 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.

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-FN to ground 24 volts
lamps relay (91).

NOTE: 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-BN to ground volts check circuit 45L to flasher module.

NOTE: Put driving lamp switch (95) in position 2 or 3.

Check fuse ECB-F7 and lamp switch (95). Also check circuit
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.
 4002-101

101 – Left Hand Rear Combination Lamp (Europe Only)

Correct
Check Points Possible Cause of Bad Reading
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.

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-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.

Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
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
Check Points Possible Cause of Bad Reading
Reading

Bulb Continuity Bad bulb.

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.
4002-102

102 – License Plate Lamp (Europe Only)

Located on the right rear of the machine with combination lamp.
Correct
Check Points Possible Cause of Bad Reading
Reading

Bulb Continuity Bad bulb.

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
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-JB to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).

Bad back-up alarm disable switch (79). If machine is not a TUV

Terminal for wire 35A-H to ground 24 volts
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
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-JB to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).

Bad back-up alarm disable switch (79). If machine is not a TUV

Terminal for wire 35A to ground 24 volts
model, check connector 209F and 209M is connected.

NOTE: If the readings are good, replace the back-up alarm.

 4002-103

CAB WINDOW WASHER AND WIPER SYSTEM

109 110

111
112

107 108

104 106
113
105
RCPH10WHL094FAH

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
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.
4002-104

104 – Front Wiper High Speed Relay

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Terminal for wire 19J-D and 19J-E to Bad fuse ECA-F12, check circuit 19J, also check power relay
24 volts
ground module B (14).

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

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-G to ground 24 volts
module B (14).

Terminal for wire 63L-B to ground 24 volts Bad wiper cut out relay.

NOTE: Put the front wiper switch in the HIGH position.

Terminals for wire 63HC-A to ground Continuity Bad front wiper and washer switch (108).

Terminals for wire 63L-B to ground 0 volts Bad wiper cut out relay.
 4002-105

106 – Front Wiper Low Speed Relay

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Bad fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-F to ground 24 volts
module B (14).

NOTE: Put the front wiper switch in the LOW position.

Terminals for wire 63C to ground 24 volts Bad wiper low speed relay.

NOTE: Put the front wiper switch in the HIGH position.

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

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B23 to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position.

Bad fuse ECA-F13 or power relay module B (14). Also check

Terminal for wire 19K-B to ground 24 volts
circuit 19K.

Bad fuse ECA-F13 or power relay module B (14). 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.

NOTE: Put the driving lamp switch in position 3.

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.
4002-106

108 – Front Wiper and Washer Switch

Located on right side console.
Correct
Check Points Possible Cause of Bad Reading
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 B (14).

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.
 4002-107

109 – Front Wiper Motor

Located in front of steering column.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B8 to ground Continuity Bad ground circuit.

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

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Terminal for wire 19J-A to ground 24 volts Check fuse ECA-F12, also check circuit 19J.

NOTE: Put the front wiper and washer switch (108) in the LOW position.

Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63L-A to ground 24 volts
and washer switch (108), low speed relay or cut out relay.

Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (108)

NOTE: Put the front wiper and washer switch (108) in the HIGH position.

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-A 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.
4002-108

110 – Rear Wiper Motor

Located in top of rear cab head liner.
Correct
Check Points Possible Cause of Bad Reading
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

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Terminal for wire 19K-D 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
Check Points Possible Cause of Bad Reading
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
Check Points Possible Cause of Bad Reading
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.
 4002-109

113 – Wiper Diodes

Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector 140M 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 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 A Continuity Bad diode.

Multimeter positive on pin C to pin B Continuity Bad diode.

Multimeter positive on pin C to pin D Continuity Bad diode.

Multimeter positive on pin C to pin E Continuity Bad diode.

Multimeter positive on pin C to pin F Continuity Bad diode.

4002-110

SECONDARY STEERING

114 116 118

115 117
RCPH10WHL094FAH

114.SECONDARY STEERING DIODES 117.SECONDARY STEERING MOTOR

115.SECONDARY STEERING SOLENOID 118.SECONDARY STEERING PRESSURE SWITCH
116.SECONDARY STEERING MODULE
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.
 4002-111

114 – Secondary Steering Diodes

Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Disconnect wiring harness connector DM from diode connector.

Multimeter positive on pin A to pin C Continuity Bad diode.

Multimeter positive on pin B to pin C Continuity Bad diode.

Multimeter positive on pin C to pin A None Bad diode.

Multimeter positive on pin C to pin B None Bad diode.

115 – Secondary Steering Solenoid (Option)

Located in the rear frame of the machine.
Correct
Check Points Possible Cause of Bad Reading
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).
4002-112

116 – Secondary Steering Module (Option)

Located in the rear frame of the machine.
Correct
Check Points Possible Cause of Bad Reading
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.

Pin 11 of connector SSM to ground Continuity Bad ground circuit.

Pin 12 of connector SSM to ground Continuity Bad ground circuit.

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 C(15), ignition switch,

Pin 1 of connector SSM to ground 24 volts
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.
 4002-113

117 – Secondary Steering Motor (Option)

Located in the rear frame of the machine.
Correct
Check Points Possible Cause of Bad Reading
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)

Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Check Points Possible Cause of Bad Reading
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.
4002-114

CAN COMMUNICATION

119

RCPH10WHL094FAH

119.DIAGNOSTIC CONNECTOR
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.
 4002-115

119 – CAN Communication Diagnostics Connector

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal A for wire 0-DH to ground Continuity Bad ground circuit.

Terminal B for wire 18K-D to ground 24 volts Check fuse ECC-F9, check circuit 18K.
4002-116

RADIO AND POWER CONVERTER

125

122 123
124

121

RCPH10WHL094FAH

120. 123.RADIO
121.POWER CONVERTER 24 TO 12 VOLT 124.RIGHT SPEAKER
122.12 VOLT POWER OUTLETS (OPTION) 125.LEFT SPEAKER
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.
 4002-117

120 –

121 – Power Converter 24 volts to 12 volts (Option)

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-EJ to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position.

Terminal for wire 19L-B and 19L-A to 24 volts Bad fuse F1 in power relay module A, 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
Check Points Possible Cause of Bad Reading
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 ECB-F1 and F2, also
12 volts
ground check wire 12V-A.

NOTE: If the readings are good replace the power outlet.

123 – 12 Volt Radio Ready (Option)

Located in the cab.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal in radio connector for wire Continuity Bad ground circuit.

0-EN to ground

NOTE: Put master disconnect switch and ignition switch in ON position.

Terminal in radio connector for wire Check fuse ECB-F9, also check circuit 12V. Also check the
12 volts
12V-HA to ground remote radio power converter (121).
4002-118

124 – Right Speaker (Option)

Located in the cab.
Correct
Check Points Possible Cause of Bad Reading
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
Check Points Possible Cause of Bad Reading
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.

 4002-119

AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR

126
130

129

127

128

RCPH10WHL094FAH
BS06H241 / BS06H242

126.AIR SEAT 129.HIGH/LOW SWITCH

127.CIGAR LIGHTER 130.AIR CONDITIONING COMPRESSOR CLUTCH
128.AIR CONDITIONING CLUTCH 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.
4002-120

126 – Seat Compressor and Switch (Option)

Located in the cab.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-DK to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

Check fuse ECA-F16 and power relay module B(14). 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
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 19W to ground 24 volts Check fuse ECA-F18, 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

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-DJ to ground Continuity Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Put fan speed 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.
 4002-121

129 – A/C High/Low Pressure Switch

Located on the rear frame in front of the rear axle.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Put the fan speed 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. (Low and high
switches)

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
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Put fan speed 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.
4002-122

CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL

135 136 137

140 141

131

132 133 134 138 142 139

RCPH10WHL094FAH

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
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.
 4002-123

131 – Electronic Panel

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only.

132 – External Air Temperature Sensor

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only.

133 – Internal Air Temperature Sensor

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only.

134 – Sun Sensor

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only.

135 – Blower Motor Resistor

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only

136 – Blower Motors

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only

137 – Thermocouple Sensor

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only.

4002-124

138 – Mixed Air Sensor

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only.

139 – Compressor Relay

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only

140 – Recycling Motor

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only

141 – Electronic Water Valve

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only

142 – 24 to 12 Volt Converter

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Automatic climate control only.

 4002-125

STANDARD CLIMATE CONTROL

143 144 145

146 147 148

149 150 151

152 153

RCPH10WHL094FAH

143.ACTUATOR 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
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.
4002-126

143 – Actuator
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connectors from DNS Actuator and DNS Driver prior to testing.

Pin 6 in wiring harness connector to Continuity Bad wire or connector.

pin 4 in Driver module (DNS49)

Pin 5in wiring harness connector to Continuity Bad wire or connector.

pin 5in Driver module (DNS48)

144 – Driver
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connectors from DNS Driver and HVAC2.

Between DNSS2 and DNS75 Continuity Bad wire or connector.

145 – Electronic Water Valve

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: No information at time of print.

146 – Blower Motor Speed Resistors with Thermal Fuse

Correct
Check Points Possible Cause of Bad Reading
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

Between terminals 2 and 4 of blower Approximately

Bad blower motor resistor.
motor connector x.x ohms

Between terminals 3 and 4 of blower Approximately

Bad blower motor resistor.
motor connector x.x ohms
 4002-127

147 – Blower Motor

Correct
Check Points Possible Cause of Bad Reading
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 fan speed switch
(149) to position 4.

Terminal for wire DNS65 to ground 24 volts Check the fan speed switch (149).

NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the fan
speed switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the
blower fan resistor (146).

148 – Thermostat
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connector from thernostat.

Continuity
above 5C (41F)
Between terminals on thermostat +/-1C, open Bad thermostat.
below 0C
(32F)+/-1C.

149 – Blower Switch

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position.

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.

NOTE: Turn the blower switch to position 2.

Terminal for wire DNS62 to ground 24 volts Bad blower switch.

NOTE: Turn the blower switch to position 3.

Terminal for wire DNS63 to ground 24 volts Bad blower switch.

NOTE: Turn the blower switch to position 4.

Terminal for wire DNS73 to ground 24 volts Bad blower switch.

4002-128

150 – Air Conditioning Switch

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connector from AC switch.

Between terminal 1 and 2 on AC Continuity with

Bad AC switch.
switch switch on.

151 – Control Panel Lights

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connector from Control panel lights.

Between terminal 1 and 2 on light. Continuity Bad light(s).

152 – Water Valve Potentiometer

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connector from Water valve potentiometer.

Between terminals measure Resistance

Bad potentiometer.
resistance change. change

153 – Air Recirculating Switch

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connector on Air recirculating switch.

Continuity with
Between terminals 1 and 2. Bad recirculating switch.
switch on.
 4002-129

HOOD RAISE AND LOWER SYSTEM

157
156

154
155

RCPH10WHL094FAH

154.HOOD UP RELAY 156.HOOD SWITCH

155.HOOD DOWN RELAY 157.HOOD MOTOR
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.
4002-130

154 – Hood Up Relay

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B25 to ground Continuity Bad ground circuit.

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

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-B16 to ground Continuity Bad ground circuit.

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
Check Points Possible Cause of Bad Reading
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
 4002-131

157 – Hood Motor

Located in the left side of the engine compartment.
Correct
Check Points Possible Cause of Bad Reading
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.

4002-132

STARTING / IGNITION SYSTEMS

158
159
160
RCPH10WHL094FAH
158.IGNITION POWER LATCH 160.START LOCKOUT
159.IGNITION POWER CONTROL
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.
 4002-133

158 – Ignition Power Latch

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-EW 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 13K to ground 24 volts Check circuit 13K, check Ignition switch (10).

Terminal for wire 0-EA to 0-EU on Continuity Bad wire or connector

Program relay module A (13)

Bad ignition power latch relay or ignition power control relay

Terminal for wire 0-ET to ground Continuity
(159).

159 – Ignition Power Control

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 0-KA 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 13K-A to ground 24 volts Check circuit 13K, check ignition switch (10).

Terminal for wire 0-EY to ground Continuity Bad ignition power control relay.

160 – Start Lockout

Located in the cab access panel for fuses and relays.
Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Used with Telematics on future models

4002-134

JOYSTICK STEERING/ MISC

RCPH10WHL094FAH

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.
 4002-135

161 – Rear View Camera / Monitor

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: See Camera manual for details

162 – Differential Lock Switch (Manual)

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connector SDM from switch

Normally
open,
Between terminals 2 and 3 Continuity Bad Lock Switch.
when switch is
closed

163 – Differential Lock Switch

Correct
Check Points Possible Cause of Bad Reading
Reading

NOTE: Remove connector from switch

Normally
open,
Between terminals 2 and 3 Continuity Bad Lock Switch
when switch is
closed

164 – Differential Lock Solenoid

Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 34C-A to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and ignition switch in ON position.

Terminal 1 for wire 34A-D to ground 24 volts Bad TECM module. Also check circuit 34C.

NOTE: If the readings are good, replace the differenital lock solenoid.

NOTE: See transmission section for more details

4002-136

165 – Lockup Solenoid

Correct
Check Points Possible Cause of Bad Reading
Reading

Terminal for wire 24T-B to ground Continuity Bad ground circuit.

NOTE: Put the master disconnect switch and ignition switch in ON position.

Terminal 1 for wire 25R-B to ground 24 volts Bad TECM TRANS module. Also check circuit 25R.

NOTE: If the readings are good, replace the lockup solenoid.

NOTE: See transmission section 6000 for more details

166 – Joystick PVRES

NOTE: See service manual section 5009 for Joystick steering details.

167 – Transmission Kick Down Switch

NOTE: See service manual section 5009 for Joystick steering details..

168 – ARM POS

NOTE: See service manual section 5009 for Joystick steering details..

169 – FNR Switch (option)

NOTE: See service manual section 5009 for Joystick steering details.

170 – FNR Relay

NOTE: See service manual section 5009 for Joystick steering details.

171 – Pilot Dump Valve

NOTE: See service manual section 5009 for Joystick steering details.

172 – JSS Valve

NOTE: See service manual section 5009 for Joystick steering details.

173 – Load Sense Pressure Sensor

NOTE: See service manual section 5009 for Joystick steering details.

174 – Pilot Pressure Switch

NOTE: See service manual section 5009 for Joystick steering details.
 4002-137

175 – JSS Relay

NOTE: See service manual section 5009 for Joystick steering details.

176 – Joystick STR Switch (option)

NOTE: See service manual section 5009 for Joystick steering details.

177 – JSS Controller

NOTE: See service manual section 5009 for Joystick steering details.
4002-138

CONNECTORS
CONNECTOR 108F - DIAGNOSTIC CONNECTOR

291663A1

CONNECTOR 197F - MAIN CAB FNR

CONNECTOR 140M - DIODE MODULE

225350C1

245488C1
 4002-139
CONNECTOR 197M - FNR-MAIN_CAB CONNECTOR 209F - BACKUP ALARM DISABLE
JUMPER

225351C1
245481C1

CONNECTOR 209M - BACKUP ALARM DISABLE

JUMPER

CONNECTOR 202M - ROLLBACK JUMPER

245480C1

245482C1
4002-140
CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH

225316C1

CONNECTOR 215F - ALTERNATOR RESISTOR CONNECTOR 64F - FLASHER CONNECTOR

245481C1
199436A1

CONNECTOR 216F - ALTERNATOR RESISTOR CONNECTOR 64M - FLASHER CONNECTOR

199436A1
245480C1
 4002-141
CONNECTOR AIC2 - ADV INSTRUMENT
CLUSTER 2

CONNECTOR ACT - AIR CONDITIONING

COMPRESSOR CLUTCH

8602417 87410948

CONNECTOR AIC1 - ADV INSTRUMENT

CLUSTER
87419488
4002-142
 4002-143

CONNECTOR BUZ - AIC BUZZER

222136A1
4002-144
 4002-145
CONNECTOR CAB-RF - CAB TO ROOF CONNECTOR CAB-T - CAB TO TRANMISSION
CONNECTION

380839A1

388710A1
4002-146
CONNECTOR CL - CIGAR LIGHTER

3227856R1

CONNECTOR CNV - 24V TO 12V POWER

CONVERTER

225351C1
 4002-147
CONNECTOR DM - DIODE OR
CONNECTOR D-OR - DIODE OR

245485C1

245485C1

CONNECTOR DISC - DISCONNECT ENGINE

245482C1
4002-148
CONNECTOR DNS-DRIVER

411311A1
 4002-149
CONNECTOR DS - DOOR SWITCH

CONNECTOR EM - HEIGHT CONT RTT RTD

245482C1

225351C1

CONNECTOR E-HD - TRANSMISSION HOOD

245485C1
4002-150
CONNECTOR ECA - ELECTRICAL CENTER A

87315248
4002-151
4002-152
CONNECTOR ECB - ELECTRICAL CENTER B

87312843
4002-153
4002-154
CONNECTOR ECC - WORK LIGHTS

87315249
4002-155
4002-156
CONNECTOR ECD - ELECTRICAL CENTER D

87312843
4002-157
4002-158
CONNECTOR EDC7 - ENGINE CONTROLLER

BOSCH-89-POLE
 4002-159
CONNECTOR ENG-D - DISCONECT HARNESS CONNECTOR ESS - ENGINE SPEED SENSOR

245483C1

291718A1

CONNECTOR ENG-H - ENGINE TO HOOD

CONNECTOR FFH - FULE FILTER HEATER

225320C1

182069A1
4002-160
CONNECTOR FLSHR - FLASHER MODULE

225389C1

CONNECTOR FM - FILTER MAINTENANCE

SWITCH

CONNECTOR FWM - FRONT WIPER MOTOR

371614A1

245715C1
 4002-161
CONNECTOR FWMG - FRONT WIPER MOTOR CONNECTOR GHC - GRID HEATER RELAY
GROUND

3227856R1

245480C1

CONNECTOR FWW - FRONT WASHER

3227856R1
4002-162
CONNECTOR - CAB GROUND SPLICE

87324393

CONNECTOR - SPLICE BACK LIGHT GROUND

87324393
4002-163
4002-164
CONNECTOR HD - HOOD SWITCH

245485C1

CONNECTOR HD-E - HOOD HARNESS TO

TRANSMISSION HARNESS

245484C1
 4002-165
CONNECTOR HD-N - HOOD TO ENGINE

225319C1 CONNECTOR HOT - HYDRAULIC OIL

TEMPERATURE SENDER

194788A1

CONNECTOR HDM - HOOD LIFT MOTOR

225316C1
4002-166
CONNECTOR HVAC2 - HVAC2

87552622

CONNECTOR ISS - INT-SPEED-SENSOR

291718A1
4002-167
4002-168
CONNECTOR LLF - LH FRONT LIGHTS CONNECTOR LLR-E - LH REAR COMBINATION
LAMP

225351C1
225351C1

CONNECTOR LPL - LICENSE PLATE LAMP

245482C1
 4002-169
CONNECTOR LRF - RH FRONT LAMP

CONNECTOR LRR-E - RH REAR COMBINATION

LAMP

225351C1

225351C1

CONNECTOR LSPK - LEFT SPEAKER

195552A1
4002-170
CONNECTOR PAF - AIR FILTER RESTRICTION
SWITCH

291718A1

CONNECTOR OSS - OUTPUT SPEED SENSOR

291719A1
CONNECTOR PBD - BRAKE DECLUTCH
PRESSURE SWITCH

245482C1
 4002-171
CONNECTOR PBL - BRAKE LAMP PRESSURE CONNECTOR PO1 - POWER OUTLET
SWITCH

222136A1
12176446

CONNECTOR PO2 - POWER OUTLET

12176446
4002-172
CONNECTOR PRB1 - REDUNDANT BRAKE
SWITCH

245483C1
 4002-173
CONNECTOR PSS - SECONDARY STEERING CONNECTOR PXF - RTD
PRESSURE SWITCH

245485C1
245485C1
4002-174
CONNECTOR RAD - RADIO POWER CONNECTOR RAD-J2 - SPEAKER

292495A1 292501A1

CONNECTOR RAD-J1 - RADIO POWER

CONNECTOR RAD-J3 - RADIO JUMPER

411311A1
292497A1
 4002-175
CONNECTOR RECT - ENGINE COOLANT CONNECTOR ROOF - ROOF TO CAB
TEMPERATURE CONNECTION

194788A1 388708A1

CONNECTOR RSPK - RIGHT SPEAKER

195552A1
4002-176
CONNECTOR RTHP - THROTTLE PEDAL CONNECTOR RWMG - REAR WIPER MOTOR
GROUND

225351C1

245480C1

CONNECTOR RWW - REAR WASHER

CONNECTOR RWM - REAR WIPER MOTOR

3227856R1

245715C1
 4002-177
CONNECTOR S-KEY - IGNITION SWITCH TO CONNECTOR SC - SEAT COMPRESSOR MOTOR
PEDESTAL HARNESS

245482C1

225253C1

CONNECTOR SBE - BEACON SWITCH

CONNECTOR SDC - DECLUTCH SWITCH

382391A1

382391A1
4002-178
CONNECTOR SDR - DRIVING LIGHTS SWITCH CONNECTOR SFWW - REAR WIPER AND
WASHER SWITCH

382391A1 87345132

CONNECTOR SHC - HEIGHT CONTROL SWITCH

382391A1
 4002-179
CONNECTOR SPK - SPEAKER

292494A1
CONNECTOR SPB - PARKING BRAKE SWITCH

382391A1
4002-180
CONNECTOR SPL-BCK-LGT - SPLICE BACK CONNECTOR SPL-BCK-LGT
LIGHT GD

87324393 87324393
 4002-181
CONNECTOR SPL-PED-BL - SPL BACK LIGHT CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY
POWER 6 PACK

87324462

87324391
4002-182
CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY CONNECTOR SPL-TRNS-PWR - TRANSMISSION
POWER

87324462
87324393

CONNECTOR SRC - RIDE CONTROL SWITCH

382391A1
 4002-183
CONNECTOR SRC-1 - STARTER RELAY CONNECTOR SRTD - DETENT SWITCH

225316C1

382391A1

CONNECTOR SRHSTLK - RH STALK SWITCH

87318288
4002-184
CONNECTOR SS-TR - SS-MOD-TRANS CONNECTOR STA - TRANSMISSION AUTO
SWITCH

245489C1

382391A1

CONNECTOR SSM - SECONDARY STEERING

MODULE

225389C1
 4002-185
CONNECTOR SWL - WORK LIGHTS SWITCH CONNECTOR TCOT - TORQUE CONVERTER
OUTPUT SENDER

382391A1

291718A1
4002-186
CONNECTOR TECM - TRANSMISSION

411398a1
 4002-187
CONNECTOR TRANS - CAB TO TRANSMISSION

CONNECTOR TR-SS - SEC-STR-MOD-OPT 380838A1

245488C1
4002-188
CONNECTOR TRC - TRANSMISSION CONTROL CONNECTOR TS2 - TRANSMISSION SHIFTER

245487C1

371566A1

CONNECTOR TSS - TURBINE SPEED SENSOR

CONNECTOR TS1 - TRANSMISSION SHIFTER

291718A1

245486C1
 4002-189

CONNECTOR WF - WATER IN FUEL SENSOR

CONNECTOR YFN - FNA PWM SOLENOID

8602416

CONNECTOR WSH - WATER SEPARATOR

HEATER 256340A1

182069A1
4002-190
CONNECTOR YFR - FAN REVERSING SOLENOID

225316C1

CONNECTOR YPP - PILOT PRESSURE

SOLENOID

245482C1

CONNECTOR YPE - PIN ENGAGE

CONNECTOR YRC - RIDE CONTROL OPT

245482C1

291718A1
 4002-191

CONNECTOR YSS - SECONDARY STEERING

SOLENOID

225316C1
4002-192

NOTE
 4002-193
Symbols Cluster, Instrument Connector 2 ...........................77
12 Volt Radio .......................................................117 Compressor Clutch ..............................................121
Compressor Clutch Relay ...................................120
A Compressor, Seat ...............................................120
A/C High/Low Pressure Switch ............................121 Connector 108F ...................................................138
Air Filter Restriction Switch ....................................73 Connector 140M ..................................................138
Air Seat Compressor and Switch .........................121 Connector 197F ...................................................138
Alarm Connector 202M ..................................................139
Back-up (Europe Only) ....................................102 Connector 209F ...................................................139
Back-up (North America Only) ........................102 Connector 209M ..................................................139
Back-up, Disable Switch ...................................82 Connector 20M ....................................................140
Back-up, Relay ..................................................82 Connector 215F ...................................................140
Alternator ...............................................................47 Connector 216F ...................................................140
Connector 64F .....................................................140
B Connector 64M ....................................................140
Back-up Alarm (Europe Only) ..............................102 Connector 69 .......................................................177
Back-up Alarm (North America Only) ..................102 Connector ACT ....................................................141
Back-up Alarm Disable Switch ..............................82 Connector AIC1 ...................................................141
Back-up Alarm Relay .............................................82 Connector AIC2 ...................................................141
Batteries ................................................................48 Connector CAB_RF .............................................145
Beacon Switch .......................................................85 Connector CAB_T ...............................................145
Beacon, Rotating (Option) .....................................84 Connector CL ......................................................146
Brake Lamp Pressure Switch ................................89 Connector CNV ...................................................146
Brake Lamps Relay ...............................................89 Connector D_OR .................................................146
Brake Warning Pressure Switch ............................74 Connector DISC ..................................................147
Buzzer ...................................................................72 Connector DM .....................................................147
Connector DNS-DRIVER ....................................148
C Connector DS ......................................................149
CAN Communication Diagnostics Connector ......115 Connector E_HD .................................................149
Cigar Lighter ........................................................122 Connector ECA ...................................................150
Climate Control, Automatic Connector ECB ...................................................152
24 to 12 Volt Converter ...................................124 Connector ECC ...................................................154
Blower Motor Resistor .....................................123 Connector ECD ...................................................156
Blower Motors .................................................123 Connector ENG_D ..............................................159
Compressor Relay ..........................................124 Connector ENG_H ..............................................159
Electronic Panel ..............................123, 134, 135 Connector ESS ....................................................159
Electronic Water Valve ....................................124 Connector FFH ....................................................159
External Air Temperature Sensor ....................123 Connector FLSHR ...............................................159
Internal Air Temperature Sensor .....................123 Connector FM ......................................................160
Mixed Air Sensor .............................................124 Connector FWM ..................................................160
Recycling Motor ..............................................124 Connector FWMG ...............................................161
Sun Sensor .....................................................123 Connector FWW ..................................................161
Thermocouple Sensor .....................................123 Connector GHC ...................................................161
Climate Control, Standard Connector GND_CAB_SPL .................................162
Air Conditioning Switch ...................................128 Connector GND_CAB_SPL2 ...............................162
Air Recirculation Motor ....................................126 Connector HD ......................................................164
Air Recirculation Switch ..................................128 Connector HD_E .................................................164
Blower Motor ...................................................127 Connector HD_N .................................................165
Blower Motor Speed Resistors with Thermal Fuse Connector HDM ...................................................165
126 Connector HOT ...................................................165
Blower Switch ..................................................127 Connector HVAC2 ...............................................166
Control Panel Lights ........................................128 Connector ISS .....................................................166
Driver ...............................................................126 Connector LLF .....................................................168
Electronic Water Valve ....................................126 Connector LLR_E ................................................168
Thermostat ......................................................127 Connector LPL ....................................................168
Water Valve Potentiometer .............................128 Connector LRF ....................................................169
Cluster, Instrument Connector 1 ............................71 Connector LRR_E ...............................................169
4002-194
Connector LSPK ..................................................169 Connector YFR .................................................... 190
Connector OSS ...................................................170 Connector YPE .................................................... 190
Connector PAF ....................................................170 Connector YPP .................................................... 190
Connector PBD ....................................................171 Connector YRC ...................................................190
Connector PBL ....................................................171 Connector YSS .................................................... 191
Connector PO1 ....................................................171 Connector, Diagnostic ...........................................69
Connector PO2 ....................................................171 Coolant Level Sender ............................................80
Connector PRB1 ..................................................172 Crank Control Relay ..............................................48
Connector PSS ....................................................172 Crank Request Relay ....................................48, 132
Connector PXF ....................................................173
Connector RAD ...................................................174 D
Connector RAD_J1 ..............................................174 Declutch Brake Switch .......................................... 69
Connector RAD_J2 ..............................................174 Declutch Switch .....................................................69
Connector RAD_J3 ..............................................174 Diagnostic Connector ............................................69
Connector RECT .................................................175 Diodes
Connector ROOF .................................................175 Lights ................................................................ 87
Connector RSPK .................................................175 Secondary Steering ........................................ 111
Connector RTHP .................................................176 Wipers .............................................................109
Connector RWM ..................................................176 Dome Lamp ...........................................................85
Connector RWMG ...............................................176 Door Switch ...........................................................84
Connector RWW ..................................................176 Driving Lamp Switch ..............................................92
Connector S_KEY ...............................................177
Connector SBE ....................................................177 E
Connector SC ......................................................177 Electrical Wire Identification ....................................8
Connector SDC ...................................................177 Electromagnetic Detents ....................................... 60
Connector SDR ...................................................178 Electronic Diesel Control ....................................... 57
Connector SFC ....................................................178 Engine Speed Sensor ...........................................69
Connector SFNR .................................................178
Connector SFWW ................................................178 F
Connector SHC ...................................................178 Fan PWM Solenoid ...............................................67
Connector SPB ....................................................179 Fan Reverse Relay ................................................ 65
Connector SPK ....................................................179 Fan Reversing Solenoid ........................................67
Connector SPL_BCK_LGT ..................................180 Fan Reversing Switch ...........................................65
Connector SPL_BCK_LT_GD .............................180 Filter Maintenance Switch .....................................69
Connector SPL_PED_BL ....................................181 Flasher Module ...................................................... 90
Connector SPL_PK1 ...........................................181 FNR Switch for Joystick Controls .......................... 69
Connector SPL_PK3 ...........................................182 FNR Switch for Single Axis Controls .....................69
Connector SPL_TRNS_PWR ..............................182 Front
Connector SRC ...................................................182 Left Hand Work Lamp ....................................... 85
Connector SRC_1 ...............................................183 Right Hand Work Lamp .....................................86
Connector SRHSTLK ..........................................183 Front Left Hand Combination Lamp ...................... 94
Connector SRTD .................................................183 Front Right Hand Combination Lamp ....................95
Connector SS_TR ...............................................184 Front Washer Pump Motor ..................................108
Connector SSM ...................................................184 Front Wiper and Washer Switch .......................... 106
Connector STA ....................................................184 Front Wiper Cut Out Relay ..................................104
Connector SWL ...................................................185 Front Wiper High Speed Relay ............................104
Connector TCOT .................................................185 Front Wiper Low Speed Relay ............................105
Connector TECM .................................................186 Front Wiper Motor ...............................................107
Connector TR_SS ...............................................187 Fuel Filter Heater ................................................... 54
Connector TRANS ...............................................187 Fuel Level Sender .................................................72
Connector TRC ....................................................188
Connector TS1 ....................................................188 G
Connector TS2 ....................................................188 Grid Heater ............................................................53
Connector TSS ....................................................188 Grid Heater Relay ..................................................53
Connector WF .....................................................189
Connector WSH ...................................................189 H
Connector YFN ....................................................189
Hazard Switch ....................................................... 91
 4002-195
Heater Lights Diodes .........................................................87
Fuel Filter ..........................................................54 Locating Components on the Schematic Posters .45
Grid ...................................................................53
Water Separator ................................................54 M
Height Control Switch ............................................59 Magnetic Detents ..................................................60
Height Control/Return-To-Travel Proximity Switch 61 Master Disconnect Switch .....................................49
High-Low Beam Switch .........................................91 Module
Hood Flasher ..............................................................90
Down Relay .....................................................129 Secondary Steering .........................................112
Motor ...............................................................130 Transmission Electronic Control .......................69
Switch ..............................................................129 Motor
Up Relay .........................................................129 Hood ...............................................................130
Horn .......................................................................96 Starter ...............................................................49
Horn Relay .....................................................96, 136
Horn Switch ...........................................................91 N
Hydraulic Filter Restriction Switch .........................78 Neutral Start Relay ........................................50, 133
Hydraulic Oil Temperature Sender ........................78
O
I Outlet, Power .......................................................117
Ignition Switch .......................................................50 Output Speed Sensor ............................................69
Instrument Cluster Connector 1 .............................71
Instrument Cluster Connector 2 .............................77 P
Intermediate Speed Sensor ...................................69 Parking Brake Relay ..............................................72
Parking Brake Solenoid .................73, 135, 136, 137
L Parking Brake Switch ............................................79
Lamp Pilot Control Relay .................................................61
Dome .................................................................85 Pilot Control Switch ...............................................66
High Beam ..................................................94, 95 Pilot Pressure Solenoid .........................................62
Left Hand Front Combination ............................94 Pin Engage Solenoid .............................................62
Left Hand Front Work ........................................85 Pin Engage Switch ................................................62
Left Hand Rear Combination (Europe Only) ...101 Potentiometer
Left Hand Rear Combination (North America Only) Throttle ..............................................................56
..........................................................101 Power Converter (24 volts to 12 volts) ................117
Left Hand Rear Work ........................................88 Power Outlet ........................................................117
License Plate (Europe Only) ...........................104 Power Relay Module
License Plate (North America Only) ................103 A Ignition Power ..........................................52, 53
Low Beam ...................................................96, 97 B Ignition Power ................................................52
Position .......................................................96, 97 Proximity Switch
Right Hand Front Combination ..........................97 Height Control/Return-To-Travel .......................61
Right Hand Front Work .....................................88 Return-To-Dig ...................................................60
Right Hand Rear Combination (Europe Only) .101
Right Hand Rear Combination (North America On- R
ly) .......................................................98 Radiator Coolant Temperature Sender .................73
Right Hand Rear Work ......................................86 Radio
Switch, Driving ..................................................92 12 Volt .............................................................117
Turn .............................................................92, 95 Rear
Left Hand Front Combination Lamp ......................94 Left Hand Combination Lamp (Europe Only) ..101
Left Hand Front Work Lamp ..................................85 Left Hand Combination Lamp (North America On-
Left Hand Rear Combination Lamp (Europe Only) ly) .....................................................100
102 Left Hand Work Lamp .......................................86
Left Hand Rear Combination Lamp (North America Right Hand Combination Lamp (Europe Only) ..99
Only) .......................................................100 Right Hand Combination Lamp (North America On-
Left Hand Rear Work Lamp ...................................86 ly) .......................................................98
Left Speaker ........................................................118 Right Hand Work Lamp .....................................86
License Plate Lamp .....................................101, 102 Rear Washer Pump Motor ...................................108
License Plate Lamp (Europe Only) ......................102 Rear Wiper and Washer Switch ..........................105
License Plate Lamp (North America Only) ..........101 Rear Wiper Motor ................................................108
4002-196
Redundant Brake Pressure Switch 1 .....................79 Sensor
Redundant Brake Pressure Switch 2 .....................79 Engine Speed ................................................... 69
Relay Intermediate Speed ...........................................69
Backup Alarm ....................................................82 Output Speed ....................................................69
Brake Lamps .....................................................89 Transmission Solenoid Valve and Temperature ...
Compressor Clutch .........................................120 71
Crank Control ....................................................48 Turbine Speed ..................................................69
Crank Request ..........................................48, 132 Water In Fuel ....................................................56
Fan Reverse ......................................................65 Shifter, Transmission ............................................. 69
Front Wiper Cut Out ........................................106 Solenoid
Front Wiper High Speed ..................................104 Fan PWM .......................................................... 67
Front Wiper Low Speed ..................................105 Fan Reversing ................................................... 67
Grid Heater ........................................................53 Parking Brake ........................... 73, 135, 136, 137
Hood Down .....................................................129 Pilot Pressure ....................................................62
Hood Up ..........................................................129 Pin Engage ....................................................... 62
Horn ...........................................................96 136 Ride Control ...................................................... 66
Neutral Start ..............................................50, 132 Secondary Steering ........................................ 111
Parking Brake ....................................................72 Speaker
Pilot Control .......................................................61 Left .................................................................. 118
Power Relay Module A Ignition Power ........52, 53 Right ................................................................118
Power Relay Module B Ignition Power ..............52 Specifications ..........................................................7
Ride Control ......................................................64 Speed Resistors
Starting ..............................................................47 Blower Motor ...................................................126
Resistor Starter Motor ......................................................... 49
Alternator ...........................................................47 Starting Relay ........................................................47
Return to Dig Switch Switch ..................................61 Steering
Return-To-Dig Proximity Switch ............................60 Secondary, Module .........................................112
Return-To-Travel/Float Switch ...............................59 Secondary, Motor ............................................113
Ride Control Relay ................................................64 Secondary, Pressure Switch ........................... 113
Ride Control Solenoid ............................................66 Secondary, Solenoid ....................................... 111
Ride Control Switch .......................................64, 136 Switch
Right Hand Front Combination Lamp ....................95 A/C High/Low Pressure ...................................121
Right Hand Front Work Lamp ................................86 Air Filter Restriction ...........................................73
Right Hand Rear Combination Lamp (Europe Only) . Back-up Alarm Disable .....................................82
99 Beacon ..............................................................85
Right Hand Rear Combination Lamp (North America Blower .............................................................127
Only) .........................................................98 Brake Lamp Pressure ....................................... 89
Right Hand Rear Work Lamp ................................86 Brake Warning Pressure ................................... 74
Right Speaker ......................................................118 Declutch ............................................................69
Rollback Jumper ....................................................67 Declutch Brake ..................................................69
Rollback Pressure Switch ......................................66 Door ..................................................................84
Rotating Beacon (Option) ......................................84 Driving Lamp .....................................................92
Fan Reversing ................................................... 65
S Filter Maintenance ............................................69
Seat Compressor and Switch ..............................120 FNR for Joystick Controls .................................69
Secondary Steering FNR for Single Axis Controls ............................ 69
Module ............................................................112 Front Wiper and Washer ................................. 106
Motor ...............................................................113 Hazard ..............................................................91
Pressure Switch ..............................................113 Height Control ................................................... 59
Solenoid ..........................................................111 High-Low Beam ................................................ 91
Secondary Steering Diodes .................................111 Hood ...............................................................130
Sender Horn ..................................................................91
Coolant Level ....................................................80 Hydraulic Filter Restriction ................................ 78
Fuel Level ..........................................................72 Ignition ..............................................................50
Hydraulic Oil Temperature ................................78 Master Disconnect ............................................49
Radiator Coolant Temperature ..........................73 Pad .................................................................... 76
Torque Converter Output Temperature .............69 Parking Brake ................................................... 79
 4002-197
Pilot Control Switch ...........................................66 Work Lamp Switch ................................................84
Pin Engage ........................................................62
Proximity, Height Control/Return-To-Travel ......61
Proximity, Return-To-Dig ...................................60
Rear Wiper and Washer ..................................105
Redundant Brake Pressure 1 ............................79
Redundant Brake Pressure 2 ............................79
Return to Dig .....................................................61
Return-To-Travel/Float ......................................59
Ride Control ..............................................64, 136
Rollback Pressure .............................................66
Seat Compressor ............................................120
Secondary Steering Pressure .........................113
Transmission Auto ............................................69
Transmission Enable .........................................69
Transmission Kick-down ...................................69
Turn Signal ........................................................91
Work Lamps ......................................................84
Switch Pad .............................................................76

T
Thermal Fuse
Blower Motor ...................................................126
Throttle Potentiometer ...........................................56
Torque Converter Output Temperature Sender ....69
Transmission Auto Switch .....................................69
Transmission Electronic Control Module ...............69
Transmission Enable Switch .................................69
Transmission Kick-down Switch ............................69
Transmission Shifter ..............................................69
Transmission Solenoid Valve and Temperature Sen-
sors ...........................................................69
Turbine Speed Sensor ...........................................69
Turn Signal Switch .................................................91

U
Understanding the Troubleshooting Tables ...........45

W
Warning Buzzer .....................................................72
Water In Fuel Sensor .............................................56
Water Separator
Heater ...............................................................54
Wiper
Front Cut Out Relay ........................................104
Front Motor ......................................................107
Front Switch ....................................................106
Front Washer Pump Motor ..............................108
Front Washer Switch .......................................106
Front Wiper High Speed Relay .......................104
Front Wiper Low Speed Relay ........................105
Rear Motor ......................................................108
Rear Switch .....................................................105
Rear Washer Pump Motor ..............................108
Rear Washer Switch .......................................105
Wiper Diodes .......................................................109
Wire Identification ....................................................8
4002-198
NOTES
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
level of the electrolyte every 1000 hours of operation
or six months, whichever occurs first. For all other
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.

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 B790863

1. TEMPERATURE IN F 2. TEMPERATURE IN C
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.
8. If the difference between the high reading and
the low reading is less than 0.050, but the level of
charge is less than 75% in any of the cells,
charge the battery and check the specific gravity
again. If after charging:
A. The level of charge is less than 75% in any of
the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.
4003-6

Capacity (Load) Test NOTE: Never apply a load for longer than 15
seconds. After each 15 seconds, turn the load control
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
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.
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
of the battery. Use the charging guide for the correct
charging rate and time.
See Specifications in Section 4001 for the reserve
capacity of the battery in this machine.

Charging Guide For Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity - See

Reserve Capacity under 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

15 Hours at 5 Amperes 3.75 Hours at 20 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

30 Hours at 5 Amperes 7.5 Hours at 20 Amperes

Above 170 to 250 Minutes 15 Hours at 10 Amperes 3 Hours at 50 Amperes

*initial rate for standard taper charger.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.
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

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

15 Hours at 5 Amperes 3.75 Hours at 20 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

30 Hours at 5 Amperes 7.5 Hours at 20 Amperes

Above 170 to 250 Minutes 15 Hours at 10 Amperes 3 Hours at 50 Amperes

6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes

*initial rate for standard taper charger.

PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
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
4003a

4003a
JUMP POST OPTION
4003a-2

TABLE OF CONTENTS
Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
 4003a-3

JUMP POST OPTION

STEP 1 7. Remove the booster battery negative (-) cable
from the jump post and then from the machine
being used for starting. Remove the positive (+)
cable from the jump post terminal and then from
the booster battery.
8. Install the terminal covers.

RCPH10WHL214AAH.PNG

The Jump Post option can be used to provide power

to star t the machine if its batteries become
discharged.
The option can be used to provide power to the
machine for the purpose of raising the hood if its
batteries have become discharged.
The option can be used to star t other disabled
equipment without accessing the main batter y
terminals.
NOTE: Note: Make sure that the voltage of the
booster batteries is the same as that of the machine
system (24 volts). The jump post is located on the left
hand side of the machine inside the main electrical
disconnect compartment.
1. Turn off the ignition and all accessories on the
machine(s). Use the jump post to connect the
auxiliary battery.
2. Remove the terminal covers and connect one
end of the positive (+) cable to the positive (+)
terminal on the booster battery.
3. Connect the other end of the positive (+) cable to
the positive (+) terminal of the jump post (red).
4. Connect the negative (-) cable to the negative (-)
terminal on the booster battery.
5. Connect the other end of the negative (-) cable to
the negative (-) terminal of the jump post (black).
Do not connect it to sheet metal or any rotating
part, as damage can result. Do not connect to
the negative (-) terminal on the battery.
6. Start the engine.
4003a-4

NOTE
 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
Service screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

.
 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. Repair/replace
3. All LED’s (Light Emitting Diodes) will illuminate the wire as required. If continuity is found go to
for 2 - 3 seconds. 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 Forward. 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 •A - Automatic
The LCD Multi-Function Display is located at the •M - Manual operation.
center of the modular dashboard. On start up the B. If the Transmission is not operating normally
cluster will flash the instructional lamps and the LCD the display will show
Multi-Display will display, CASE, with the machine
model and current hour reading. •C - Substitute Clutch.
•L - Limp Home.
•S - Transmission Shutdown.
•U - TCU Shutdown.
5. This example (not displayed) will show the
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.
7. This example will show the Time in either 12 hour
or 24 hour.
BD06F185
LCD MULTI-FUNCTION DISPLAY
The LCD Multi-function display (liquid crystal display
is located at the center of the modular dashboard. On
start up, the console indicator lamps will momentarily
flash. The LCD Multi-display will flash the machine
model. The initial standard driving screen will then
appear. Once operator preferences are set, the
screen will reflect those selections.
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
fr o m on e s c r e e n to a n o th e r, c h o o s e va r i o u s
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.
 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, engine oil temperature 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
in either Fahrenheit or Celsius, as consumption per hour.
well as oil pressure PSI.

BD06F170
By continuing to scroll down, the fifth screen will
BD06F184
display the Trip 2 screen. Trip 1 and Trip 2 screens
Push the down button again and the Info 3 screen. can be reset independently. The previous screen can
This screen displays the temperature in Fahrenheit or be accessed by using the up arrow key.
Celsius of the transmission oil, hydraulic oil, sump oil
.
4005-8
Reset The Trip Information

BD06F170

Highlight the trip screen you wish to set.

BD06F187
Press the confirm button to reset the trip selection to
zero.

The trip screen will indicate a reset message. At this

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.
 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 main menu screen. Use down arrow to
scroll through the menu’s.
Items and selections in this menu are:
1. Settings
2. Display
3. Diagnostics
4. Service
4005-10

RCPH10WHL060HAH
 4005-11
Service screens
After the machine has been started or the key switch
has been turned to ON, the operator or service
technician may use the main menu to adjust machine
con figura tio ns to wor king c ond itio ns, to te st
components, view faults that may have occurred, or
to select preferences. Languages can be set at the
beginning of the menu configuration to allow the
operator to work in the language of choice.

RCPH10WHL367BAH
Engine selections
RCPH10WHL366AAH
Auto idle (Off, Low, Accelerated)
Settings
Power Mode (Max, Standard, Auto, Eco)
Selections at the setting menu include:
Engine options (fan auto, Work idle)
Engine
Auto Shutdown (optional) is used for interval settings
Transmission
Joystick steering (option will display only if machine
is joystick steering equipped).

W130R0034
Transmission selections
Max gear
Min gear
POWERINCH (Optional 5-speed)
4005-12
Display Diagnostics

RCPH10WHL447AAH

Highlight the desired selection and press confirm.

NOTE: Pressing the escape key will return the LCD
RCPH10WHL358BAH
back to the normal driving screen. In order to lock the
Highlight the display selection and press confirm
changes into memory, the operator must press the
Items and selections in this menu are: confirm key, then use the escape key to return to the
•Languages (English, German, French, Italian, main screen. turning the machine off will also lock
spanish, Portuguese) the settings into memory.

•Units (metric, English, Imperial) Selecting Power Modes

•Clock (Hour, minute, month, day, year) The power mode allows the operator to choose the
•Backlight (Day display, day LED, night display, night most effective machine power for the current job
LED). conditions. Most commonly auto is chosen, as the
power will automatically increase or decrease
between maximum power and standard power while
the machine is working. This allows for maximum
power if necessary, but will switch to standard mode
for economy. Maximum power can be chosen for
more severe work conditions. Economy can be
chosen for limited power and fuel efficiency.
Press and hold the confirmation button for two
seconds to arrive at the service screen.

RCPH10WHL376BAH

Service
Highlight the desired selection and press confirm.
The tests in the configuration menu should be
performed only by a qualified operator or technician.
Some test require the engine to be running at high
RPM’S.
Items and selections in this menu are: RCPH10WHL372BAH

•Calibration (Park brake and pedal calibration) At the screen shown above, highlight the power
mode and press the confirmation button to move to
•Select tires (tire size) the Power Mode Selection Menu.
 4005-13
Auto idle shutoff (optional)

BD06F178
At the Power Mode Menu press the confirmation RCPH10WHL375BAH

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 An optional feature that allows the operator to turn

highlighted section will flash to indicate a new the economy auto engine shutdown on or off along
selection can be made. with setting the shutdown intervals (5-60 minutes) in
five minute increments. The engine and key switch
Press the up or down button to select the Power
electric power shut down when the machine is
Mode, and then press the confirmation button again.
stopped, the transmission is in neutral, and the
This changes the mode and locks it into memory.
engine is at idle. the screen will display engine
The selected mode will display in zone 3 (bottom) of shutdown in a count down of seconds. This allows
the Multi-Function Display when power mode is the operator to cancel this operation. The feature is
correctly selected. d e s i g n e d s ave f u e l a n d m a c h i n e we a r w h e n
NOTE: Selecting options and navigating through the machines are at an idling condition for a set period of
screen menus are the same for all functions. The time.
display will tell the operator if errors have occurred. In the engine protection mode, a higher level of
system protection is offered. If a warning occurs
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 while the machine is moving, the engine speed will
confirmation button to acknowledge and begin again. reduce to low idle (900 RPM’s) to allow continued
movement. When the machine stops, the engine will
shut down. the protection system activates if a critical
problem occurs. At the screen shown, highlight the
selection, and press the confirm key.
4005-14
Preferences Clock

RCPH10WHL358BAH RCPH10WHL363BAH

Language Screen, Measurement Units, To set hour and date, from the select screen choose
and Clock the clock designation and press the confirm key. Use
the arrow keys to show field for time and date by
The LCD screen can be set with language, units, and pressing the arrow key. When the correct time and
clock preferences. Use the arrow keys to scroll to the date have been entered by using the up and down
preferences menu. Press confirm. arrow keys (up increases numbers, down decreases
Choose the preferences desired, language in the numbers), press the confirm key to lock in correct
(English, Italian, Spanish, Portuguese, German, time. Press the escape key to return to the main
French, measurement units in English, Metric, or driving screen and lock selections into memory.
Imperial and clock units in either 12 or 24 hour).
Display backlight menu
Highlight the preference you wish to change and
press the confirm key. The preference will flash and
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.

RCPH10WHL364BAH

The background and brightness of the screen can be

changed with the backlight menu. Use the arrow keys
to make the selection to suit working conditions. The
screen will change to night function illumination when
the head lamps are turned on.

RCPH10WHL361BAH
 4005-15
RPM’S/Speedometer Fan auto (if equipped)

RCPH10WHL373BAH

In automatic mode, the fan speed switches between

RCPH10WHL359BAH high, low, or reverse as conditions require. This will
Speed or RPM’s can be shown on the machine as depend upon system temperatures. Scroll through
desired. Highlight the desired choice, press the selections and selection the desired fan mode.
confirm key, then the escape key to lock selection
Auto idle (if equipped)
into memory. If engine speed or RPM’s settings are
not selected, the screen will display the hourmeter.
Engine settings menu

RCPH10WHL371BAH

The auto idle feature has three settings that control

the engine low idle speed. this feature only applies
when the wheel loader is stationary, in neutral, and
not under load. The OFF setting will keep the low idle
RCPH10WHL366BAH
speed constant at the factory setting independent of
Use the arrow keys to choose the settings menu. engine or ambient temperature. The LOW setting will
Press the enter key, and the settings sub-menu will allow the low idle speed to decrease below the
appear. choose options for the fan, idle, power mode, factory setting. By reducing the low idle speed, fuel
etc. consumption will be reduced. The ACCELERATED
setting will allow the low idle speed to increase above
the factory setting. Increasing the low idle speed
helps at warm-up and can improve A/C performance.
NOTE: If the machine is shifted out of neutral, put
under any load, or if the temperature limits are not
met, the idle will default to the standard factory set
idle speed.
4005-16
Work Idle Calibrating the gear box
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 and scroll to Calibration.

RCPH10WHL373BAH

The work idle feature allows the low engine idle

speed to be adjusted to a value different from the
factory set default low idle. This feature only applies
when the transmission is in gear and when the
engine speed has gone above the work idle set
speed. Setting the work low idle to a low engine
speed allows for increased machine control during
delicate work and improves fuel consumption.
Setting the work low idle to a higher engine speed
increases the responsiveness of the machine for
maximum performance. To change the work idle RCPH10WHL37BAH

setting, highlight the Eng Options selection and press Scroll to Calibration, high light and press the confirm
confirm. Select the Work idle selection and press key. always follow the prompts on the screen. Should
confirm. Increase or decrease the work idle speed an error occur, use the escape key to start over
using the arrow keys, then press confirm. Return to again.
the main driving screen by pressing the escape key.
.
NOTE: If the transmission is shifted into neutral, the
work idle feature will be deactivated.

BD06F195

This screen will prompt the operator or technican to

confirm or escape.
If, conditions are not correct, an error message will
appear. Follow the prompts.
There are six, if conditions not met errors:
•Not in neutral
•Park Brake OFF
•Machine moving
•Oil temp too low
 4005-17
•Oil temp too high
•Engine RPM low
•Engine RPM high
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.
If the process is not completed the operator or
technican will be prompted to escape.
4005-18

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 C
5. 5000 to 5999 eltro-hydraulic system errors.
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.
 4005-19

VEHICLE FAULT CODES

DEFINITION POSSIBLE STEPS FOR REPAIR

1310 Hydraulic filter blocked Change filter

1311 Engine air filter blocked Change filter
1312 Hydraulic oil temperature above normal 1. Stop machine operations
2. Run engine at 1500 rpm
1313 Hydraulic oil temperature to high 3. Check fan operation
1314 4. Check cooling core for clogs
Transmission oil temperature above normal
1315 Transmission oil temperature to high
1. Stop machine operations
2. Run engine at 1500 rpm
1316 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
1. Stop machine operations
2. Run engine at 1500 rpm
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
2. Run engine at 1500 rpm
1319 3. Check fan operation
Engine coolant temperature high - critical
4. Check radiator core for clogs
1320 Engine oil pressure too low 1. Stop machine operations
2. Check engine oil level
1321 Engine oil pressure below normal 3. Check pressure sender unit
1. Check engine oil for proper type
1322 Engine oil pressure above normal 2. Check pressure sender unit
1323 Battery voltage low
Check charging system
1324 Battery voltage high
1. Stop machine operations
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
1329 WIF sensor not present 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
4005-20

DEFINITION POSSIBLE STEPS FOR REPAIR

1. Stop machine operations

2. Run engine at 1500 rpm
1335 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
1336 Transmission oil filter blocked Replace filter
1341 Sec. steering pressure too low No information available at time of print.
Check wiring, sensor installation and proper
1342 Steering pressure sensor open circuit
functioning of steering pressure sensor
Check wiring, sensor installation and proper
1343 Sec. steering pressure sensor open circuit
functioning of sec steering pressure sensor
Open circuit, Short to battery or short to Check wiring, switch installation and proper
1812
ground at JSS armrest switch. functioning of armrest switch.
Open circuit / JSS activation switch Check wiring, switch installation and proper
1816
mechanical defect functioning of JSS activation switch.
Check wiring, installation, and proper functioning
Check JSS relay, JSS valve, JSS joystick
1820 of JSS components. See electrical schematics
power supply connections
and section 5009 for details.
Short to ground on JSS relay 85/AIC 1.21 or Check wiring, installation, and proper functioning
1821 short to power on relay 86/87a. Or activation of JSS components. See electrical schematics
switch failure and section 5009 for details.
JSS relay, ground connect., bad elec. Check wiring, installation, and proper functioning
1823 connect. Permanent ground at JSS relay (87) of JSS components. See electrical schematics
open circuit or short to power and section 5009 for details.
Check wiring, installation, and proper functioning
Short to battery at activation button. Activation
1824 of JSS components. See electrical schematics
switch failure
and section 5009 for details.
Check wiring, installation, and proper functioning
Open circuit between activation switch Pin 3
1830 of JSS components. See electrical schematics
and C5.E Pin 1
and section 5009 for details.
Check wiring, installation, and proper functioning
JSC controller, wrong operation. JSC
1831 of JSS controller. See electrical schematics and
controller internal fault
section 5009 for details.
Check wiring, installation, and proper functioning
JSC controller, JSC signal in, out of limits. of JSS components. See electrical schematics
1832 Input signal from JSS joystick to JSC and section 5009 for details. (Joystick Neutral:
controller out of limits. USignal>40%UBat+<60%Ubat;Joystick
actuated: USignal>20%UBat+<80%UBat)
Check connector of JSS valve and JSC
Output signal from JSC controller to valve out
1833 controller.
of limits.

JSS controller, JSC output, SC to BAT Power Check electrical connection for short to power. Or
1834
is applied to one of the JSC controller outputs. JSC internal relay is defective.
 4005-21

DEFINITION POSSIBLE STEPS FOR REPAIR

Check wiring, installation, and proper functioning

JSS-valve/Pin4 JSC/Pin5 short to power,
1835 of JSS valve. See electrical schematics and
short to ground or open circuit
section 5009 for details.
JSS controller, board temperature, out of limits
Check ambient temperature or short circuit at
1836 temperature on the JSC board is <-40C or
JSC power outputs
>+85C;
JSS controller, switched power, out of limits
Check elect connection for electrical transients,
1837 switched power supply at JSC Pin3 is out of
burst or drifts.
limit;
Check wiring, installation, and proper functioning
1838 Neutral switch out of range of neutral switch. See electrical schematics and
section 5009 for details.
See electrical schematics and section 5009 for
1839 Joystick steering is not calibrated
details.
Check wiring, installation, and proper functioning
JSS valve internal error, spool position not of JSS valve. See electrical schematics and
1841
accurate or signal voltage out of range section 5009 for details.

Check wiring, installation, and proper functioning

1842 JSS valve Pin2 (alarm signal) open circuit of JSS valve. See electrical schematics and
section 5009 for details.
Pilot pressure switch open when HSS is Pilot dump valve stuck close or short to power on
1843 deactivated. High pilot pressure on JSS valve valve power supply. Or open circuit on JSS pilot
even when JSS is not active. pressure switch lines or JSC/Pin8.
Check wiring, installation, and proper functioning
1844 Pilot pressure switch short to ground of pilot pressure switch. See electrical
schematics and section 5009 for details.
Error is displayed when JSS active and Pilot
Pilot pressure switch stays closed (Input pressure stays low. Pilot dump valve stuck open
JSC8+1) although JSS is activated. With low or open circuit or short to ground on JSS valve
1845
pilot pressure on JSS valve no steering with power supply (valve connector Pin4). Or short to
JSS possible. power on JSS pilot pressure switch lines or input
JSC/Pin8.
Standard steering orbit or tank pressure Check wiring, installation, and proper functioning
1846 transducer switch short to power or short to of switch. See electrical schematics and section
ground 5000 for details.
JSC Model type not available, no model type
1847 information available in JSC, probably missing No information available at time of print.
information from AIC
JSS joystick Pins2, 4, or 6 short to ground, Check wiring, installation, and proper functioning
1850 short to battery or open circuit, or JSS joystick of JSS joystick. See electrical schematics and
internal failure. section 5009 for details.
Check wiring, installation, and proper functioning
JSS joystick Pins5 open circuit, or JSS joystick
1852 of JSS joystick. See electrical schematics and
internal failure
section 5009 for details.
4005-22

DEFINITION POSSIBLE STEPS FOR REPAIR

1860 CAN timeout of C5.E detected by JSC No information available at time of print.
1861 CAN timeout of AIC detected by JSC controller No information available at time of print.
Internal malfunction transmission controller.
1863 TCU message JSS F-N-R disabled or JSS No information available at time of print.
F-N-R not activated.
1864 Test No information available at time of print.

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.
 4005-23

ENGINE FAULT CODES

DESCRIPTION AND POSSIBLE

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.
Short circuit in wiring or in accelerator pedal.
3002 Foot throttle sensor signal above range max.
Check wiring or replace accelerator pedal.
Short circuit in wiring or in accelerator pedal.
3003 Foot throttle sensor signal below range min.
Check wiring or replace accelerator pedal.
3004 Foot throttle sensor - no signal Check wiring or replace accelerator pedal
Coolant temperature sensor signal not See OTS (Oil Temperature Sensor) plausibility
3006
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.
Check wiring or replace sensor.
The Engine Control Unit (ECU) generated an
error from a fault associated with the Boost
Pressure sensor. The Boost Pressure sensor is
an integrated sensing device used to sense both
temperature and pressure. This fault is related
to the temperature sensing function of the device.
Air intake temperature sensor - signal above This error could result from a signal out of range
3010
range max. or a signal that is either erratic or intermittent.
When the ECU determines that the Boost
Pressure sensor value is not valid, it will
substitute a default value of 29.96 °C (86 °F).
Cause:
The Boost Pressure sensor signal to the ECU is
out of range of the upper threshold limit.
4005-24

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

The Engine Control Unit (ECU) generated an

error from a fault associated with the Boost
Pressure sensor. The Boost Pressure sensor is
an integrated sensing device used to sense both
temperature and pressure. This fault is related
to the temperature sensing function of the device.
Air intake temperature sensor - signal above This error could result from a signal out of range
3011
range min. or a signal that is either erratic or intermittent.
When the ECU determines that the Boost
Pressure sensor value is not valid, it will
substitute a default value of 29.96 °C (86 °F).
Cause:
The Boost Pressure sensor signal to the ECU is
out of range of the lower threshold limit.
Air intake temperature sensor - (via CAN) No
3012 See engine manual for details.
signal.
Sensor defective or short circuit to external
3015 Fuel temperature signal above range max. source.
Check wiring or replace sensor.
Sensor defective or short circuit to ground.
3016 Fuel temperature signal below range min.
Check wiring or replace sensor.
Sensor defective or short circuit to external
Boost pressure sensor signal above range
3019 source.
max.
Check wiring or replace sensor.
No CAN plausibility check performed, restart
3021 Boost pressure sensor null (via CAN) system, if problem reoccurs.
Check wiring or replace sensor.
Difference of ambient and boost pressure is out
3022 Boost pressure sensor signal not plausible of range.
Check wiring or replace sensor.
Atmospheric pressure sensor signal not
3023
plausible
Ambient pressure sensor inside ECU is defect.
3024 Atmospheric pressure sensor signal above
Replace ECU (not necessary if never running in
range max.
high altitude and if turbocharger is without VGT)
Atmospheric pressure sensor signal below
3025
range min.
Inaccurate oil pressure sensor or defect (e.g. too
low oil level, leakage...) in the oil system.
3028 Oil pressure sensor pressure too low
Check oil pressure sensor for accuracy and
check oil system.
Sensor defective or short circuit to external
3029 Oil pressure sensor short-circuit to battery source.
Check wiring or replace sensor.
Sensor defective or short circuit to ground.
3030 Oil pressure sensor short-circuit to ground
Check wiring or replace sensor.
 4005-25

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

The Engine Control Unit (ECU) generated a fault

associated with the Oil temp / press sensor. The
Oil temp / press sensor is an integrated sensing
device used to sense both temperature and
pressure. This fault is related to the
pressure sensing function of the device. This
error could result from a signal out of range or a
plausibility check (oil pressure too high). The
plausibility check is only started if there are no
sensor power supply ( 5 volts dc) or Analog
3031 Oil pressure sensor ADC conversion error to Digital Converter (ADC) signal errors detected.
Cause:
The Oil temp / press sensor signal to the ECU is
either erratic or intermittent.

Possible failure modes:

1. Faulty Oil temp / press sensor.
2. Faulty electrical wiring or intermittent
connection between Oil temp / press sensor and
ECU.
3. Faulty ECU, supply voltages or grounds.
3032 Oil pressure sensor pressure too high Oil pressure sensor pressure too high.
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.
Sensor defective or short circuit to external
Oil temperature sensor signal above range
3034 source.
max.
Check wiring or replace sensor.
Oil temperature sensor signal below range Sensor defective or short circuit to ground.
3035
min. Check wiring or replace sensor.
No CAN plausibility check performed, restart
Oil temperature sensor signal CAN
3036 system, if problem reoccurs.
transmission disturbed
Check wiring or replace sensor.
Sensor defective or short circuit to ground.
3037 Boost pressure sensor signal low
Check wiring or replace sensor.
Cruise control actuating device - Evaluation
3039 See engine manual for details.
error.
1. Faulty reading from component.
2. Connectors not mated fully, pins not pushed
into connector fully, bent pin or broken wire at
rear of connector.
High pressure Pump relay - Short circuit to
3047 3. Wiring or circuits open.
battery
4. Wiring or circuits shorted.
5. Connector pins corroded or dirty. When
removing connectors inspect and clean pins.
Clean female pins by installing and removing.
4005-26

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

High pressure Pump relay - Short circuit to 1. Faulty reading from component.
3048
ground. 2. Wiring or circuits shorted.
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.
1. Faulty reading from component.
2. Connectors not mated fully, pins not pushed
into connector fully, bent pin or broken wire at
rear of connector.
3059 ECM afterrun was interrupted. 3. Wiring or circuits open.
4. Wiring or circuits shorted.
5. Connector pins corroded or dirty. When
removing connectors inspect and clean pins.
Clean female pins by installing and removing.
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
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 Check the wiring and the injection signals,

Cylinder 1 signal low
replace ECU
Defective coil of injector.
3063 Cylinder 1 short-circuit high side to low side
Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3064 Cylinder 5 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 5 injector cable short-circuit low side Short circuit in wiring with external source.
3065
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3066 Cylinder 5 signal low
replace ECU.
Cylinder 5 injector cable short-circuit high side Defective coil of injector.
3067
to low side Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3068 Cylinder 3 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
 4005-27

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

Cylinder 3 injector cable short-circuit low side Short circuit in wiring with external source.
3069
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3070 Cylinder 3 signal low
replace ECU.

3071 Defective coil of injector.

Cylinder 3 short-circuit high side to low side
Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3072 Cylinder 6 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 6 injector cable short-circuit low side Short circuit in wiring with external source.
3073
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3074 Cylinder 6 signal low
replace ECU.
Cylinder 6 injector cable short-circuit high side Defective coil of injector.
3075
to low side Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3076 Cylinder 2 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 2 injector cable short-circuit low side Short circuit in wiring with external source.
3077
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3078 Cylinder 2 signal low
replace ECU.
Cylinder 2 injector cable short-circuit high side Defective coil of injector.
3079
to low side Check the wiring and replace injector
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3080 Cylinder 4 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 4 injector cable short-circuit low side Short circuit in wiring with external source.
3081
to battery Check the wiring or replace injector
Check the wiring and the injection signals,
3082 Cylinder 4 signal low
replace ECU.
Cylinder 4 injector cable short-circuit high side Defective coil of injector.
3083
to low side Check the wiring and replace injector
Signal interrupted due to wiring problem,
defective or incorrectly installed crankshaft speed
3088 sensor.
Crankshaft sensor lost synchronization
Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)
4005-28

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

Check wiring, sensor installation and proper

3089 Crankshaft sensor defective functioning of crankshaft sensor (evaluate raw
signals).
Signal interrupted due to wiring problem,
defective 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)
Check wiring, sensor installation and proper
Camshaft sensor phase synchronization
3091 functioning of camshaft phase sensor (evaluate
failure
raw signals).
Offset between camshaft and crankshaft - Not
3092 See engine manual for details.
plausible.
Signal interrupted due to wiring problem,
defective or incorrectly installed camshaft or
Offset between camshaft and crankshaft crankshaft sensor.
3093
outside boundaries Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)
Check wiring, sensor installation and proper
3095 Operating with camshaft sensor only functioning of crankshaft sensor (evaluated raw
signals).
3096 ECM Busoff on vehicle CAN See engine manual for details.
3097 ECM Busoff on Engine private CAN See engine manual for details.
Timeout of CAN Message TSC1-TE (when
3098 See engine manual for details.
active).
Timeout of CAN Message TSC1-TE (when
3099 See engine manual for details.
inactive).
Timeout of CAN Message TSC1 -AE (when
3100 See engine manual for details.
active).
Timeout of CAN Message TSC1-AE (when
3101 See engine manual for details.
inactive).
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
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
 4005-29

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

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:
3106 Rail pressure relief valve did not open after Stuck PRV or wrong application parameter.
pressure shock Check application value of maximum rail
pressure, check functioning of the PRV
Short circuit of wiring to external source or inside
Metering unit output short-circuit to battery on
3107 relay.
low side
Check wiring or replace relay
The engine control unit (ECU) has determined
that a short to low source circuit condition exists
in the fuel high pressure pump low side circuit.
The metering unit of the fuel high pressure pump
regulates the pressure in the common rail. The
metering unit is closed-loop controlled by both
main relay 1 (high side) and a low side power
stage (Main Relay 1 is an electronic control circuit
within the ECU, providing source voltage to
devices external to the ECU. The low side power
stage works in conjunction with the Main Relay 1
3108 Metering unit - short circuit to Ground. source, providing sensing and current limiting for
the circuit). The monitoring at low side is stopped
if a short circuit to ground at the high side (main
relay 1) is detected or it is switched off for some
reason. Failure detection of is only possible if the
low side power stage is switched off. With
the current settings, the monitoring is shut off
during after-run. This error is the result of the
power stage hardware report of ’short circuit to
ground’ (on the low side of the metering unit)
longer than 0.28 seconds and the power stage
has most likely switched off.
Rail pressure sensor offset monitoring signal
3110 Rail pressure sensor inaccurate.
above range max.
Ensure correct wiring and proper functioning of
3111 Rail pressure sensor offset monitoring signal rail pressure sensor, replace sensor
below range min.
Short circuit of wiring to external source or
defective pressure sensor, rail pressure
Rail pressure sensor CP3 signal above range
3112 overshoot.
max.
Check wiring and proper functioning of rail
pressure sensor
Short circuit of main relay to external source or
Main Relay 1 (High Pressure Pump) short to defective main relay.
3113
battery. Check the wiring connecting the battery to the
EDC or replace main relay
4005-30

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

Short circuit to ground of main relay or defective

Main Relay 1 (High Pressure Pump) short to main relay.
3114
GND. 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
3133 Cold start lamp - No load See engine manual for details.
3134 Cold start lamp - Short circuit to battery See engine manual for details.
3135 Cold start lamp - Short circuit to ground. See engine manual for details.
3136 Cold start lamp - Excessive temperature. See engine manual for details.
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
High pressure system: Rail pressure sensor
inaccurate, high pressure pump defective.
3141 Set point of fuel volume flow through metering
Low pressure system: Metering unit reflux too
unit is lower than calculated limit
low.
Check for defects according to failure list.
The engine control unit (ECU) has acknowledged
that the ’High Pressure Test’ is running. The ’High
Pressure Test’ is a test procedure used to
evaluate the performance of the fuel high
pressure unit (pump, rail pressure control valve,
etc.) and is executed via a diagnostic tester
3142 High pressure test - Test active
request. If this test is running the rail pressure
monitoring has to be deactivated, which is done
by setting this fault path. Therefore, this failure
path is used more for information purposes
and inhibit handling than as an actual error
status.
 4005-31

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

NOTICE: Fault Code 3145 is stored historical

information. For multiple occurrences of this fault
proceed with the following tests.
NOTE: See engine repair manual for electrical
schematic information. When available use special
tool 380040185 harness diagnostic/repair kit.
Cause:
3145 Terminal 15 - No signal
1. Faulty reading from component.
2. Connectors not mated fully, pins not pushed
into connector fully, bent pin or broken wire at
rear of connector.
3. Wiring or circuits open.
4. Wiring or circuits shorted.
5. Connector pins corroded or dirty.
Oil temperature sensor signal above normal Check oil temperature sensor for accuracy and
3147
range check oil system.
Coolant temperature sensor dynamic test -
3148 Failure (Minimum temperature raise not See engine manual for details.
reached).
Short circuit of wiring to external source or inside
3154 Grid heater relay short-circuit to battery relay.
Check wiring or replace relay
Short circuit of wiring to ground or inside relay.
3155 Grid heater relay short-circuit to ground
Check wiring or replace relay

3156 Broken or disconnected wiring or defective relay.

Grid heater relay no load
Check wiring or replace relay
Engine dataset information was not available
3157 See engine manual for details.
from EDC in required time
Engine dataset does not match dataset
3158 See engine manual for details.
registered for this machine
3160 Fan actuator - Short circuit to battery See engine manual for details.
3161 Fan actuator signal low See engine manual for details.
3162 Fan actuator - Open load See engine manual for details.
3163 Fan actuator - Temperature too high See engine manual for details.
3166 Fuel filter heater relay - Short circuit to battery See engine manual for details.
3167 Fuel filter heater relay - Short circuit to ground. See engine manual for details.
3168 Fuel filter heater relay - Open load. See engine manual for details.
3169 Fuel filter heater relay - Signal not plausible. See engine manual for details.
4005-32

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

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.
The Engine Control Unit (ECU) has detected an
engine over-speed condition. An engine
over-speed can occur both during certain engine
operating conditions without any defect in a
component, for example downhill driving, or as a
result of, for example another ECU error. This
error is for information purposes and is initiated
by engine speed in excess of 2800 RPM for over
5 seconds and is reset once the engine speed is
3177 Engine overspeed detected.
below the threshold for over 2 seconds.
Though this error by itself does not require any
action, the over-speed state can cause an
injection shutoff request within the ECU. If this
error reoccurs frequently, check driving
conditions of the vehicle, engine speed
acquisition and injection system for quantity
set-point and actual value during fault
recognition, check also for other ECU errors.
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.
Rail pressure positive deviation too high
3181 See engine manual for details.
concerning setpoint.
3182 Timeout of CAN Message RXCCVS See engine manual for details.
Timeout of CAN Message TSC1-VR (when
3183 See engine manual for details.
active)
Timeout of CAN Message TXC1-VR (when
3184 See engine manual for details.
inactive)
3185 Timeout of CAN message TF See engine manual for details.
 4005-33

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

3188 Cylinder 1 open load

3192 Cylinder 2 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.
3204 Cylinder 5 open load
3208 Cylinder 6 open load
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
Check the wiring or replace injector.
3212 Bank 1 no signal See engine manual for details.
Depending on the pattern, various reasons can
cause the defect, internal ECU problem.
3213 Bank 1 unclassified error
Check the wiring and the injection signals,
replace ECU
Short circuit of high-side to battery or ground.
3218 Bank 2 general short-circuit on injection cable
Check the wiring or replace injector.
Short circuit of low-side to ground in injector
Bank 2 injection cable short-circuit low side to
3219 cable.
ground
Check the wiring or replace injector.
3220 Bank 2 no signal See engine manual for details.
Depending on the pattern, various reasons can
cause the defect, internal ECU problem.
3221 Bank 2 unclassified error
Check the wiring and the injection signals,
replace ECU
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.
3228 Injection processor error - stop engine
If no recovery, replace ECU.
Internal failure of ECU or 'TESTMODE' takes too
long.
3229 Injection processor error - stop engine
Check 'TESTMODE' parameters or replace ECU
if problem reoccurs
Defective SPI-bus participant, timing problem
due to software bug.
3230 Injection processor error - stop engine
Replace ECU if problem reoccurs (Send in ECU
for investigation)
4005-34

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

3231 Injection processor error - stop engine

3232 Injection processor error - stop engine Defective ECU.
3233 Injection processor error - stop engine Replace ECU if problem reoccurs

3234 Injection processor error - stop engine

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
The engine control unit (ECU) has detected an
error during the last EEPROM read operation.
The hardware encapsulation of the ECU checks
each data block of the EEPROM and sets a status
flag depending on if an error is found or not found.
These flags are processed every 20 milliseconds
by the Diagnostic System Management (DSM)
3239 ECM EEPROM - Read operation failure and depending on their value a failure or no
failure is detected. If a failure is detected this
error sets and should reset immediately if the
EEPROM operates correctly. This failure can be
the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU
correctly with the proper data set. If the error
persists, replace the ECU.
The engine control unit (ECU) has detected an
error during the last EEPROM write operation.
The hardware encapsulation of the ECU checks
each data block of the EEPROM and sets a status
flag depending on if an error is found or not found.
These flags are processed every 20 milliseconds
by the Diagnostic System Management (DSM)
3240 ECM EEPROM - Write operation failure and depending on their value a failure or no
failure is detected. If a failure is detected this
error sets and should reset immediately if the
EEPROM operates correctly. This failure can be
the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU
correctly with the proper data set. If the error
persists, replace the ECU.
 4005-35

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

The engine control unit (ECU) has detected that

substitute values for the EEPROM values are
used. This happens if a checksum error (CRC) is
registered during reading. The hardware
encapsulation of the ECU checks each data block
of the EEPROM and sets a status flag depending
on if an error is found or not found. These flags
are processed every 20 milliseconds by the
3241 ECM EEPROM - Default value used Diagnostic System Management (DSM) and
depending on their value a failure or no failure
is detected. If a failure is detected this error sets
and should reset immediately if the EEPROM
operates correctly. This failure can be the result
of wrong programming / flashing of the ECU or an
internal defect. Try to flash the ECU correctly with
the proper data set. If the error persists, replace
the ECU.
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.
3245 Communication supervision watchdog control If error exists only temporary (i.e. injection
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
4005-36

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

The engine control unit (ECU) has detected that

the TPU (time processing unit) and CPU (central
processing unit) have operated outside the
established parameters more than 4 times since
last ECU recovery (initialization). As the time
base of the CPU is checked according to a query
/ response communication with the monitoring
module (watchdog) it should be correct if no error
has been detected and therefore can be used to
check the time base of the TPU. For this purpose
the time basis of the TPU and CPU are compared
TPU monitoring - Time deviation between TPU
3249 every 10 ms. After 100 ms the maximum and
and system not plausible
the minimum value together with the absolute
value of the sum of the time differences are
evaluated. If the maximum time difference
between the TPU and CPU time base exceeds
the threshold of 81 ms or the minimum time
difference is below the limit of 81 ms or the
absolute value of the sum of the time differences
is above 81 ms an error counter is incremented. If
this counter exceeds the value of 4, this fault is
set and initiates an ECU recovery (reset). If this
failure persists, the ECU will need to be replaced.
NOTE: See engine repair manual for electrical
ECU software variant Dataset failure - Dataset schematic information.
3250
not valid. Cause:
1. Internal ECU error
NOTE: See engine repair manual for electrical
schematic information.
3251 Dataset - Requested variant could not be set.
Cause:
1. Internal ECU error
The engine control unit (ECU) has detected an
internal (SPI Bus) communication failure. The
central processing unit (CPU) and monitoring
module (watchdog) contained with in the ECU,
communicate with each other via the SPI
bus. Both devices mutually monitor each other for
correct functioning. If, however, the SPI
communication between them fails this
monitoring is impaired and an error counter is
Controller watchdog - SPI communication incremented. If the error counter exceeds 2 over
3252
failure. two 20 ms (two tests) checks, this fault is
activated. Communication status is checked
autonomously by the SPI driver component every
20 ms and reports a detected error to the ECU.
This error initiates ECU recovery (reset). If the
ECU functions correctly after recovery, the SPI
error is temporary and can be ignored and
deleted from fault memory. If the SPI error is
permanent and the ECU does not leave
boot-block, the ECU needs to be replaced.
 4005-37

DESCRIPTION AND POSSIBLE

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 of wiring to external source or inside
Short-circuit to battery at high side power
3258 relay.
stage
Check wiring or replace relay

3259 Short-circuit to ground at high side power Short circuit of wiring to ground or inside relay.
stage Check of wiring or replace relay
Broken or disconnected wiring or defective relay.
3260 Open load at low side power stage
Check wiring or replace relay
Short circuit of wiring to external source or inside
Short-circuit to battery or excessive
3261 relay.
temperature at low side power stage
Check wiring or replace relay

3262 Short circuit of wiring to ground or inside relay.

Short-circuit to ground at low side power stage
Check wiring or replace relay
Electronic disturbances, requested torque
increase via tester, wrong application of injection
3265 Energizing time exceeds limit of over run
relevant parameters, defective ECU.
monitoring
Check injection relevant application, if failure
persists replace ECU
Electronic disturbances, internal ECU problem.
3266 Plausibility error in engine speed check
If failure persists after reinstallation replace ECU
3267 Main relay 3 - Short circuit to battery See engine manual for details.
3268 Main relay 3 - Short circuit to ground See engine manual for details.
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,
3279 internal defect of the EDC.
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
4005-38

DESCRIPTION AND POSSIBLE

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
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3283 Sensor supply voltage 2 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Insufficient battery voltage, defect in wiring
harness, electrical failure connected sensors or
in the EDC.
3284 Sensor supply voltage 2 low
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3285 Sensor supply voltage 3 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Insufficient battery voltage, defect in wiring
harness, electrical failure connected sensors or
in the EDC.
3286 Sensor supply voltage 3 low
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Turbo compound monitoring signal not
3290 See engine manual for details.
plausible
Rail pressure governor deviation exceeded
3297 See engine manual for details.
max limit with fuel delivery quantity on limit.
Rail pressure governor deviation exceeded
3301 See engine manual for details.
min limit with fuel delivery quantity on limit.
Rail pressure governor deviation below min
3305 See engine manual for details.
limit for speed
Rail pressure governor deviation exceeded
3309 See engine manual for details.
max limit
Rail pressure drop rate is higher than
3313 See engine manual for details.
expected.

3315 Minimum number of injections not reached -

See engine manual for details.
stop engine.
 4005-39

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

The engine control unit (ECU) has determined

that the minimum number of injections was not
reached. The injector shutoff function (within the
ECU) can switch off a single injector valve or an
entire injection bank if a defect has been
detected in a component (monitoring is
performed in other fault paths). The shutoff
procedure is performed either for an individual
Minimum number of injections not reached -
cylinder or for an entire bank. However, if too
3316 stop engine.
many cylinders are shut down by the shutoff
function it is no longer possible to run the engine
securely and it has to be shut down entirely. In
this case the fault path at hand is set. It is
possible for the engine to continue running on two
cylinders. The test frequency is once per
injection. If this error occurs, see individual
injector and injection-bank errors which have
triggered the shutoff or error in the component.
Minimum number of injections not reached -
3317 stop engine. See engine manual for details.

Minimum number of injections not reached -

3318 stop engine. See engine manual for details.

3319 DM1DCU SPN2 message - Error in DCU

See engine manual for details.
active.
DM1DCU SPN3 message - Error in DCU
3320 See engine manual for details.
active.
DM1DCU SPN4 message - Error in DCU
3321 See engine manual for details.
active.
DM1DCU SPN5 message - Error in DCU
3322 See engine manual for details.
active.
CAN Data Link communications from the ECU
have been lost.
Cause:
CAN Data Link communications from the ECU
have been lost. This fault code will be displayed
with other CAN Data Link fault messages. The
engine may go into Limp Home Mode and engine
speed will be set to 1500 RPM.
Timeout of CAN message TSC1-PE Torque
3334
(when active).
Possible failure modes:
1. Connectors not mated fully, pins not fully
seated in connector, bent pin or broken wire at
rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
4005-40

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

Timeout of CAN message TSC1-PE Torque

3335 See engine manual for details.
(when inactive).
Timeout of CAN message TSC1-VE Torque
3338 See engine manual for details.
(when inactive).
CAN Data Link communications from the ECU
have been lost.
Cause:
CAN Data Link communications from the ECU
have been lost. This fault code will be displayed
with other CAN Data Link fault messages. The
engine may go into Limp Home Mode and engine
speed will be set to 1500 RPM.
Timeout of CAN message TSC1-VE Torque
3339
(when active).
Possible failure modes:
1. Connectors not mated fully, pins not fully
seated in connector, bent pin or broken wire at
rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
NOTICE: Replace Starter Relay and test system
before proceeding.
NOTE: See engine repair manual for electrical
schematic information.

Cause:
1. Faulty reading from component.
2. Connectors not mated fully, pins not pushed
3350 Terminal 50 - Always On
into connector fully, bent pin or broken wire at
rear of connector.
3. Wiring or circuits open.
4. Wiring or circuits shorted.
5. Connector pins corroded or dirty. When
removing connectors inspect and clean pins.
Clean female pins by installing
and removing.
Main Relay 4 (Engine brake exhaust valve) -
3354 See engine manual for details.
Short circuit to ground.
Main Relay 4 (Engine brake exhaust valve) -
3355 See engine manual for details.
Short circuit to battery or open load.
3358 CAN Transmit timeout See engine manual for details.
NOTE: See engine repair manual for electrical
Atmospheric pressure sensor - signal not schematic information.
3363
plausible. Cause:
1. ECU internal error
3367 Coolant temperature test failure. See engine manual for details.
 4005-41

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

Info: Torque limitation due to OBD

3368 See engine manual for details.
performance limiter by legislation.
3369 Torque reduction due to smoke limitation. See engine manual for details.
Info: Torque limitation due to engine protection
3370 (against excessive torque, Engine overspeed See engine manual for details.
and overheat)
Info: Torque limitation due to fuel quantity
3371 See engine manual for details.
limitation because of injection system errors.
3512 DCU State monitoring - DCU not ready in time See engine manual for details.
4005-42

TRANSMISSION FAULT CODES

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

1. Check the cables from the TCU to the FNR

switch.
4113 Logical error at Gear Range Signal 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch.
1. Check the cables from the TCU to the FNR
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.
1. Check the cables from the TCU to the FNR
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.
1. Check the cable from TCU to brake light
2. Check the connectors from brake light device to
4122 Short circuit to ground at brake light 1 TCU
3. Check the resistance of brake light
1. Check the cable from TCU to brake light
2. Check the connectors from brake light device to
4123 Short circuit to battery voltage at brake light 1 TCU
3. Check the resistance of brake light
1. Check the cable from TCU to brake light
2. Check the connectors from brake light device to
4124 Open circuit at brake light 1 TCU
3. Check the resistance of brake light
1. Check the cable from TCU to brake light
2. Check the connectors from brake light device to
4125 Short circuit to ground at brake light 2 TCU
3. Check the resistance of brake light
1. Check the cable from TCU to brake light
2. Check the connectors from brake light device to
4126 Short circuit to battery voltage at brake light 2 TCU
3. Check the resistance of brake light
1. Check the cable from TCU to brake light
2. Check the connectors from brake light device to
4127 Open circuit at brake light 2 TCU
3. Check the resistance of brake light
 4005-43

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4133 at transmission sump temperature sensor 2. Check the connectors.
input 3. Check the temperature sensor.

Short circuit to ground at transmission sump

4134
temperature sensor input
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4135 at retarder/torque converter temperature 2. Check the connectors.
sensor input 3. Check the temperature sensor.

Short circuit to ground at retarder/torque

4136
converter output temperature sensor input
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.
1. Check the cables from TCU to the sensor.
4138 Inchsensor - Signal mismatch 2. Check the connectors.
3. Check the sensor.

4145 Short circuit to battery voltage or open circuit 1. Check the parking brake fuse.
at engine speed input 2. Check the parking brake relay.
4146 3. Check the parking brake solenoid.
Short circuit to ground at engine speed input
1. Check the cables from TCU to the sensor.
2. Check the connectors.
3. Check the speed sensor.
4147 Logical error at engine speed 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.

4148 Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
at turbine speed input 2. Check the connectors.
4149 3. Check the speed sensor.
Short circuit to ground at turbine speed input
1. Check the cables from TCU to the sensor.
2. Check the connectors.
4150 Logical error at turbine speed input 3. Check the speed sensor.
NOTE: This fault code is reset after power up of the
TCU.
Short circuit to battery voltage or open circuit
4151 1. Check the cables from TCU to the sensor.
at intermediate speed input
2. Check the connectors.
Short circuit to ground at intermediate speed 3. Check the speed sensor.
4152
input
1. Check the cables from TCU to the sensor.
2. Check the connectors.
4153 Logical error at intermediate speed input 3. Check the speed sensor.
NOTE: This fault code is reset after power up of the
TCU.
4005-44

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4154
at output speed input 2. Check the connectors.
4155 3. Check the speed sensor.
Short circuit to ground at output speed input
1. Check the cables from TCU to the sensor.
2. Check the connectors.
4156 Logical error at output speed input 3. Check the speed sensor.
NOTE: This fault code is reset after power up of the
TCU.
1. Check the sensor signal of the output speed
sensor.
2. Check the connector connected to the output
Output speed zero, doesn’t fit to other speed speed.
4158
signals. 3. Check the cable from the TCU to the sensor.
NOTE: This fault code is reset after power up of the
TCU.
1. Check the cluster controller.
4180 Vehicle controller time-out (CAN) 2. Check wire of CAN-Bus
3. Check the cable to the cluster controller
1. Check Joystick steering controller.
4181 JSS timeout 2. Check wire of CAN-Bus.
3. Check cable to Joystick steering controller.
1. Check engine controller
4182 Engine CONF timeout 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check EEC controller
4183 EEC1 timeout 2. Check wire of CAN-Bus
3. Check cable to EEC controller
1. Check EEC controller
4184 EEC3 timeout 2. Check wire of CAN-Bus
3. Check cable to EEC controller
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
1. Check I/O controller
4193 AEB Request signal 2. Check wire of CAN-Bus
3. Check cable to I/O controller
1. Check engine controller
4197 Engine torque signal 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check engine controller
4201 Reference engine torque signal 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check engine controller
4202 Actual engine torque signal 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check engine controller
4203 NOM friction torque signal 2. Check wire of CAN-Bus
3. Check cable to engine controller
 4005-45

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

1. Check EEC timeout

4206 EEC2 timeout 2. Check wire of CAN-Bus
3. Check cable to EEC controller
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4209 Short circuit to battery voltage at clutch K1 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4210 Short circuit to ground at clutch K1 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4211 Open circuit at clutch K1 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4212 Short circuit to battery voltage at clutch K2 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4213 Short circuit to ground at clutch K2 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4214 Open circuit at clutch K2 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4215 Short circuit to battery voltage at clutch K3 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4216 Short circuit to ground at clutch K3 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4217 Open circuit at clutch K3 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
Short circuit to battery voltage at converter 1. Check the cable from TCU to the valve
4218 2. Check the regulator resistance
clutch.
1. Check the cable from TCU to the valve
4219 Short circuit to ground at converter clutch 2. Check the regulator resistance
1. Check the cable from TCU to the valve
4220 Open circuit at converter clutch 2. Check the regulator resistance
1. Check the cable from TCU to the gearbox
2. Check the connectors from gearbox to TCU
4225 Short circuit to battery voltage at clutch K4 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
4005-46

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

1. Check the cable from TCU to the gearbox

2. Check the connectors from gearbox to TCU
4226 Short circuit to ground at clutch K4 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from gearbox to TCU
4227 Open circuit at clutch K4 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from gearbox to TCU
4228 Short circuit to battery voltage at clutch KV 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from gearbox to TCU
4229 Short circuit to ground at clutch KV 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from gearbox to TCU
4230 Open circuit at clutch KV 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from gearbox to TCU
4231 Short circuit to battery voltage at clutch KR 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from gearbox to TCU
4232 Short circuit to ground at clutch KR 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the gearbox
2. Check the connectors from gearbox to TCU
4233 Open circuit at clutch KR 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
1. Check the cable from TCU to the valve
4234 Short circuit to ground at DLM transversal 2. Check the connectors
output 3. Check the resistance of valve
1. Check the cable from TCU to the valve
4235 Short circuit to battery voltage at DLM 2. Check the connectors
transversal output 3. Check the resistance of valve
1. Check the cable from TCU to the valve
4236 Open circuit at DLM transversal output 2. Check the connectors
3. Check the resistance of valve
Short circuit to ground at relay reverse warning 1. Check the cable from the TCU to the backup.
4241
alarm alarm relay.
2. Check the connectors from the backup alarm
Short circuit to battery voltage at relay reverse relay to TCU.
4242
warning alarm 3. Check the resistance of backup alarm relay
4243 Open circuit at relay reverse warning alarm circuit.
 4005-47

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

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.
1. Check pressure at clutch K2.
2. Check main pressure in the system.
4274 Slippage at clutch K2 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
1. Check pressure at clutch K3.
2. Check main pressure in the system.
4275 Slippage at clutch K3 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
1. Check pressure at clutch K4.
2. Check main pressure in the system.
4276 Slippage at clutch K4 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
1. Check pressure at clutch KV.
2. Check main pressure in the system.
4277 Slippage at clutch KV 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
1. Check pressure at clutch KR.
2. Check main pressure in the system.
4278 Slippage at clutch KR 3. Check signal at internal speed sensor.
4. Check signal at output 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 Overtemp SUMP the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
4281 Overspeed Engine Check engine speed sensor
1. Check oil filter.
2. Check wiring from TCU to filter maintenance
4282 Differential Pressure Oil Filter switch.
3. Check filter maintenance switch (measure
resistance).
4005-48

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

1. Check pressure at converter lockup clutch

2. Check main pressure in the system
3. Check sensor gap at engine speed sensor
4283 Slippage at converter lockup clutch 4. Check sensor gap at turbine speed sensor
5. Check signal at engine speed sensor
6. Check signal at turbine speed sensor
7. Replace clutch
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.
3. Stop machine and perform required service on
4291 Overtemp converter output 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.
Short circuit to ground at joystick status 2. Check the connectors from the TCU to the
4292
indicator. joystick.
3. Check the resistance of the joystick.
1. Check the cables from the TCU to the joystick.
Short circuit to battery voltage at joystick 2. Check the connectors from the TCU to the
4293
status indicator joystick.
3. Check the resistance of the joystick.
1. Check the cables from the TCU to the joystick.
2. Check the connectors from the TCU to the
4294 Over current at joystick status indicator joystick.
3. Check the resistance of the joystick.
1. Check EEC controller
4298 Engine retarter config timeout 2. Check wire of CAN-Bus
3. Check cable to EEC controller
1. Check EEC controller
4299 ERC1 timeout 2. Check wire of CAN-Bus
3. Check cable to EEC controller
Short circuit to battery voltage at power supply 1. Check the cables from the sensors TCU.
4305 2. Check the connectors from the sensors to the
for sensors.
TCU.
Short circuit to ground at power supply for
4306
sensors.
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.
 4005-49

CODE DEFINITION POSSIBLE STEPS FOR REPAIR

1. Check the cable from TCU to the display

Short circuit to battery voltage at display 2. Check the connectors at the display
4323
output. 3. Change display
1. Check the cable from TCU to the display
4324 Short circuit to ground at display output 2. Check the connectors at the display
3. Change display
1. Check display controller
4325 Vehicle ID #1 time out 2. Check wire of CAN-Bus
3. Check cable to display controller
4326 Illegal ID request via CAN. No information available at time of print.
4337 General EEPROM fault Replace the TCU.
Reprogram the correct configuration for the
4338 Configuration lost
vehicle.
4339 Application error Replace the TCU.
4341 Clutch failure during AEB
Clutch adjustment data lost or inchpedal Do the transmission clutch calibration procedure.
4342
calibration data lost
4005-50

INSTRUMENT CLUSTER FAULT CODES

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

9100 CreateMbx 20ms DM1 BAM No information available at time of print.

9101 AddMsg DM1 BAM No information available at time of print.
9102 AddMsg DM1 PCK No information available at time of print.
9103 Timeout Packet No information available at time of print.
9104 Missed a Packet No information available at time of print.
9105 CreateMbx 20ms DM1 Packets No information available at time of print.
9106 InitCAN, check diagmsg No information available at time of print.
9107 InitCAN, check diagmsg No information available at time of print.
9108 InitCAN, check diagmsg No information available at time of print.
9109 InitCAN, check diagmsg No information available at time of print.
9110 Error Index out of range in set error No information available at time of print.
9111 Null error, not permitted No information available at time of print.
9121 Logical error when retrieving flash data No information available at time of print.
9122 Logical error when retrieving flash data No information available at time of print.
9123 Logical error when retrieving flash data No information available at time of print.
9124 Logical error when retrieving flash data No information available at time of print.
9125 Never started receiving message No information available at time of print.
9126 Never started receiving message No information available at time of print.
9127 Never started receiving message No information available at time of print.
9128 CAN timed out during operation 1. CAN communication interrupted during normal
operation.
9129 CAN timed out during operation 2. Faulty reading from component.
3. Connectors not mated fully, pins not pushed into
connector fully, bent pin or broken wire at rear of
9130 CAN timed out during operation connector.
4. Wiring or circuits open.
5. Wiring or circuits shorted.
9131 CAN timed out during operation No information available at time of print.
9132 CAN timed out during operation No information available at time of print.
9133 Never started receiving message No information available at time of print.
CAN timed out during operation C5.E detected
9134 No information available at time of print.
by AIC
CAN timed out during operation JSC detected
9135 No information available at time of print.
by AIC
9136 CAN time out speed limit module C5F No information available at time of print.
9138 HW Part number unknown in SW No information available at time of print.
 4005-51

DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR

9140 LogicalError in list0 No information available at time of print.

9141 LogicalError in list1 No information available at time of print.
9142 Logical Error in list2 No information available at time of print.
9143 Logical Error in list3 No information available at time of print.
9144 Logical Error in list4 No information available at time of print.
9145 Logical Error in list5 No information available at time of print.
9146 Logical Error in list6 No information available at time of print.
9147 Logical Error in list7 No information available at time of print.
9151 Logical Error when retrieving flash data No information available at time of print.
9152 Logical Error when retrieving flash data No information available at time of print.
9153 Logical Error when retrieving flash data No information available at time of print.
9154 Logical Error when retrieving flash data No information available at time of print.
9155 Logical Error when retrieving flash data No information available at time of print.
9156 Logical Error when retrieving flash data No information available at time of print.
9157 Logical Error when retrieving flash data No information available at time of print.
1. CAN communication interrupted during normal
operation.
2. Faulty reading from component.
3. Connectors not mated fully, pins not pushed into
9160 HourMeter Failure - Both copies are wrong connector fully, bent pin or broken wire at rear of
connector.
4. Wiring or circuits open.
5. Wiring or circuits shorted.
1. CAN communication interrupted during normal
operation.
2. Faulty reading from component.
HourMeter Failure - One of two copies are 3. Connectors not mated fully, pins not pushed into
9161
wrong connector fully, bent pin or broken wire at rear of
connector.
4. Wiring or circuits open.
5. Wiring or circuits shorted.
1. CAN communication interrupted during normal
operation.
2. Faulty reading from component.
HourMeter Failure - Pre-crank and after-crank 3. Connectors not mated fully, pins not pushed into
9162
check are wrong connector fully, bent pin or broken wire at rear of
connector.
4. Wiring or circuits open.
5. Wiring or circuits shorted.
9180 VCM controller CAN timeout No information available at time of print.
9181 VCM controller CAN did not start No information available at time of print.
Wheel Loader Configuration Plausibility
9182 No information available at time of print.
Failure - Wrong engine type
4005-52

NOTE
 SECTION INDEX

STEERING

Section Title Section Number

Removal and Installation of Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5001

Steering Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002
Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005
Center Pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006
Auxiliary Steering Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5008
Joystick Steering System (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5009
 5001
Section
5001

REMOVAL AND INSTALLATION OF

STEERING COMPONENTS
5001-2

TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
 5001-3

STEERING CONTROL VALVE

Removal STEP 8
NOTE: When disconnecting hydraulic fittings, plug hoses
and cap fittings to prevent entry of foreign matter into
hydraulic system.

STEP 1
Park loader on level ground and lower bucket to
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down engine.

STEP 2
Put master disconnect switch in OFF position.
BD07B099

STEP 3 Pull floor mat away from the column.

Remove the front skirt from the cab or canopy.
STEP 9
STEP 4
Remove all dirt and grease from steering control
valve.

STEP 5
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.

STEP 6
Tag hoses connected to steering control valve.

STEP 7 BD07B100

Remove the mounting screws from the lower trim.

STEP 10

BD06G262
Disconnect hoses from steering control valve, cap or
plug the fittings and hoses, turn off the vacuum
pump.
BD07B101

Tilt the steering wheel and remove the mounting

screws from lower trim, remove the trim.
5001-4
STEP 11 Installation
STEP 12

1 2

BD07B102

Remove the four mounting bolts for the steering

control valve, two shown and two in the front. BD07B141

IMPORTANT: Have an assistant support and remove the Put the rubber bushing (1) on the spacer with the
valve while removing the mounting bolts. tapered end towards the steering valve. Rubber
bushing (2) is mounted between the cab and the
steering valve.

STEP 13
Put one rubber bushing on the sleeve and place in
the mounting hole and hold in place, have an
assistant push the other rubber bushing onto the
sleeve.

STEP 14
Have an assistant push the valve into place while
turning the steering shaft, this will engage the
splines.

STEP 15

BD07B102

Install and tighten the four mounting bolts for the

steering control valve, two shown and two in the
front.
NOTE: Finger tighten all bolts before tightening, check for
proper wheel operation after tightening.
 5001-5
STEP 16 STEP 19

BD07B101 BD06G262

Install the lower trim onto the column, tilt the steering Start the vacuum pump, remove the caps and plugs
wheel and install and tighten the mounting screws. the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
STEP 17 removal, remove and discard the tags.

STEP 20
Remove the vacuum pump from the reservoir, install
and tighten the reservoir fill cap.

STEP 21
Put battery disconnect switch in ON position. 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.

BD07B100
STEP 22
Install and tighten the mounting screws into the lower Install the front skirt onto the cab or canopy.
trim.
STEP 23
STEP 18 Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.

BD07B099

Put floor mat back into position on the cab floor.

5001-6

AUXILIARY STEERING PRIORITY VALVE

Removal Installation
1. Park loader on level ground and lower bucket to 1. Install and tighten cap screws (1).
ground. Put transmission in NEUTRAL, apply 2. Connect and tighten pressure hose (9).
parking brake, and shut down engine,
3. Connect and tighten pressure hose (5).
2. Put master disconnect switch in OFF position.
4. Connect and tighten steering pressure hose (7).
3. Remove all dirt and grease from auxiliary
5. Connect and tighten steering load sensing hose
steering priority valve and adjacent area. See
(3).
illustration on page 7.
6. Connect and tighten load sensing hose (4).
4. Remove hydraulic reservoir fill cap.
7. Connect electrical connector to the pressure
5. Connect a vacuum pump to hydraulic reservoir.
switch (8).
6. Start vacuum pump.
8. Connect electrical connector to the steering
7. Tag and disconnect tank return tube (6) from the solenoid (2).
priority valve. Install a cap on the elbow and a
9. Start vacuum pump.
plug in the tube.
10. Connect and tighten tank return tube (6).
8. Stop the vacuum pump.
11. Stop vacuum pump. Disconnect vacuum pump
9. Tag and disconnect the wiring from the steering
from hydraulic reservoir.
solenoid (2).
12. Install fill cap on hydraulic reservoir.
10. Tag and disconnect the wiring from the pressure
switch (8). 13. Put battery disconnect switch in ON position.
Start engine and run at low idle for 30 seconds.
11. Tag and disconnect load sensing hose (4) from
Stop engine and check for leaks.
auxiliary steering priority valve. Install a cap on
the elbow and a plug in the hose. 14. Check to make sure priority valve operates
correctly. See Section 5002.
12. Tag and disconnect load sensing hose (3) from
the priority valve. Install a cap on the elbow and 15. Check fluid level in hydraulic reservoir. Add oil as
a plug in the hose. required. See Section 1002 for specifications.
13. Tag and disconnect steering pressure hose (7)
from priority valve. Install a cap on the fitting and
a plug in the hose.
14. Tag and disconnect pressure hose (5) from
priority valve. Install a cap on the fitting and a
plug in the hose.
15. Tag and disconnect pressure hose (9) from
priority valve. Install a cap on the fitting and a
plug in the hose.
16. Support auxiliary steering priority valve. Remove
cap screws (1).
17. Remove auxiliary steering priority valve.
 5001-7

3 4

7
8 6

9
10
BS07D339

1. CAP SCREWS 6. TANK RETURN TUBE

2. STEERING SOLENOID 7. STEERING PRESSURE HOSE
3. STEERING LOAD SENSING HOSE TO PRIORITY VALVE 8. PRESSURE SWITCH
4. STEERING LOAD SENSING HOSE TO STEERING VALVE 9. PRESSURE HOSE
5. PRESSURE HOSE PUMP OUTPUT 10. INLET HOSE TO PUMP
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION
5001-8

AUXILIARY STEERING PUMP AND MOTOR

Removal 6. Connect ground cable (1) to ground stud of

auxiliary steering pump and motor (6) 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, 7. Connect positive cable (2) to B+ stud of auxiliary
steering pump and motor (6) following tag
2. Put master disconnect switch in OFF position. installed during removal.
3. Tag and disconnect two wiring harness from 8. Connect wiring harness wires to auxiliary
auxiliary steering pump and motor solenoid. See steering pump and motor following tags installed
illustration on page 9. during removal.
4. Tag and disconnect positive cable (2) from B+ 9. Put master disconnect switch in ON position.
stud of auxiliary steering pump and motor (6).
10. 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 instrument cluster is
(6). 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.
8. Start vacuum pump.
11. With engine at low idle and machine steering
9. Disconnect suction hose (5). Install a plug in straight ahead, turn key switch to OFF position to
suction hose and cap on fitting. stop engine and then immediately back to ON
10. Stop vacuum pump. position (not START position). Auxiliary steering
pump and motor should start operating
11. Disconnect pressure hose (4). Install a plug in immediately. Check that auxiliary steering light
suction hose and cap on fitting. on instrument cluster is ON and auxiliary steering
12. Support auxiliary steering pump and motor (6). pump and motor is operating.
Remove nuts (3), cap screws, and washers 12. Turn steering wheel all the way to left and right to
securing auxiliary steering pump and motor (6). make sure that auxiliary steering pump and
13. Remove auxiliary steering pump and motor (6). motor operates correctly.
13. Restart engine. Check that auxiliary steering light
on instrument cluster stays ON and auxiliary
steering pump and motor is operating. After
Installation about three seconds motor should stop operating
1. Position auxiliary steering pump and motor (6) on and auxiliary steering light should go out.
its mounting plate, have an assistant install cap 14. Let engine run and allow batteries to recharge for
screws, washers, and nuts (3) to secure auxiliary a minimum of 10 minutes.
steering pump and motor (6), tighten the nuts.
See illustration on page 9.
2. Remove plug from pressure hose (4) and cap
from elbow. Connect pressure hose to the
auxiliary steering pump and motor (6).
3. Start vacuum pump.
4. Remove plug from suction hose (5) and cap from
elbow. Connect suction hose to elbow installed in
auxiliary steering pump and motor (6).
5. Stop and disconnect vacuum pump. Install fill
cap in hydraulic reservoir.
 5001-9

3
2
4

BS07D349

1. GROUND CABLE 4. PRESSURE HOSE

2. POSITIVE CABLE 5. SUCTION HOSE
3. NUT (4) 6. AUXILIARY STEERING PUMP AND MOTOR
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
5001-10

STEERING CYLINDER

Removal Installation
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 Ma ke su re th at wa shers (4) are installed
fill cap. between steering cylinder (11) and rear frame.
See illustration on page 11.
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 steering
11. cylinders (11) if possible. If only one washer (4) can be
installed, place washer (4) at bottom of steering cylinders
3. Disconnect hydraulic hoses (2, 3, 9, and 10) from
(11).
steering cylinders (11).
2. Make sure washers (14) are installed between
4. Install a plug in each hose (2, 3, 9, and 10) to
steering 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 after
12. Remove steering cylinders (11). tightening.
7. Connect hose assemblies (2, 3, 9, and 10) to
steering cylinders (11).
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.
 5001-11

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
5001-12

STEERING BACK PRESSURE VALVE

Removal Installation
1. Remove the fill cap for the hydraulic reservoir to 1. Install the valve, bolts, spacers and nuts onto the
release pressure in the reservoir, 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.
6. Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
 5001-13

1
2

4
7 5
6

BS07D334

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

5001-14
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
 5002-3

SPECIAL TOOLS

B785789 B009638

380001731 FLOWMETER 380001739 PRESSURE TEST FITTING KIT

B797157

380001740 FLOWMETER FITTING KIT

TROUBLESHOOTING THE STEERING SYSTEM

NOTE: The steering hydraulic schematic is included in the 3. Do the main hydraulic pump test. See Section
hydraulic schematic. Refer to the rear pocket of this 8002. If the main pump is bad, repair or replace
manual. the main hydraulic pump.
1. Make sure the oil level in the hydraulic reservoir 4. Test the steering cylinders for leakage, refer to
is correct. Visually inspect the steering system instructions on page 10. If a steering cylinder is
for leakage and damage. leaking, repair or replace the steering cylinder.
2. Do the steering relief valve pressure test. Refer
to page 7. If the pressure is above or below
specifications, adjust the steering relief valve in
the loader control valve.
5002-4

AUXILIARY STEERING SYSTEM PUMP TEST

Equipment Required
1. 380001731 Flowmeter
2. 380001740 Flowmeter fitting kit

Test Procedure
1

BB830300

1. AMMETER CLAMP
6. Connect the ammeter clamp (1) to the cable as
1 in illustration above.
7. Make sure that the parking brake is applied and
the bucket is on the floor.
BD00M030
8. Make sure that the oil is at operating
1. ARTICULATION LOCK temperature.

1. Install articulation lock. 9. Make sure that the load valve for the flowmeter is
open (zero pressure).
NOTE: When performing this pressure check, always be
sure the articulation lock is in place, especially when 10. Start and run the engine.
working in the articulation joint areas. 11. Stop the engine and turn the key back to the On
2. Loosen and remove the outlet hose of the position.
Auxiliary Steering Pump from the Steering 12. Turn the steering wheel, this will activate the
Priority Valve. auxiliary steering pump.
3. Install a plug into the hose. 13. Turn the load valve on the flowmeter towards
4. Connect the inlet of the flowmeter to the outlet CLOSED until the pressure is 104 bar (1500 psi).
fitting on the Steering Priority Valve. 14. Read the flowmeter and ammeter gauges and
5. Install the outlet hose of the flowmeter in the record the readings.
hydraulic reservoir and hold in place with wire. 15. The flowmeter reading must not be less than
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
1. A 24 volt battery that is fully charged. 2
1
NOTE: A 24 volt battery system (two 12 volt batteries in a
series) is used for this test. A 12 volt battery system will
cause damage to the auxiliary steering motor. 4
3
2. A remote starter switch.
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
System Tester.
5
Test Procedure B790852

1. Remove the connector that is between the 1. REMOTE STARTER SWITCH

terminals on the magnetic switch and the 2. TESTER
3. AUXILIARY STEERING MOTOR
auxiliary steering motor.
4. AMMETER CLAMP
2. Remove the auxiliary steering motor from the 5. 24 VOLT BATTERY SYSTEM
auxiliary steering pump.
3. Remove the drive coupling from the auxiliary
steering motor (3).
4. Connect the auxiliary steering motor (3), remote
starter switch (1) and tester (2) to the 24 volt
battery system (5) as illustrated in Figure 3. 8
6 7
5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
6. Turn the load control (8) until the voltmeter (7)
indicates 24 volts. Refer to figure 4. Look at the
ammeter (6) in the tester. Make a record of the
ammeter indication.
B795328
7. Hold the tachometer against the armature shaft.
Look at the tachometer. Make a record of the 6. AMMETER
7. VOLTMETER
indication.
8. LOAD CONTROL
8. Release the button on the remote starter switch
(1).
5002-6

UNDERSTANDING THE RESULTS OF THE TEST

1. If the ammeter indication in step 6 was 30 4. If the armature did not turn, and the ammeter
amperes or less and the tachometer indication in indication was zero amperes, possible causes
step 7 was 6950 r/min (rpm) or more, the include the following:
auxiliary steering motor is good.
A. An open field coil.
2. If the armature speed was less than 6950 r/min
B. An open armature coil. After the motor is
(rpm) and the ammeter indication was higher
disassembled, look at the commutator on the
than 30 amperes, possible causes include the
armature. If the commutator is badly burned,
following:
the armature coil is probably open.
A. Damaged bearings.
C. Broken brush springs or worn brush springs.
B. Loose pole shoes.
5. If the armature speed was less than 6950 r/min
C. A short circuit in the armature coil. The (rpm) and the ammeter indication was less than
armature coil must be checked on an 30 amperes, possible causes include the
armature tester after the motor is following:
disassembled.
A. Bad connections between the brushes and the
D. A ground connection in the field coil. field coil.
3. If the armature did not turn and the ammeter B. Dirty commutator.
indication was higher than 30 amperes, possible
6. If the armature speed was 6950 r/min (rpm) or
causes include the following:
more and the ammeter indication was more than
A. The motor terminal is in contact with the field 30 amperes, there is probably a short circuit in
frame. the field coil. A short circuit in the field coil is
difficult to find. It is recommended that a new
B. A damaged bearing that will not let the
field frame assembly be installed.
armature turn.
 5002-7

STEERING RELIEF VALVE

NOTE: The pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002 Testing and
Adjusting the Pump Differential Pressure.

Pressure Setting Test

1
1

BD03A092

1. SAFETY LINK
BD03A092

1. SAFETY LINK
3. Remove the safety link (1) and lower the loader
arms to the ground.
1. Install the safety link (1) and lower the loader
arms slowly, until the safety link is supporting the 4. Stop the engine.
loader arms.

1
BD00M030

BD00M041 1. ARTICULATION LOCK

1. COVER PLATE
5. Install articulation lock (1).
2. Remove the cover plate (1) to gain access to the IMPORTANT: When performing the following pressure
loader control valve. check and adjustment, the articulation lock must be
installed. Use caution when working in or near the
articulation area.
5002-8
6. Make sure that the temperature of the hydraulic
oil is at least 52° C (125° F).
7. To measure the temperature of the oil using the
instrument panel:
A. Press the program switch (left side of the
program/reset switch).
B. Press the up count switch to function 008.
C. Return the program switch to the OFF (center)
position.
1
8. Apply the parking brake.
2
9. Start and run the engine at full throttle. BD00N018

10. Hold the bucket control lever in the rollback 1. LOADER CONTROL VALVE
position. 2. PUMP PRESSURE TEST
PORT
11. Hold the lift lever in the “FLOAT” position.
15. Remove the dust cap from the test port (2).
12. Continue holding until the specified temperature
16. Connect a 345 bar (5000 psi) pressure gauge to
of the oil is reached.
the test port (2) on the front of the loader control
13. Stop the engine. valve (1).
14. Remove the cap on the hydraulic reservoir to NOTE: Make sure when you connect the pressure gauge
release any pressure in the hydraulic system. that you do so in a manner that you can read the pressure
gauge while sitting in the operators seat.
17. Start the engine and operate the machine at full
throttle.
18. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
19. Continue holding the steering wheel, and read
the pressure gauge.
20. The pressure gauge must indicate 239 to 243
bar (3465 to 3523 psi). If the pressure is not
correct, adjust the steering relief valve.
 5002-9

Pressure Setting Adjustment

1
1

BD03A092

1. SAFETY LINK
BD03A092

1. SAFETY LINK
3. Remove the safety link (1), and lower the loader
arms to the ground.
1. Install the safety link (1) before adjusting the
steering relief valve. 4. If the pressure gauge is still connected, repeat
steps 17 through 20 in the Pressure Setting Test
Procedure. If the pressure gauge is not
connected, do the entire Pressure Setting Test
Procedure.
5. If necessary, adjust the relief valve again until
the relief valve is within the specified range.
6. Stop the engine before removing the pressure
gauge.

BS01A046

1. LOADER CONTROL VALVE

2. STEERING RELIEF VALVE

2. Turn the adjusting screw clockwise to increase

the pressure setting. Turn the adjusting screw
counterclockwise to decrease the pressure
setting.
NOTE: 1/4 turn of the adjusting screw will change the
pressure by approximately 35 bar (500 psi).
5002-10

STEERING CYLINDER LEAK TEST

NOTE: Make sure all persons are clear of the area of the 9. Connect the tube to the rod end of the left-hand
center pivot. Make sure the center pivot is free of any steering cylinder.
obstructions.
10. Turn the machine all the way to the left.
1. Park the machine on a level surface.
11. Stop the engine.
2. Turn the machine all the way to the right.
12. Find the tube that is connected to the rod end of
3. Stop the engine and apply the parking brake. the right-hand steering cylinder. Disconnect the
tube from the right-hand steering cylinder.
4. Find the tube that is connected to the rod end of
the left-hand steering cylinder. Disconnect the 13. Install a plug in the tube.
tube from the left-hand cylinder.
14. Start and run the engine at full throttle.
5. Install a plug in the tube.
15. Turn the steering wheel to the left. Hold the
6. Start and run the engine at full throttle. steering wheel for a full left turn. Have another
person check for leakage at the opening of the
7. Turn the steering wheel to the right. Hold the
rod end of the right-hand steering cylinder.
steering wheel for a full right turn. Have another
person check for leakage from the opening of the 16. If there is constant leakage from the rod end, the
rod end of the left-hand steering cylinder. piston packing in the right-hand steering cylinder
is damaged. Repairs must be made. See Section
8. If there is constant leakage from the rod end, the
5005.
piston packing in the left-hand steering cylinder
is damaged. Repairs must be made. See Section 17. Connect the tube to the rod end of the right-hand
5005. steering cylinder.
 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.
2. Remove gland (1) from tube (18). If piston rod is bent, install a new piston rod.
3. Pull piston rod (14) and piston (9) straight out of 3. Inspect inside of tube (18) for deep grooves and
tube (18). other damage. If there is any damage to tube, a
new tube must be used.
4. Fasten piston rod (14) yoke in vise and put a
support below piston rod near piston (9). Put a 4. Remove small scratches on piston rod (14) or
shop cloth between support and piston rod to inside tube (18) with emery cloth of medium grit.
prevent damage to piston rod. Use emery cloth with a rotary motion.
5. Loosen and remove bolt and washer (8) that hold 5. Inspect bushing (17). If bushing requires
piston (9). replacement, remove grease fitting (15) and
retaining rings (16) then press bushing from tube
6. Remove piston (9) from piston rod (14).
end.
7. Remove and discard seal (13), loader ring (12),
wear ring (11), 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 part B. Install and tighten self-tapping screw (19) to a
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
(250 to 350 pound-feet).
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
380001730....................................................................................................................... Hand pump (hydraulic ram)

380001734....................................................................................................................................... 10 ton ram (long)

380001735........................................................................................................... Puller set, includes 24827 leg ends

380001736................................................................................Bearing cup and seal puller, includes 24850 adapter

380001729..............................................................................................................................Vacuum pump (12 volt)

380001744................................................................................ *Top bearing driver, bottom bearing driver and plate

* (Requires screw, two nuts, and two washers from 380001735)

BC06A174
380001744 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).
39. Apply the parking brake.
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
8. Tighten a nut (18) on the screw (19) until the
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.
11. Tighten a nut (18) on the screw (19) until the
bearing retainer (7) is tight against the upper
pivot bearing assembly (9).

17 18 19 27
7

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

26. Tighten a nut (18) on the screw (19) until the

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

30. Tighten a nut (18) on the screw (19) until the

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).
34. Tighten a nut (18) on the screw (19) until the
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
(45 to 60 pound-feet).
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.
illustration 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
5009

JOYSTICK STEERING SYSTEM

(JSS)

5009
5009-2

TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
JOYSTICK STEERING SYSTEM (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of the JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F-N-R Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Procedures for Turning the JSS On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Kick-down Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustration of the valve PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Illustration of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEERING VALVES PVG32 AND PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
JSS HYDRAULIC PRESSURE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Steering Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
STEERING SPEED CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
 5009-3

SAFETY RULES

WARNING
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 machine damage, serious injury, or death.
M171C

WARNING
Be cautious when turning with joystick steering. Abrupt movements of the joystick to the left or right could cause the machine to
turn more sharply than acceptable. Take necessary precautions. Do not use the joystick for primary steering. It is intended for
short repetitive operations. Failure to comply could result in machine damage, death or serious injury.
M1336
.

WARNING
If hydraulic pilots are disengaged, the joystick steering still remains active. Always disengage joystick steering when not in use.
Failure to comply could result in machine damage, death or serious injury.
M1348

WARNING
Do not use joystick steering when loading or unloading the machine from a truck or trailer. Always use the primary steering
wheel when loading or unloading the machine from transport. Failure to comply could result in machine damage, death or
serious injury.
M1345

WARNING
Use caution when moving about in the operator’s compartment when joystick steering is active. An inadvertent movement
against the joystick steering control could cause the machine to turn or move abruptly. Failure to comply could result in machine
damage, death or serious injury.
M1347

WARNING
Do not use joystick steering when traveling on a public road or highway. The left arm rest must be raised and in a locked
position. Use the primary steering wheel if travel on a public road or highway is required. Failure to comply could result in
machine damage, death or serious injury.
M1346

WARNING
Do not use joystick steering if operating at speeds over 20 km/h (12.4 mph). Always use the primary steering wheel at higher
speeds for optimum control of the machine. Failure to comply could result in machine damage, death or serious injury.
M1349
5009-4

JOYSTICK STEERING SYSTEM (JSS)

Description of the JSS Preliminary check

The JSS is mounted in parallel with the standard Preset condtion must be met by:
steering system. The standard steering system ● left armrest completely lowered
always has priority. If during joystick operation, the ● gear lever in neutral
primary steering wheel is moved, steering will revert
to primary steering. Joystick steering is designed for ● equipment locking switch disenabled
short, repetitive machine operations. ● pilot pressure switch on
● joystick steering switch in neutral
WARNING ● machine is stationary.
Do not use joystick steering if operating at speeds over 20
km/h (12.4 mph). Always use the primary steering wheel System efficiency check
at higher speeds for optimum control of the machine.
● with the JSS off, the pilot pressure must be less
Failure to comply could result in machine damage, death
than or equal to 8 bar (115 psi).
or serious injury.
M1349
the software monitors the armrest position switch.
When the JSS is turned on and during operation,
the switch position is checked. If the position of the
3 armrest is raised or the switch is shorted, the
system will deactivate.

After all conditions have been met, the JSS will be

powered by closing PIN 1:21 of the output AIC that
switches over the relay K2 enabling the electric
supply of the JSS with consequent activation of the
system under safety conditions.
The system will stay active if the following conditions
are maintained:
the left armrest stays lowered
4 1
the main gear lever stays in neutral
5 the steering wheel stays inactive
the control switch stays ON
no system errors occur
2
Joystick steering is turned off as soon as:
the left armrest is raised.
521E-4R001 the gearbox / main lever control is moved from
1. JOYSTICK STEERING CONTROL neutral to forward or reverse drive.
2. ARMREST
3. MONITOR the steering wheel is operated.
4. FORWARD - NEUTRAL- REVERSE SWITCH
the proportional valve suffers trouble.
5. KICK-DOWN BUTTON
system errors occur.
Activation logic of the software and
joystick steering the JSS switch is disconnected.

To activate the joystick steering system, it is ignition turned off.

necessary that the machine meet specific conditions
prior to activation. The software will run a preliminary
test to verify the machine is in the preset conditions
and check the condition of the JSS system.
 5009-5

ALARM In order to activate the JSS F-N-R switch, it is

An audible alarm and a message on the instrument necessary to check the position of the switch
cluster display will indicate the JSS is not functioning. A. the JSS F-N-R switch must be in neutral
To reactivate the JSS, turn the switch OFF and back B. if the JSS F-N-R switch is not in neutral, move
to the ON position. the JSS F-N-R switch to the neutral position
Errors for the JSS system are only displayed when and the system will be activated without
the JSS switch is in the ON position. They can be pressing the JSS activation switch again
reset by cycling the JSS switch to OFF and then back The JSS F-N-R switch is deactivated when the
to the ON position. JSS is turned OFF

F-N-R Switch Turning the JSS ON

The joystick steering system requires the integration Press the JSS switch to the ON position
of third F-N-R switch. The software of the A. the armrest on left-hand side must be lowered
transmission control unit (TCU) is able to turn the B. loader locking switch disabled
F-N-R switch on the armrest ON/OFF when the JSS
is activated. C. JSS pilot pressure must be low
D. JSS joystick in neutral
Locations of F-N-R switches E. no error in the JSS system
1. Main F-N-R located on steering column F. steering column F-N-R lever in neutral
2. AUX F-N-R on the equipment control joystick (or G. vehicle stationary
on right-hand console)
3. AUX JSS F-N-R on the armrest on the left-hand The JSS is turned OFF by one of the following:
side A. Using the steering wheel
B. F-N-R lever on the steering column is moved
Procedures for Turning the JSS On out of the neutral position
and Off C. armrest on left-hand side is raised
Of the three F-N-R controls, the one on the steering D. JSS switch is turned OFF
column has priority over the two auxiliary F-N-R
switches. The auxiliary F-N-R switches have a E. an error occurs in the JSS system
specific signal when activated. If activated, the JSS F. ignition switch is turned OFF
F-N-R switch on the left-hand armrest has priority
over the F-N-R switch on the equipment control Kick-down Button
joystick (or on right-hand console).
The joystick steering system in the left arm rest
Steering Column F-N-R Lever features a kick down button that can be activated
when the JSS system is activated.
The steering column F-N-R lever is always active
The steering column F-N-R lever has priority over
all the auxiliary F-N-R switches
One of the auxiliary F-N-R switches can be
activated only if the steering column F-N-R lever is
in neutral

Activation Procedure For Auxiliary JSS F-N-R

The JSS F-N-R switch is in the left-hand side
armrest:
The JSS F-N-R switch will be enabled with the
activation of the JSS
When the JSS is activated, a message is sent via
CAN to the transmission control unit (TCU)
This will activate the JSS F-N-R switch
5009-6
Summary table of the ON/OFF statuses
State of activation of the JSS, JSS F-N-R and auxiliary F-N-R:

Starting JSS OFF JSS OFF JSS OFF JSS ON

status

JSS / AUX F-N-R (JSS) AUX F-N-R JSS / AUX F-N-R JSS (AUX) F-N-R
disabled enabled disabled enabled

Activation JSS activation signal JSS activation signal Auxiliary F-N-R F-N-R enable signal
signal enabling signal or JSS enable signal

JSS safety ƒ Equipment locking ƒ Equipment locking

conditions to switch disabled; switch disenabled;
ƒ Armrest on left-hand ƒ Armrest on left-hand
be met
side lowered; side lowered;
ƒ Vehicle stationary; ƒ Vehicle stationary;
ƒ Main F-N-R gear ƒ Main F-N-R gear
lever = neutral; lever = neutral;
ƒ JSS pilot pressure ƒ JSS pilot pressure
less than 8 bar; less than 8 bar;
ƒ JSS Joystick = ƒ JSS Joystick =
neutral; neutral;
ƒ No errors on JSS ƒ No errors on JSS
system. system.

Resulting ƒJSS ON ƒJSS ON ƒJSS OFF ƒJSS ON

JSS status

F-N-R ƒ JSS ON ƒ JSS ON ƒ Vehicle stationary; ƒ Vehicle stationary

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

Resulting ƒ JSS F-N-R Enabled ƒ JSS F-N-R Enabled ƒ AUX F-N-R ƒ JSS F-N-R
F-N-R ƒ Stays enabled. ƒ Stays enabled. Enabled Enabled
ƒ within 8 seconds
status
release parking
brake and engage
F or R to maintain
enabling.

F-N-R ƒ If JSS F-N-R not in ƒ If JSS F-N-R not in ƒ If AUX F-N-R not in
conditions neutral. neutral. neutral.
not met

F-N-R ƒ JSS / AUX F-N-R ƒ JSS / AUX F-N-R ƒ JSS / AUX F-N-R
alternative disabled. disabled. disabled.
status
 5009-7
ERROR CODES
Errors for the JSS will only be displayed if the switch is in the ON position.
The errors can be reset by turning the JSS system OFF and On. The following two errors will not reset:
1821r Power Supply Failure 1830y Activation Switch failure.
The errors will always be shown on the display once they are present. To reset these errors the engine must be
turned off.
ERROR CODES TABLE

Error
Item Error Message
1 1812 JSS Failure Armrest Switch- short to battery or ground
2 1816 JSS Activation Button Failure – mechanical defect
3 1820 JSS Power Supply Failure – check JSS relay, valve, or joystick
4 1821 JSS Short to ground or power on relay, or activation switch
failure
5 1823 JSS Relay Ground Failure
6 1824 JSS Activation Switch Short to Battery
7 1830 JSS Activation Switch failure
8 1831 JSS Error JSC – wrong operation, controller internal fault
9 1832 JSS Signal Input Error JSC – controller out of limits
10 1833 JSS Signal Output Error JSC – controller out of limits
11 1834 JSS JSS controller, JSC output, short to BAT power
12 1835 JSS Valve Failure Power Supply
13 1836 JSS JSS controller, board temperature out of limts
14 1837 JSS JSS controller, switched power out of limits
15 1838 JSS Neutral switch out of range
16 1839 JSS Joystick steering is not calibrated
17 1841 JSS Valve Alarm
18 1842 JSS Valve Alarm Open Circuit
19 1843 JSS Pilot Pressure is High
20 1844 JSS Pilot Pressure Switch Short to Ground
21 1845 JSS Pilot Pressure is Low
22 1846 JSS Failure on LS Pressure Switch
23 1847 JSS JSC model type not available
24 1850 JSS Joystick Failure - Neutral Switch / Power Supply
25 1852 JSS Error in Ground Connection
26 1860 JSS CAN timeout of C5.E detected by JSC
27 1861 JSS CAN timeout of AIC detected by JSC controller
28 1863 JSS Internal malfunction transmission controller
29 9134 JSS CAN communication failed
30 9135 JSS CAN communication failed
5009-8

210 bar
3

211.6 bar
1
210 bar
2

W190-4R091
ILLUSTRATION OF THE VALVE PVFC

Connections
Port 1 - to the steering priority valve
Port 2 - to the auxiliary steering valve
Port 3 - to the LS port of the valve PVG32
 5009-9

TO
T

LX

PP
A T2
B
P

W190-4R092
ILLUSTRATION OF THE VALVE PVG32

Connections
Ports A / B to the steering cylinder on the stem Port PP pilot pressure switch 8 bar
side and bottom side 350 bar, 65 l/min Port T outlet 25/40 bar
LS port to port 3 of the valve PVFC Port T2 not used
Port P to the steering priority valve 350 bar, 65 Port TO LX not used
l/min
5009-10

2
6

9
11

4
3
8
10

1
5

W190-4R099
EXPLODED VIEW OF THE VALVE PVG32

1. Valve PVPV 7. Screws

2. Valve PVM 8. Seal
3. Valve PVB 9. Seal
4. Shuttle PVBS 10. Seal
5. Valve PVES 11. Seal
6. Shuttle PVSI
 5009-11

ELECTRICAL SYSTEM

Removal STEP 4

STEP 1
Park loader on level ground and lower bucket to 1
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down engine. Put the master
disconnect switch in the OFF position.

STEP 2 11
Remove all dirt and grease from the steering system
valves and adjacent area.
IMPORTANT: Tag all connections prior to disassembly.
9
STEP 3 10

1
3
W190-4R072
Remove nut (11) from the stud (9) to release the
2 chassis grounding cable (1).

4 STEP 5
7

2
8
5
6
W190-4R071

Disconnect the chassis harness (1) from the valve

PVG32 (2). Disconnect connector (3) from the pilot
pressure switch, connector (4) from the proportional
valve, connector (5) from the solenoid valve. From
the PVFC valve (6) disconnect connector (7) and
remove strap (8). 1

W190-4R073
Open the access panel on the right-hand side of the
cab to access the fuse and relay compartment.
Disconnect the connector from the chassis harness
(1) from the joystick cable (2). Remove the chassis
frame cable (1).
5009-12
STEP 6 STEP 8

5
2

3 8

2
W190-4R074
Disconnect the joystick harness (2) from the cab
wiring harness (3). W190-4R076

Disconnect the joystick cable (2) from the steering

STEP 7 control module (5) by detaching the sixteen-position
connector (6). Disconnect connector (7) from the
transmission switch and the cab harness connector
(8).

3 STEP 9
1

10
2
W190-4R075
9
Disconnect the connector (1) from the joystick 5
harness (2). Disconnect the armrest harness (3) from
the six-position connector (4). 12
11
W190-4R077

Remove the steering control module (5) from the

supporting plate (9) by removing the three nuts (10),
capscrews (11) and washers (12).
 5009-13
STEP 10

6 2
3
4

W190-4R078
Detach the joystick harness (1) from the mounting
brackets on the fuse and relay panel (2). Remove the
two connectors (3) by removing the two nuts (4),
washers (5) and capscrews (6). Remove the joystick
harness (1).

STEP 11

W190-4R080
To remove the armrest harness (9), see page 30.
5009-14

Installation STEP 14

STEP 12

1
3

4 12
7
14

13

16

15
8 W190-4R083
5 Open the access panel on the right-hand side of the
cab to access the fuse and relay compartment. Install
6
the steering control module (12) on the supporting
W190-4R071
plate (13) by installing the three nuts (14), capscrews
Connect the chassis harness (1) to PVG32 valve (2),
(15) and washers (16). Tighten the capscrews.
connect connector (3) to the pilot pressure switch
connector (4). Connect connector (5) to the solenoid
valve. Connect connector (7) to the pressure switch
on valve PVFC (6) and secure the harness with strap STEP 15
(8) on the valve.
4
STEP 13 1

5
1

11 6

7
10
W190-4R088
Connect the chassis harness (1) to the grounding
stud (9), install and tighten the nut (11).
W190-4R084
Connect the joystick harness (1) to the steering
control module (4) with connector (5). Connect
connector (6) to the cab harness connector (7).
 5009-15
STEP 16 STEP 18
12 9
8 10

11
2

W190-4R085
Mount the joystick cable (1) to the fuse and relay
panel (9) by installing the two nuts (10), washers (11)
and capscrews (12). Tighten the capscrews.
1
STEP 17
W190-4R073
Connect connector (1) to the joystick harness (2).

14 STEP 19

13

1
W190-4R086
3
Connect the joystick harness (1) to the cab harness
(13) with connector (14).
W190-4R082
To install the armrest cable (3), see page 36.
5009-16
STEP 20

3 4

W190-4R087

Connect interface connector (4) of the joystick

harness (2), connect the armrest harness (3) to
connector (5).
 5009-17

8
14
D

C 20

19
12 11 10

27
28
15 29
F

16 Detail E
13 Detail C
view from F
view from D

18
1

1. Plate 18. Armrest cable

21 2. Steering control device 19. Control joystick
2 9 3. Cab/joystick cable 20. CAN Module
22 4. Chassis cable 21. Relays
23 5. Washer 22. Diode
3 6. Screw 23. 8 bar pressure switch
26 7. Nut 24. 60 bar pressure switch
6 5 8. Joystick Steering System 25. Steering valve PVFC
7
switch 26. Steering valve PVG32
24 9. Nylon strap 27. Armrest position switch
10. Screw 28. F-N-R switch
25 30 11. Washer 29. Kick-Down switch
17 12. Nut 30. Solenoid valve
4 13. 10A fuse in position ECA-F2
View from A 14. Cab
15. Stud pin on rear chassis frame
16. Cable terminal with eyelet
17. Metal cable clamp

721E-4R001

ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM

5009-18

84419913 SHT 13

WIRING DIAGRAM OF THE JOYSTICK STEERING SYSTEM

 5009-19

STEERING VALVES PVG32 AND PVFC

Removal STEP 3

STEP 1
Remove all dirt and grease from the steering valves
and adjacent areas. 5

STEP 2
4
2

2
W130R0043

Disconnect the tie flexible hose (4) from the valve

PVFC (2), with the solenoid valve of the emergency
3
steering assembly and the flexible hose (5) coming
from the tool distributor. Plug the flexible hoses in
order to avoid oil spillage and the fittings to prevent
debris from getting inside.

1 STEP 4

W130R0042

Detach the rigid steering pipe LS (3) from the valve

PVG32 (1) and from the valve PVFC (2).

W110R362

Disconnect the suction flexible hose of the solenoid

valve of the emergency steering assembly from the
valve PVG32.
5009-20
STEP 5 STEP 8

W190-4R005
Tag and disconnect the outlet hose.

STEP 6
1

3 4

W130R0044
Remove the steering valve PVG32 (2) from the
support bracket (1) by removing the four capscrews
(3) and washers (4).
W190-4R006
Tag and disconnect the supply hose to the steering STEP 9
cylinder line.

STEP 7

1
W190-4R007
Tag and disconnect the supply hose to the steering
2
cylinder line.

4
5 3
W130R0045
Remove the mounting bracket (1) from the rear
chassis removing three nuts (2), washers (3),
capscrews (4) and washers (5).
 5009-21
STEP 10 STEP 13

1 1

W190-4R010 W190-4R014
Remove the mounting bracket (1). Remove the pilot pressure switch (1) with seal (2)
from the steering valve PVG32.
STEP 11
STEP 14
1 8
7

9
10
6 3

W190-4R011
Remove the steering valve PVFC (6) from the W190-4R015
mounting bracket (1) by removing the two nuts (7), Remove the reduction fitting (3).
washers (8), capscrews (9) and washers (10).
STEP 15
STEP 12

14

14 4

2 W190-4R016
Unscrew the union (4) from the “LS” port of the
steering valve PVG32.
W130R0046
Unscrew the fittings (14) from the steering valve
PVFC (2).
5009-22
STEP 16 Installation
5 NOTE: Before assembling the steering valves, clean the
parts using solvent and dry them.
1. Inspect each part for defects.
2. Replace all damaged or deformed parts with new
ones.

STEP 19

1
W190-4R017
Remove the two fittings (5) from ports “A” and “B”.

STEP 17

W190-4R020
Install the joint (1) into port “T” of the steering valve
PVG32. Tighten the joint to 310 N m (230 pound
feet).
W190-4R018
Remove the fitting (6) from the port “P”. STEP 20
2
STEP 18

W190-4R021
Install fitting (2) into port “P”. Tighten the fitting to 170
N m (125 pound feet).

W190-4R019
Remove joint (7) from port “T”.
 5009-23
STEP 21 STEP 24

3 3

W190-4R025
W190-4R022
Install the two fittings (3) into ports “A” and “B”. Install the pilot pressure switch (3) with seal (4) into
Tighten the fittings to 100 N m (75 pound feet). the reducer (2).

STEP 22 STEP 25

6 8

1 5
W190-4R023
Install the firing (1) into port “LS”. Tighten the fitting to
45 N m (33 pound feet). W130R0047
Install fitting (6) into port “1” of the steering valve
STEP 23 PVFC (5), fitting (7) into port “2” and fitting (8) into the
port “3”. Tighten all the fittings to 45 N m
(33 pound feet).

STEP 26
1 4
3

W190-4R024
Install the reducer (2) for the pilot pressure switch on
the port “Pp”. Tighten the reducer to 45 N m (33 5 6
pound feet). 2
W190-4R028
Mount the steering valve PVFC (2) onto the mounting
bracket (1) using two capscrews (3), washers (4),
nuts (5) and washers (6).
5009-24
STEP 27 STEP 29

12

W190-4R010 1
Position the mounting bracket (1) for the steering
valves into the LH side rear chassis.

STEP 28

13
14

W130R0049
Install the steering valve PVG32 (12) onto the
mounting bracket (1) using the four capscrews (13)
and washers (14). Tighten the screws to a torque of
30 N m (22 pound feet).

STEP 30

8 10
11
W130R0048
Install three capscrews (7), washers (8), nuts (10)
and washers (11). Tighten the nuts to 110 N m (80
pound feet).

W190-4R007
Connect the stem side steering cylinder supply hose
onto the fitting. Tighten the hose to 60 N m (44 pound
feet).
 5009-25
STEP 31 STEP 34

1
2

W190-4R006
Connect the bottom side steering cylinder hose.
Tighten to a torque of 60 N m (44 pound feet). W130R0050
Connect the hose (2) and hose (3) to valve PVFC (1).
STEP 32 Tighten to 14 N m (10 pound feet).

STEP 35

W190-4R005
Connect and tighten the outlet hose to 125 N m (92 5
pound feet).

STEP 33

W130R0051
Connect the line for the “LS” (5) on the valve PVG32
(4) and on the valve PVFC (1). Tighten the line
14 N m (10 pound feet).

W190-4R004
Connect the suction hose of the steering priority
valve. Tighten the pipe to a torque of 60 N m
(44 pound feet).
5009-26
LEGEND OF JSS HYDRAULIC COMPONENTS WITH AUXILIARY STEERING SYSTEM (table 1)
1. Bracket valve steering
2. Proportional valve PVG32
3. Washer
4. Bolt
5. Valve PVFC
6. Connector
7. Tube steering LS
8. Connector
10. Hose to cylinder
11. Hose to tank
12. Connector
13. Connector
15. Elbow
16. Hose suction valve
18. Hose steering load sense
19. Washer
20. Nut
21. Bolt
22. Washer
23. Nut
24. Bolt
26. Switch pilot pressure
27. Seal
30. Hose steering LS
32. Reduction
33. Connector with orifice
34. Elbow
 5009-27

23 22 26
27 32 7 13 10
C

18 33 11 10
34

5
30
C
24
12
22 8
6
D 16

15

B 20
19
21

A-B

A
1

3
4

W130R0052

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERING SYSTEM - Table 1
5009-28

36

38
42
37

9
18 40
29
41 35
28

39
44

10

10

14 43

30

16

W130R0053

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERING SYSTEM - Table 2
 5009-29
LEGEND OF JSS HYDRAULIC COMPONENTS WITH AUXILIARY STEERING SYSTEM (table 2)
9. Connector
10. Hose to cylinder
14. Connector
16. Hose suction valve
18. Hose steering load sense
28. Hose right side rod
29. Hose steering cylinder
30. Hose steering LS
35. Connector
36. Connector
37. Hose steering return with Joystick Steering System
38. Connector
39. Hose bleeding to tank
40. Pressure trasmitter
41. Loader valve
42. Orbitrol valve
43. Manifold auxiliary steering
44. Reliefe valve
5009-30

JOYSTICK STEERING SYSTEM ARMREST

Removal STEP 3

STEP 1
3

1 6
4
W190-4R037

Remove the locking screws (6, qty. 4) of the cover of

W190-4R036 the armrest (3) from the support (4). Remove the
Unscrew and remove the knob (1) and the washer cover (3).
(2) for armrest adjustment.
STEP 4
STEP 2
8

4 7

9
5

W190-4R101
W190-4R035

Remove the cover (3) complete with support (4) from Disconnect the two-position “DEUTSCH” connector
the armrest adjustment device (5). (7) of the “Kick-Down” button (8) with the armrest
cable connector (9).
 5009-31
STEP 5 STEP 7

3
8 7 12
1

9 10

W190-4R102 11
From the inside and bottom of the armrest cover (1)
unscrew the threaded washer (2) and remove the W190-4R038

“Kick-Down” button (3). Remove the two nuts (8), washers (9), screws (10)
and washers (11) from the PVRES joystick (7).
STEP 6 Disconnect the connector (12) from the valve (7).

STEP 8
5

5 4 6 7
1

3
1

2
6
W190-4R040

Disconnect the connector (2) from the CAN module

(1). Release the armrest cable (3) from the mounting
4
bracket by removing the nut (4) and the washer (5),
capscrew (6) and the washer (7).

W190-4R103

Disconnect the connector (4) from the “F-N-R” switch

(5) from the armrest cable (6). Remove the switch (5)
from the armrest (1).
5009-32
STEP 9 STEP 11

12
1

10

2
W190-4R039

Detach the CAN module (1) from the support (8).

STEP 10
13
11
9

W190-4R041

Unscrew and remove the knob (10) for height

adjustment of the armrest and spacer (11). Raise
and remove the armrest (12) from the support (13).

W190-4R042
STEP 12
Disconnect the connector (9) from the armrest
positioning switch. Remove the armrest cable. 1

3 5

4 4
2 6
W190-4R043

Remove the armrest height / angle adjustment (2)

from the support assembly (1) by removing the nut
(3), washers (4), capscrew (5) and two nylon
bushings (6).
 5009-33
STEP 13 STEP 14

10 8 2
7 11
3

4
9
2 7
5 6
W190-4R104
W190-4R044
Remove the locking bracket (7) with pin (8) from the Unscrew the knob (2) from the support (1) and
armrest height/angle adjustment (2). Unscrew the extract the armrest height/angle adjustment pin (3).
two nuts (9), capscrews (10) and the washers (11). Remove the plate (4) from the support (1) by
Remove the pin (8) from inside the seat of the removing the four capscrews (5) with washers.
bracket (7). Remove the armrest position switch (6) from the
inside of the support (1) by removing the two screws
(7) and washers.

STEP 15

8 9

W190-4R045
Disconnect the wiring harness from the operator’s
seat (if equipped with air seat). Remove the four
capscrews (8), washers (9) from the base of the seat.
Remove the seat.
5009-34
STEP 16 STEP 19

13
12

10 11

1
W190-4R046
W190-4R049
Remove the support fastening the seat belt by
Raise while slowly rotating the seat cushion
removing nut (10), washer (11), capscrew (12) and
support plate (1).
washer (13).
STEP 20
STEP 17
4

14
3

W190-4R050
W190-4R047
Unhook the rod (4) from the support (3) and remove
Remove the four screws (14) and washers from the the seat cushion plate (1).
seat cushion.
STEP 21
STEP 18

1 5

7
2
6
W190-4R051
W190-4R048
Turn the knob of the support (3) clockwise and move
Pressing down on the seat cushion support plate (1),
plate (5) forward until the four sliding blocks (6) are in
slightly tilt the aluminium tongue (2) to release the
slots (7). Remove the plate (5).
support (1) and allow raising/rotating the front. Use
caution when releasing aluminium tongue (2) to
avoid breaking it.
 5009-35
STEP 22 STEP 23

2 3

4 5
8

W190-4R052

Remove the plate (1) of the seat by removing the four

retaining bolts (2) and washers (3). Slide the plate (1) W190-4R053
forwards to gain access to the two front nuts (4) and Remove the armrest support plate (8).
washers (5) inside the two guides (6) under the plate
(1) of the seat. Repeat the procedure for the two rear
screws (7) by sliding the plate (1) back.
5009-36

Installation STEP 26

STEP 24

8
6

3 4

8
W190-4R054

Position the armrest support plate (8) on the seat

runners (6).

STEP 25 5 6

W190-4R056

2 Push the seat plate (1) forward. From the top, insert
1 the two front capscrews (3) and washers (4). From
the seat runners (7) install nuts (5) and washers (6).
Tighten the nuts to a torque of 32 Nm. Repeat the
W190-4R055
procedure for the two rear capscrews.
Position the seat plate (1) on the seat support plate
(2).
 5009-37
STEP 27 STEP 30

9 10
4
3
1

W190-4R057 W190-4R059

Install the seat plate (9). Turn the locking support Install the seat cushion (3) onto plate (1) and secure
(10) clockwise and at the same time push the plate it with four screws (4) and washers.
(9) toward the rear of the seat to locking it.
STEP 31
STEP 28

13 11 5 6
9 7 8

12
W190-4R060
Install the seat belt, install capscrew (5) and washer
W190-4R058
(6), nut (7) and washer (8). Tighten the nut to a
Insert the two lugs for the seat cushion plate (11)
torque of between 47 and 68 Nm. Check that the
inside the two openings on the seat plate (9). Hook
seat belt mounting hardware is tight and the seat belt
the rod (13) to the catch (12). Slowly lower the seat
is not cut or frayed.
cushion support plate (11).
STEP 32
STEP 29

9 10
2

W190-4R061
W190-4R048
Lock the seat cushion support plate (1) by bending Put the seat in the cab. Connect the wiring harness
the aluminium tongue (2) into position. Use caution to the operator’s seat (if equipped with air seat).
when bending the aluminium tongue (2) to avoid Install the seat on the base and secure it with the four
breaking it. capscrews (9) and washers (10). Tighten the screws
to a torque of between 73 and 87 Nm.
5009-38
STEP 33 STEP 34

5 11 8

9 12
4

6
13

3 10
7 2
W190-4R105
W190-4R062
Install the armrest position switch (2) on the support Insert the armrest locking pin (8) in the bracket (9).
(1) using the two screws (3) and washers. Insert the install it on the armrest height/angle adjustment (10)
adjuster pin (4) inside the support (1) and screw the using the two capscrews (11), washers (12) and nuts
knob (5) on it. Install the plate (6) on support (1), (13). Tighten the nuts to 7 Nm.
secure it using four capscrews (7) and washers.
STEP 35

W190-4R106
Insert, rotate and secure the armrest locking pin (8)
as shown.
 5009-39
STEP 36 STEP 38

1
11

6 4

5 5
2 3 W190-4R065

Connect the positioning switch connector (11).

W190-4R063

Install the armrest height/angle adjustment (2) on the STEP 39

support assembly (1), insert the two nylon bushings
(3), capscrew (4), washers (5) and nut (6).

STEP 37

1
7

2
9 W190-4R066
Install the CAN module (1) in the seat (2) on the
armrest.

STEP 40

8 7 5 6
8 1
10

W190-4R064

Insert the armrest (7) inside the support (8), Install

the knob (9) for armrest height adjustment with 3
spacer (10).
W190-4R067

Connect the connector (3) to the CAN module (1).

Secure the cable (4) to the mounitng bracket using
capscrew (5), washer (6), nut (7) and washer (8).
5009-40
STEP 41 STEP 43

2
14 9 10

12

11 1

13 3
W190-4R068

Connect connector (10) to the PVRES Joystick (9).

Mount the Joystick to support (11), install the two
capscrews (12), four washers (13) and two nuts (14).
Position the valve (9) so the letter “A” stamped on it is
on the left-hand side of the armrest.

W190-4R108
STEP 42
Connect connector (1) of the “Kick-Down” button (2)
to the cable (3).
16
STEP 44
15
5

17

4
W190-4R107

Insert the “Kick-Down” button (16) on the armrest

(15) and secure it with the nut (17).
7

W190-4R109
Insert the “F-N-R” switch (5) in the armrest (4),
connect connector (6) to the cable (7).
 5009-41
STEP 45 STEP 46

4 1

2
4
9
8
3
W190-4R069

Put the armrest (4) on the support (8), secure it with

the four capscrews (9).

W190-4R070

Position armrest (1) with support (2) onto the armrest

adjustment (3) and inatll knob (4) with washer (5).
5009-42

JSS HYDRAULIC PRESSURE ADJUSTMENTS

IMPORTANT: in making the following checks and 1. with the engine OFF and bucket on the ground,
pressure adjustments, the unit articulation must be locked. connect a quick coupling pressure gauge to the
Great attention must be paid to following all the procedures pressure point P (1) of the tool distributor (2) and
for making the unit safe, particularly when operating on the to the pressure point LS (3);
articulation joint and near the arm of the loader.
2. with the engine at idle speed, with all the controls
in neutral, JSS NOT active, the difference
A. Main hydraulic pressure setting of the between the pressure P and LS must be equal to
pump that specified (22-25 bar);
This setting is given by the difference between the 3. with the engine at idle speed, with all the controls
pressure of the hydraulic pump and the LS signal, in neutral, JSS ON and joystick in neutral, the
which must be between 22 and 25 bars: difference between the pressure P and LS must
be equal to that specified (22-25 bar);

W110R379

1. Pressure point P
2. Loader valve
3. Pressure point LS

4. with the engine at idle speed, with all the controls 5. if the setting is not correct, verify that all the
in neutral, JSS ON and joystick NOT in neutral, hydraulic connections are exact, particularly the
the difference between the pressure P and LS connections on the hydraulic steering valve
must be equal to that specified (22-25 bar); PVFC that manages the LS signals.
 5009-43
B. Steering pressure limit setting
With the engine at high reves, the pressure of the 3. move the joystick completely to the right and at
port P of the tool distributor must be between the same tim e, with a chronometer, start
239 and 243 bar: measuring the time. Stop the chronometer when
the unit is completely steered on the right-hand
- make sure that the pressure value stated in
side. Take the time to compare it with the time
paragraph A is as specified (22-25 bar);
specified in the table of speed levels.
- with the engine OFF and bucket on the ground,
4. move the joystick completely to the left and at the
connect a quick coupling pressure gauge to the
same time, with a chronometer, start measuring
pressure point P of the tool distributor;
the time. Stop the chronometer when the unit is
- with the articulation locked, engine at high revs completely steered on the left-hand side. Take
and JSS ON begin steering with the joystick in the time to compare it with the time specified in
both directions to its limit stop. Keep this condition the table of speed levels. If the value is not in the
and read the pressure value on the pressure range shown in the table, follow the system
gauge, which must be equal to that specified calibration procedure;
above (239 and 243 bar);
5. repeat what is specified in point 1, 2, 3 and 4
- if the pressure gauge records a pressure above or with the difference that the engine has to have
below the specified one, check that all the high revs;
hydraulic connections have been made correctly.
6. if the adjustments are not exact, verify the
specifications given in paragraphs A and B.
C. Steering times
IMPORTANT: when carrying out the following procedure
check that the articulation of the unit is NOT locked. Great
attention must be paid to following all the procedures for
making the unit safe, particularly when operating on the
articulation joint and near the arm of the loader.
The speed of steering is not constant but depends on
the speed reached by the vehicle. On reaching
20 km/h the steering sensitivity is reduced by 80%
compared to the normal speed of steering.
The JSS can be set on three different levels of
steering speed.
The three speed levels are:
1. from 4.5 to 5.5 sec.*
2. from 3.2 to 4.5 sec.*
3. from 2.8 to 3.2 sec.*
*(time to take the unit from all right to all left).
The purpose of this setting is to make steering the
unit equipped with the JSS similar to the standard
steering system:
1. with the engine at idle speed, with all the controls
in neutral and JSS ON, steer the unit completely
to the left;
2. set a speed level (e.g. 1, 2 or 3);
5009-44

STEERING SPEED CALIBRATION PROCEDURE

STEP 1 STEP 4
Before running the unit calibration the following
procedures must be completed:
- Start the engine;
- Set the unit in a straight position;
- Activate the Joystick Steering System;
- Slightly lift the bucket off the ground;
- Release the parking brake.

STEP 2

1
W170C-4R005

Press the enter button (2) within two seconds to

confirm the calibration procedure. If you do not press
any buttons after two seconds, the screen will show
“Calibration”, “Timeout”, “Cancelled”. Repeat Step
2 reenter the calibration procedure.

STEP 5
2
W170C-4R003

At the same time press the Joystick Steering

activation switch (1) and the enter button (2).

STEP 3

W170C-4R006

If the enter button is pressed longer than two

seconds, the main menu screen appears.

W170C-4R004

Keep pressed until the screen shows “Calibration?”.

 5009-45
STEP 6 STEP 9

W170C-4R010
W170C-4R007
The display will show a screen with the wording Afterwards, the display will automatically read “Joyst
“Steer. Straight?” Press the enter button to confirm. Full Right” “Release when WL starts moving”.
Move the Joystick lever completely to the right. As
STEP 7 soon as machine movement is noticed release the
lever.

STEP 10

W170C-4R008

The display will read “Joyst Full Left” “Release

when WL starts moving”. Move the Joystick lever
W170C-4R009
completely to the left. As soon as mahcine After this operation, the display will read “O. K.”. The
movement is noticed release the lever. display will automatically read “Joyst Full Right”
“Release when WL starts moving”. Move the
STEP 8 Joystick lever completely to the right. As soon as
machine movement is noticed release the lever.

STEP 11

W170C-4R009

After this operation, the display will read “O. K.” The
display will automatically read “Joyst Full Left”
“Release when WL starts moving”. Move the W170C-4R011
Joystick lever completely to the left. As soon as The display will read “Calibration Successful”
mahcine movement is noticed release the lever. indicating calibration is complete.
5009-46
NOTES
 SECTION INDEX

POWER TRAIN

Section Title Section Number

Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001

Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002
4 Speed Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Drive Shafts, Center Bearing, and Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6006
 6001
Section
6001

REMOVAL AND INSTALLATION OF

POWER TRAIN COMPONENTS
6001-2

TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
 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
Place the master disconnect switch in the OFF
position.

STEP 3
Refer to Section 9007 and remove ROPS cab or
ROPS canopy. BD01D315-01

Disconnect transmission wiring harness connector

STEP 4 from control valve connector. Remove socket head
Refer to Section 8001 and remove the hydraulic bolt securing wiring harness clamp. Move wiring
pump. harness away from transmission.

STEP 5 STEP 8
Put a 28 liter (30 quarts) container under
transmission drain plug. Remove drain plug and
drain transmission oil. Install drain plug after oil has
drained.
NOTE: Remove optional skid plate if equipped to gain
access to transmission drain plug.

STEP 6

BD01D317-01

Just above where clamp was installed, tag and

disconnect transmission wiring harness connector
from temperature sensor. Move wiring harness away
from transmission.

BD01D306-01

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 entry of foreign matter into
hydraulic system.
6001-4
STEP 9 STEP 12

BD01D310-01 BD07N603-01

Remove two socket head bolts securing transmission Identify, tag, and disconnect transmission wiring
wiring harness clamps. harness connectors from filter maintenance switch
and output speed sensor. Move transmission wiring
STEP 10 harness away from transmission.

STEP 13

BD01D312-01

Identify, tag, and disconnect transmission wiring

harness connectors from engine speed sensor, BD03A165-01
intermediate speed sensor, and turbine speed Identify, tag, and disconnect parking brake hose from
sensor. Move transmission wiring harness away from parking brake. Plug hose and cap fitting to prevent
transmission. entry of foreign matter into hydraulic system. Move
hose away from transmission. Remove four bolts and
STEP 11 two straps securing center drive shaft to transmission
output flange. Disconnect center drive shaft from
transmission.

BD01D316-01

Remove socket head bolt securing wiring harness

clamp. Move wiring harness away from transmission.
 6001-5
STEP 14 STEP 16

BD03A161-01 BD01D318-01

Remove four bolts and two straps securing rear drive Identify, tag, and disconnect cooler hose from fitting
shaft to transmission output flange. Disconnect rear installed in LH side of transmission. Install a plug in
drive shaft from transmission. hose. Remove and discard O-ring face seal from
fitting.
STEP 15
STEP 17

BD07N608-01

Remove two bolts. Remove fill tube, with cap and oil BD01D339-01

gauge assembled, two seals, and metal strainer. Remove fitting. Remove and discard O-ring from
Discard seals. fitting. Install a plug in transmission port.

STEP 18

BD01D340-01

Repeat Steps (16) and (17) and disconnect the other

cooler hose and remove fitting.
6001-6
STEP 19 STEP 21

BD01D340-01 BD03A163-01

Connect lifting equipment to transmission lifting eyes. Remove bolts and washers securing RH and LH
Take up all slack in lifting equipment. mounting brackets to rear chassis.

STEP 20 STEP 22

BD01D342-01 BD03A164-01

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.
 6001-7
STEP 23 STEP 24

BD01D345-01 BD01D361-01

Slowly and carefully raise transmission from loader If top mounting bracket requires removal, remove
while checking that all hoses, electrical connectors, bolt and washer then remove bracket.
and wires have been disconnected and nothing
interferes with transmission removal. Remove
transmission from loader.
6001-8

Transmission Mounting

3
2
C 3
B
2 3
7
1 1
5 8

2
3
8
1
2 9
7
1

6
7
10
11
7 4
10

BS08A032

1. ISOLATOR 8. BOLT M20X50 (**)

2. WASHER 9. TRANSMISSION FILL TUBE
3. ISOLATOR BOLT M22X120 (*) 10. BOLT M16X45 TORQUE 251-319 Nm (185-235 lbs-ft)
4. TOP MOUNTING BRACKET 11. BOLT M8X50 TORQUE 17-33 Nm (12-24 lbs-ft)
5. LEFT MOUNTING BRACKET A. REAR CHASSIS TRUNNION
6. RIGHT MOUNTING BRACKET B. MOUNTING BRACKET
7. WASHER C. ISOLATOR (SMALLER PIECE ON TOP)

(*) Torque 890-1000 Nm (655-735 lbs-ft)

(**) Torque 480-590 Nm (355-435 lbs-ft)
 6001-9

Installation STEP 28

STEP 25
Check isolators for deterioration, tears, deformation,
or other damage. Replace as necessary: refer to
Page 8.

STEP 26

BD03A164-01

Install RH and LH mounting brackets on transmission

using two washers and bolts. Do not tighten bolts.

STEP 29

BD01D361-01

If top mounting bracket was removed, put bracket on

rear chassis trunnion and secure using washer and
bolt. Do not tighten bolt.

STEP 27

BD03A163-01

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).

BD01D345-01

Move transmission into position above loader. Slowly

lower transmission into loader.
6001-10
STEP 30 STEP 32
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.

BD01D343-01

Disconnect lifting equipment from transmission lifting

eyes.

BD01D342-01
STEP 33
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
34 to 41 Nm (25 to 30 pound feet).

STEP 31

BD01D34-01

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.

BD03A163-01

Tighten bolts securing RH and LH mounting brackets

to a torque of 890 to 1000 Nm (655 to 735 pound
feet).
 6001-11
STEP 34 STEP 36

BD01D318-01 BD03A161-01

Install new O-ring on fitting and install fitting in Connect rear drive shaft to transmission then install
transmission. Install new O-ring face seal in fitting two straps and four bolts. Tighten bolts to a torque of
then connect cooler hose to fitting following tag 61 to 81 Nm (45 to 60 pound feet).
installed during removal. Remove and discard tag.
STEP 37
STEP 35

BD03A165-01

BD07N608-0 Connect center drive shaft to transmission and install

Position fill tube, two new seals, and metal strainer two straps and four bolts. Tighten bolts to a torque of
on transmission; metal strainer is installed between 61 to 81 Nm (45 to 60 pound feet). Connect parking
seals. Secure using two bolts. Tighten bolts to a brake hose to parking brake following tag installed
torque of 17 to 33 Nm (12 to 24 pound feet). during removal. Remove and discard tag.
6001-12
STEP 38 STEP 40

BD01D314-01 BD01D312-01

Connect transmission wiring harness connectors to Connect transmission wiring harness connectors to
output speed sensor and filter maintenance switch turbine speed sensor, intermediate speed sensor,
following tags installed during removal. Remove and and engine speed sensor following tags installed
discard tags. during removal. Remove and discard tags.

STEP 39 STEP 41

BD01D316-01 BD01D310-01

Install socket head bolt to secure wiring harness Install two socket head bolts to secure transmission
clamp. wiring harness clamps.

STEP 42

BD01D317-01

Connect transmission wiring harness connector to

temperature sensor following tag installed during
removal. Remove and discard tag.
 6001-13
STEP 43 STEP 45

BD01D315-01 BD03A177-01

Install socket head bolt to secure wiring harness Check that transmission drain plug is tight.
clamp. Connect transmission wiring harness
NOTE: Install optional skid plate if equipped.
connector to control valve connector.
STEP 46
STEP 44
Fill transmission with 15-40W engine oil until oil level
is up to the arrow in sight glass.

STEP 47
Refer to Section 8001 and install the hydraulic pump.

STEP 48
Refer to Section 9007 and install ROPS cab or
ROPS canopy.

STEP 49
Start and run engine at idle speed with transmission
in neutral. If transmission oil level is at or below
BD01D306-01
bottom of crosshatch region, put articulation lock in
At brake valve, install new O-ring face seals in
LOCKED position and add oil specified in Section
fittings. Connect brake to hydraulic reservoir hose
1002 until oil level is up to crosshatch region. Shut
and brake pump pressure hose following tags
down engine and put articulation lock in
installed during removal. Remove and discard tags.
OPERATING position.
6001-14

FRONT AXLE

Removal STEP 4

STEP 1

BD03A167-01

Remove four bolts and two straps securing front

BD03A040-01
drive 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

BD03A166-01

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
BD03A092-01 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
Lower loade r arm s slowly until sa fe ty link is from mounting plate and remove from machine.
supporting loader arms.

STEP 3
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
 6001-15
STEP 6 STEP 8

W110R560 BD01F298-01

For machines equipped with LSD Axles (without

brake damping accumulators).
From front axle disconnect brake hose from elbow.
Remove and discard O-ring face seal from elbow.

STEP 7

BD01D392-01

Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand
under machine.

STEP 9
Repeat Step 8 to raise other front axle tire from
W110R561
ground.
For machine equipped with Heavy Duty axles,
disconnect differential lock hose.
NOTE: W130C machines with Heavy Duty axles are
equipped with brake damping accumulators.
6001-16
STEP 10 STEP 12

BD01F297-01 BD01F296-01

Use an acceptable jack to hold front axle. Remove eight nuts bolts, and washers securing front
axle to machine.
STEP 11
STEP 13
Carefully lower front axle and remove from under
machine.

BD01F295-01

Remove bolts and washers from front wheels.

Remove both wheels from front axle.
 6001-17

Front Axle Mounting

BS08A035

1. BOLT (Q.TY 8) M24X130 TORQUE 783-857 Nm (577-632 lbs-ft)

2. WASHER (Q.TY 16)
3. NUT (Q.TY 8)
4. FRONT CHASSIS AXLE PADS
6001-18

W110R562
FRONT AXLE TORQUE SEQUENCE

Installation STEP 16

STEP 14
Carefully move front axle under machine and raise
against mounting pads on machine.

STEP 15

BD01F295-01

BD01F296-01

Apply one drop of engine oil to threads prior to

assembly. Install washers, bolts, and nuts to secure
front axle to machine. Tighten bolts to a torque of 783
to 857 Nm (577 to 632 pound feet) using torque
sequence shown.

B0987A88

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.
 6001-19
STEP 17 STEP 20

BD01F297-01 W110R560

Remove jack from front axle. Install a new O-ring face seal in elbow. Connect
brake hose to elbow.
STEP 18
STEP 21

BD01F298-01

BD03A166-01

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.

BD01D392-01

Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.

STEP 19
Repeat Step 18 to remove other jack stand from
under machine.
6001-20
STEP 22 STEP 24
Refer to Section 7002 and bleed brakes.

STEP 25

BD03A167-01

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). BD03A092-01

Start engine and raise bucket. Have assistant

STEP 23 remove safety link. Lower bucket to ground and stop
If necessary, fill axle with gear lubricant specified in engine.
Section 1002.
STEP 26
Put articulation lock in OPERATING position.
 6001-21

REAR AXLE

Removal STEP 5

STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and forth at least 30 times to release any
pressure from hydraulic circuit.

STEP 2

BD03A169-01

Disconnect brake hose from elbow. Remove and

discard O-ring face seal from elbow.

STEP 6

BD03A040-01

Put articulation lock in LOCKED position.

STEP 3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.
BD01F299-01
STEP 4 Using an acceptable hydraulic jack, raise one tire
from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.

STEP 7

BD03A162-01

Remove four bolts and two straps. Use a pry bar to

disconnect rear drive shaft from rear axle.

BD01F302-01

Use an acceptable jack to hold rear axle.

6001-22
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.

BD01F295-01

Remove bolts and washers from rear wheels.

Remove both wheels from rear axle.

STEP 9

BD03A170-01

At front of trunnion, remove two screws 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 shaft
using acceptable sleeve or rod if necessary.
 6001-23

Rear Axle Mounting

6
1 5
4
3
6
2
5

7
11
10

5 9
2
6
3
12
5 8
6
BS08A036

1. TRUNNION 5. WASHER 22X37X4 9. REAR AXLE

2. O-RING 6. BOLT M20X70 10. PIVOT PIN
3. SEAL 7. WASHER 24X44X4 11. SHIM(S)
4. FRONT CAP PIVOT 8. BOLT M22X15 12. REAR CAP PIVOT
6001-24

Installation STEP 13
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-01

A
5 B
BS01E091A

Install pivot pin (10) and caps (4 and 12) in trunnion

(1) without rear axle or shim(s). Install washers (5)
and bolts (6). Tighten bolts securely. Push
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:
NOTE: Shims are available in following sizes: 0.50 mm
BD01D499-01
(0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm (0.059
inch). Clean front (A) and rear (B) pivot area of rear axle
where seals (3) will be installed.
MEASURED SHIM(S) REQUIRED
GAP (mm) (mm) STEP 14
0.07 to 0.55 None
A
0.56 to 1.09 0.50
1.10 to 1.59 1.0 3
1.60 to 2.09 1.50 4
2.10 to 2.59 0.50 plus 1.50 12
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
seal bottoms out in housing counterbore. Install an
O-ring in each and 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.
 6001-25
STEP 16 STEP 17

11
A 4 6
6 12

10 1
1
BS01E091

Lubricate pivot pin (10) using Molydisulfide Grease. BD01F295-01

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. Apply Loctite primer 345-62 on bolt threads
and let dry for 70 seconds. Then, apply Loctite
345-199 on bolt threads and install washers and
bolts (6). Tighten bolts (6) to a torque of 575 to 600
Nm (420 to 440 lbs-ft).

B0987A88

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.
6001-26
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
Put articulation lock in OPERATING position.

BD03A169-01

Install a new O-ring face seal in elbow. Connect

brake hose to elbow.

STEP 20

BD03A162-01

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).
 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 20
 6002-3

SPECIAL TOOLS
380001743 Transmission supplemental fitting kit. 380001740 Flowmeter kit
Includes: 38000509 special 90 degree adapter and
380001750 Flowmeter adapter
380001749 plug and cap set.
380001745 Flow test kit
380001739 Master pressure test kit

SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi)
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm)
Transmission oil operating temperature .........................................................................80 to 120 °C (176 to 248 °F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K2 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K3 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K4 ........................................................................................................................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 (APPLIES TO 4-SPEED
TRANSMISSION ONLY)
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
associated with hydraulically modulated
transmission.
transmissions, providing smoother shifts and
enhanced clutch life. B. Protects the engine and transmission turbine
from overspeed conditions during
The Transmission ECM relies on signals from 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.
These speed sensors are checked to
In a dd i ti o n, t h e t ra n s m i s s i o n i n c o rp o r a t es a
determine if normal sensor operation is
two-piece transmission case for ease of transmission
present. The data is also used to control
maintenance, helical cut gears that help reduce
modulation during shifting and to determine
noise, and all external hoses have been eliminated
the appropriate shift patterns.
(all oil passages are internal).
D. Detects system failures and determines the
Transmission ECM appropriate alternative actions.

Modulation and shifting are controlled by the E. Provides various diagnostic messages to the
Transmission Electronic Control Module Information Center.
(Transmission ECM). This module replaces the oil F. Provides other information to the information
and springs that are found in hydraulically modulated center, which in turn displays engine speed,
transmissions. wheel speed, gear shift selection, and actual
The Transmission ECM controls the clutch gear selection.
engagement, providing smoother shifts and G. Provides a method to calibrate the
enhanced clutch life, whether the transmission is set transmission clutch control.
to the automatic or manual shift mode.
H. Establishes clutch modulation pressure during
The Transmission ECM also informs the Information transmission shifts.
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.

Electrical Shift Solenoids

Electrical Shift Solenoids control the modulation of
the clutches, eliminating the need for a modulation
valve, and providing a smooth shift while maintaining
constant control over clutch engagement as follows:
A. A temperature sensor relays the oil
temperature to the Transmission ECM.
B. The Transmission ECM times the rate the
solenoid energizes and de-energizes.
C. As the transmission changes gears, there is
reduced hesitation from one gear to the next.
6002-10

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 b u t t h e m o d u l a t i o n w i ll s t i l l b e a
sensor in determining the load going into the predetermined amount of time.
transmission and helps determine shift points. If the transmission is shifted from neutral into a
Intermediate (Shaft Speed) Sensor - determines direction in the Clutch Modulation Substitute Mode in
differential gear speed in the transmission to check automatic, the transmission will shift into 4th gear
for clutch slippage. and shift down until it gets the correct output speed
from the turbine.
Output (Speed) Sensor - monitors transmission
output shaft speed to help determine the load on the Limp-Home Mode
transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM In this mode, the transmission will go into second
which sends the information to the speedometer in gear, forward or reverse, no matter what gear is
the Information Center. selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
The transmission ECM also reviews voltage
gears until an operable gear is found. The
information from the shifter and transmission
transmission will go into the Limp Home Mode if
solenoids to determine if there are any short circuits
there is a fault on one clutch, a fault on one clutch
or open circuits in the system.
valve, or a fault on more than one speed sensor.

Automatic Problem Modes Transmission/Transmission ECM

If the Transmission ECM detects an error condition in Shutdown Mode
the transmission system, it will generate a service
code in the Information Center and will enter one of In this mode, the Transmission ECM has detected a
three modes: severe failure that disables control of the
transmission. The transmission will go into Shutdown
A. Clutch Modulation Substitute Mode
Mode if there is a fault on more than one clutch, a
B. Limp-Home Mode fault on the solenoid power supply, or invalid voltage.
C. Transmission/Transmission ECM Shutdown In this mode, the Transmission ECM will shut off all
Mode solenoid valves and the power supply and the
transmission shifts into and stays in neutral.
If the Transmission ECM generates a code, the
wrench over the service m anual icon will be
displayed on the Information Center.
 6002-11

Transmission Clutch Calibration Gear Selections

The Transmission ECM has the capability to find the The 4 speed transmission provides 4 forward and 3
optimal adjustment of the clutch filling parameters for reverse gear selections. The transmission ratios
each individual transmission, providing the ability to were designed to give optimized speed and torque
individually adjust the optimum fill time for the for each gear selection. The torque converter is a
individual transmission in the machine. Clutch Filling single stage torque converter (one locking unit in the
Parameter Calibration is performed on each machine torque 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.
6002-12

Upshifting in Manual Mode B. The shifter is moved into neutral and then into
forward or reverse.
In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the C. The autoshift switch is recycled.
operator selects another gear or direction. The
transmission can be upshifted without reducing Manual Mode
engine speed or machine speed.
In the manual mode, the downshift button toggles
If the gear selected is two or more gears higher than between 1st and 2nd gear. The manual mode is
the present gear, the transmission will shift up useful in short haul operations. In this mode, the
through the gears at 2.5 second intervals until the downshift button functions in two ways in 1st and 2nd
selected gear has been reached. gear.
When the operator is in 2nd gear and pushes the
Downshifting in Manual Mode downshift button, the transmission instantly shifts into
The transmission can be downshifted in the manual 1st gear. When the operator pushes the downshift
mode without reducing engine speed or machine button again, the transmission upshifts into 2nd gear.
speed. If the machine is in 2nd gear and the downshift
If 1st gear is selected from 3rd or 4th gear, the button is pushed, the transmission instantly shifts into
transmission will downshift into 2nd gear for 1.2 1st gear. When the operator shuttles the shifter, the
seconds and then will shift into 1st gear. transmission upshifts back into 2nd gear.

Downshift Button Cold Start Protection System

The downshift button is located on front of the The transmission has a cold start protection system.
joystick control lever in machines with a single lever When the transmission sump temperature is minus
configuration, and on top of the control tower in 10° C (14° F), the Transmission ECM will keep the
machines with two or three lever configurations. transmission in neutral.

With the number of different ways the downshift When the transmission sump temperature warms up
button functions, the operator can tailor the use of the to minus 10° C (14°F) (within approximately one
machine to the application at hand. minute), the machine will operate in all gears.

Automatic Mode
In the Automatic Mode, the downshift button only
shifts down. The downshift button allows the operator
to downshift through the entire range of gears. This is
useful in long haul applications or roading.
Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then
from 3rd to 2nd, and then from 2nd to 1st.
The transmission will automatically downshift and
then upshift, as needed, to the last gear that was
selected with the downshift button.
Example: If the downshift button was used to shift
from 4th to 3rd gear, the transmission will
automatically shift from 3rd down and then back up to
3rd again. It will not shift into 4th until the
transmission has been returned to the full range
automatic mode.
The transmission will return to the full range
automatic mode when:
A. Another gear is selected.
 6002-13

Brake Pedal Transmission

Declutch
A transmission declutch feature concentrates more
engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and
starts. Total disconnection of the transmission from
the engine is prevented. This feature will function in
1st, 2nd, or 3rd gear only. It will not function in 4th
gear.
When the transmission declutch switch is in the on
position and the brake pedal is pushed, the
Transmission ECM reduces the pressure to the
transmission forward or reverse clutch.
The Transmission ECM will not completely
disconnect the clutch from the engine, but gradually
reduces the forward or reverse clutch pressure down
to a lower level.
When the brake pedal is released, the Transmission
ECM gradually increases the forward or reverse
clutch back up to system clutch pressure.
If the direction is changed while the transmission is
declutched, the selected forward or reverse clutch
will be filled and maintain a low pressure until the
brake pedal is released. Then the selected forward or
reverse clutch pressure will gradually increase up to
system clutch pressure.
6002-14

TRANSMISSION PRESSURE TEST POINTS DIAGRAM

DESIGNATION ON
No. IDENTIFICATION/LOCATION CONNECTION
VALVE BLOCK
Measuring Points for Pressure Oil and Temperature
51 Before the Converter - Opening Pressure 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.
 6002-15

4-SPEED TRANS. • PRESSURE REGULATOR UNDER VOLTAGE 5-SPEED TRANS. • PRESSURE REGULATOR UNDER VOLTAGE
FORWARD REVERSE NEUTRAL FORWARD REVERSE NEUTRAL
CLUTCH PRESSURE REGULATOR 1 2 3 4 1 2 3 CLUTCH PRESSURE REGULATOR 1 2 3 4 5 1 2 3
KV Y5 • • • KV Y5 • • •
KR Y2 • • • KR Y2 • • •
K1 Y3 • • K1 Y3 • •
K2 Y6 • • K2 Y6 • • •
K3 Y4 • • • K3 Y4 • • •
K4 Y1 • K4 Y1 • •
W130R0035
MEASURING POINTS AND CONNECTIONS
6002-16

CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.

P.I.N. Number: Date:

TEST POINTS

Shift P V R 1 2 3 4 5 6
LP
Speed 65 53 55 56 57 58 60 51 52

1st F

2nd F

3rd F

4th F

1st R

2nd R

3rd R

Neut

P= MAIN PRESSURE 1= FIRST GEAR CLUTCH 4= FOURTH GEAR CLUTCH LP= LUBE PRESSURE

V= FORWARD CLUTCH 2= SECOND GEAR CLUTCH 5= CONVERTER IN

R= REVERSE CLUTCH 3= THIRD GEAR CLUTCH 6= CONVERTER OUT
 6002-17

PRESSURE TEST RESULTS

All or Most Pressures Low and/or Not Enough Power

Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.

2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
(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.
6002-18

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 38000509 Special 100° C (176 to 212° F).
Adapter. 5. While in the cab, put the transmission in
NEUTRAL. Run the engine at full throttle. Record
Test Procedure the reading in the chart on page 16. Pressure
must be a minimum of 3.5 to 6.5 bar
1. Block the machine tires. (51 to 96 psi).
2. Apply the parking brakes.

LUBRICATION PRESSURE CHECK

Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 16. Pressure must
be 0.2 to 1.2 bar (3 to 18 psi).

FLOWMETER TEST

Test Equipment Required 3. Heat the oil to an operating temperature of 80 to

100° C (176 to 212° F).
380001740 Flowmeter Kit; 380001750 Flowmeter
Adapter. 4. Remove the filter and install the 380001750
adapter.
Flowmeter Test Procedure 5. Install the flowmeter between the adapter and
the filter.
1. Block the machine tires.
6. While in the cab, run the engine at full throttle.
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.
5. While in the cab, run the engine at full throttle.
Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 L/min
(2 U.S. gpm).
 6002-19

TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56°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.
6002-20

ERROR CODES
In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with
a recorded error number. See section 4005 for error code retrieval procedures and definitions.

TRANSMISSION SHIFTER LOGIC INFORMATION

Shifter Wire Shifter Tower Shifter Shroud Harness Harness
Function Shifter Trans. ECM #
Color Connector Connector Wire # ped/cab #
power B+ black/red A A 19A_H 43 45
forward V yellow - B 25F 44 43
reverse R pink - C 25R 45 64
neutral N gray - D 25T_B 46 67
gear2(3-4) B2 green B - 25W 48 65
gear1(1-2) B1 blue C - 25Z 49 63
downshift DS purple D - 25Y 50 22

NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the
shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In
neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low
and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is
engaged.

RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES

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

6003
4 SPEED TRANSMISSION
6003-2

TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.0 Electro-hydraulic control and oil filter (replaceable filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.0 Inductive sensor Hall effect sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . 9
3.0 Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring
point “63” after the converter as described in the specifications, pressure checks and troubleshooting section
of the manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.0 Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.0 Removal of input shaft, output shaft, pump shaft (PTO -shaft) and clutches . . . . . . . . . . . . . . . . . . . . 15
7.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.0 Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches . . . . . . . . . . . 66
10.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.0 Reassembly: Engine connection, oil pressure pump, converter back-pressure valve and temperature sen-
sor (measuring point “63” after the converter as described in the specifications, pressure checks and trouble-
shooting section of the manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12.0 Reassembly - Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13.0 Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . 81
14.0 Reassembly Electro-hydraulic control with proportional valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
 6003-3

SPECIAL TOOLS

380001577 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
380001560 TRANSMISSION
INPUT/OUTPUT SHAFT SEAL 380001568
INSTALLATION TOOL TRANSMISSION OUTPUT
380001559 TRANSMISSION SHAFT SEAL
TORQUE CONVERTER SEAL INSTALLATION TOOL
INSTALLATION TOOL
W130R0065
TRANSMISSION TOOL KIT

380001558 ALIGNMENT
380001556 CLUTCH PACK DOWEL SET
H0LDER AND SPRING
COMPRESSOR TOOLS

380001554 NESTING
PLATE

380001567 CLUTCH
SPRING COMPRESSOR
380001557 CLUTCH
380001555 GEAR ASSEMBLY HOLDING
PULLER COLLET SET KNOB SET
W130R0064
TRANSMISSION OVERHAUL KIT
6003-4

SPECIAL TORQUES
Oil pipes
Studs ............................................................................................................................... 9 Nm (80 pound inches)
Socket head bolt ................................................................................................................ 23 Nm (17 pound feet)
Screw plug ......................................................................................................................... 51 Nm (38 pound feet)
Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches)
Plugs........................................................................................................................................ 25 Nm (18 pound feet)
Output shaft
Output shaft bolts (apply Loctite 243 to threads) ............................................................... 23 Nm (17 pound feet)
Housing cover bolts (apply Loctite 574 to threads) ............................................................ 46 Nm (34 pound feet)
Output flange bolts ............................................................................................................. 34 Nm (25 pound feet)
Oil feed housing and transmission pump
Transmission pump bolts ................................................................................................... 46 Nm (34 pound feet)
Oil feed housing bolts......................................................................................................... 25 Nm (18 pound feet)
Engine connection and converter
Input shaft bolts................................................................................................................ 115 Nm (85 pound feet)
Converter housing bolts ..................................................................................................... 68 Nm (50 pound feet)
Cover................................................................................................................................... 23 Nm (17 pound feet)
Converter cover.................................................................................................................. 46 Nm (34 pound feet)
Input flange ......................................................................................................................... 34 Nm (25 pound feet)
Duct plate
bolts.................................................................................................................................... 25 Nm (18 pound feet)
bolt plug.............................................................................................................................. 30 Nm (22 pound feet)
Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches)
Filter
Filter head bolts.................................................................................................................. 25 Nm (18 pound feet)
Oil distribution cover bolts .................................................................................................. 25 Nm (18 pound feet)
Speed sensor and inductive transmitter
Speed sensor bolt .............................................................................................................. 23 Nm (17 pound feet)
Inductive transmitter........................................................................................................... 30 Nm (22 pound feet)
Cover plate......................................................................................................................... 23 Nm (17 pound feet)
bolt plug.......................................................................................................................... 140 Nm (103 pound feet)

SPECIFICATIONS
Clutch KV and KR plate clearance ..................................................................... 2.45 to 2.75 mm (0.096 to 0.108 in)
Clutch K1plate clearance.......................................................................................... 2.0 to 2.3 mm (0.078 to 0.09 in)
Clutch K2 and K3 plate clearance ............................................................................ 2.0 to 2.3 mm (0.078 to 0.09 in)
Clutch K4 plate clearance................................................................................... 1.15 to 1.45 mm (0.045 to 0.057 in)
 6003-5

DISASSEMBLY
1.0 Electro-hydraulic control and oil filter STEP 2
(replaceable filter) 1.1 Removal of filter

STEP 1

BILD-02

Remove and properly discard filter (1).

STEP 3

2
1

BILD-01

Fasten transmission on assembly stand or similar

tool. Drain oil prior to starting disassembly.
WARNING: Dispose of oil according to legal
requirements.

BILD-03

Remove Torx bolts (2) and separate filter head (1)

from transmission. Remove and discard O-rings.
6003-6
STEP 4 STEP 6
1.2 Removal of electronic gear-shift control
2
3

1
1
4

BILD-06

Remove differential pressure switch (1) from fine filter

BILD-04
duct plate (4).
1. Switch with O-ring
Remove gear-shift control (1). Remove Torx bolts (2)
and separate gear-shift control housing from 2. Piston
intermediate plate.
3. Compression spring.
NOTE: For version with torque converter lock-up
clutch Solenoid valve, go to Steps 20 thru 22. STEP 7
STEP 5
2
S
1

1 BILD-07

Remove hex nuts and Torx bolts. Separate the duct

BILD-05 plate (1) and seal (2) from rear housing.
Remove gear-shift control assembly (1) and sealing
plate (2). Adjusting bolts M6 (S).
 6003-7
STEP 8 STEP 11

2 3
1

BILD-11

Separate duct plate (1) and sealing plate (2) from

valve block (3).
BILD-08

Remove converter safety valve (1) out of the housing STEP 12

hole.
1
STEP 9

2
1

BILD-12

Remove retaining clamp (1).

BILD-09
STEP 13
Mark installation position of wiring harness (1)
towards the valve block (2). 1
STEP 10
2
1

3
BILD-13

Remove Torx bolts (1) and cover (2). Repeat the

procedure on the opposite end cover (3).

BILD-10

Remove Torx bolts (1).

6003-8
STEP 14 STEP 17

2 S

3
BILD-14 BILD-17

Remove wiring harness (1). Remove cylindrical bolts Loosen the adjusting bolts (S) equally releasing the
(3), securing plates and pressure controllers (2). valve’s spring pressure. Remove the housing.

STEP 15 STEP 18

1 2
BILD-18
BILD-15

Remove cylindrical bolts, securing plates and Remove individual parts including pressure reducing
pressure controllers (1) on opposite side. valve (1), vibration dampers (2), follow-on slide (3).

STEP 16 STEP 19

1 S

3 2
BILD-19
BILD-16

Remove two Torx bolts (1) and temporarily attach Remove individual parts of opposite side including
housing using 380001577 adjusting bolts (S). main pressure valve (1), vibration dampers (2),
(Housing is spring-loaded.) Remove remaining Torx follow-on slide (3).
bolts.
 6003-9
STEP 20 STEP 22
1.3 Version with torque converter lock-up clutch
solenoid valve

1 1
5

4 4

3
2 2

3 BILD-20

Mark installation position of connecting housing (4)

towards valve block (5). Remove cylinder bolts (1)
BILD-32
and lock-up clutch valve. Remove bolt neck (2) and
Loosen nuts (1 and 2) and remove system pressure
discard O-rings. Remove Torx bolts (3), and the
pipe (3) from lock-up clutch valve to lock-up clutch.
connecting housing.
Remove screw-in sleeve (4).
NOTE: For further disassembly, go back to Steps 15
STEP 21 thru 19.
2.0 Inductive sensor Hall effect sensor,
breather, oil filler and oil drain plug

STEP 1
1 3 4

2 5
3 6
BILD-31

Remove hollow bolt (1) and O-ring. Loosen bolt nut

(2). Remove system pressure to lock-up clutch valve
pipe and O-rings.
NOTE: For further disassembly, go back to steps 4
to 8.

2
1

BILD-01

Attach transmission to assembly stand. Remove oil

drain plug (1), oil filler tube with oil dipstick (2),
breather (3), inductive sensor - n central gear chain
(4), inductive sensor - n turbine (5), inductive sensor
- n engine (6).
6003-10
STEP 2 STEP 2

BILD-02 BILD-04

Remove cylindrical bolt (1) and remove Hall effect Separate cover from converter bell housing using a
speed sensor - n output and O-ring (2). suitable lifting device.
3.0 Engine connection, oil pressure
STEP 3
pump, converter back-pressure valve
and temperature sensor (measuring
point “63” after the converter as
described in the specifications, pressure
checks and troubleshooting section of
the manual)

STEP 1
3.1 Engine connection (remote mount)

1
2 BILD-05

Remove output flange.

STEP 4

BILD-03

Remove hex bolts (1) and washer. Loosen the

cover/converter bell housing bolts (2).
NOTE: Mark radial installation position of
cover/converter bell housing with center punch.

BILD-06

Press input shaft and converter out of cover (ball

bearing).
 6003-11
STEP 5 STEP 8
3.2 Oil pressure pump
1
2
2
1

BILD-07

Remove retaining ring (1) and ball bearing (2).

BILD-10

Loosen bolted connection (1) between converter bell

STEP 6 housing and oil feed housing. Remove converter bell
housing (2).
1 2
STEP 9

1 2

BILD-08

Remove hex bolts (1) and flex plate (2) from

converter.
BILD-11
STEP 7 Remove the Torx bolts (1) from the oil feed housing
and front transmission housing. Remove cylindrical
bolts (2) from the oil pressure pump and front
2
transmission housing.
1 3
NOTE: Separate oil feed housing together with oil
pressure pump from front transmission housing.

BILD-09

Remove hex bolts (1) and flex plate (2) from input
shaft (3).
6003-12
STEP 10 STEP 12
2
1
1

BILD-12 BILD-14

Separate oil pressure pump (1) from oil feed housing Check oil gear pump for wear. In case of wear marks
(2). on the pump housing, cover, inner rotor, or outer
rotor; replace the oil pressure pump.
STEP 11 1. Cover
2. Inner rotor
3. Outer rotor
1 4. Pump housing
2
STEP 13

BILD-13

Remove O-ring (1) and cylindrical bolts (2).

BILD-15

Remove shaft seal (1) from the pump housing (2).

 6003-13
STEP 14 STEP 16
3.3 Converter back-pressure valve

1
BILD-18

Remove temperature sensor (1).

BILD-16

With a screwdriver, release the converter safety valve

(1) pressure and remove the locking plate (2). STEP 17

STEP 15
1

2
3
1 2

BILD-19

Remove stator shaft (1). If applicable, remove the

pressure relief valve (2) out of the housing hole.
BILD-17

Remove individual parts of converter safety valve NOTE: The pressure relief valve is not mounted on
which are released. all versions. Versions concerned, see the
corresponding spare parts list.
1. Pressure plate
2. Compression spring
3. Piston
6003-14
4.0 Emergency steering pump STEP 2

STEP 1 1
4.1 Version without emergency steering pump

2
2
1

BILD-02

Pull off output flange (1) and remove shaft seal (2).

BILD-01
STEP 3
Remove hex bolts (1), cover (2) and seals. 5.2 Output flange on output side with parking
brake FSG-88
5.0 Outputs and closure parts pump
shaft (PTO-shaft)
2 1
STEP 1
5.1 Output flange on converter side (Standard
version)

BILD-11

Connect a hand-operated pump at port (see arrow)

and apply approximately 80 bar (1160 PSI) pressure
to the hydraulically actuated parking brake (1) until
the brake disc (2) can be rotated by hand.

BILD-01
STEP 4
Remove hex bolts (1), washer and O-ring.

BILD-12

Remove hex nut with open end wrench.

 6003-15
STEP 5 6.0 Removal of input shaft, output shaft,
pump shaft (PTO -shaft) and clutches
2
STEP 1
1 1 2

BILD-13

Remove hex bolts (2) and parking brake (1).

STEP 6 BILD-01

Force out both cylindrical pins (1). Loosen bolted

connection (2) between front and rear transmission
housings. Separate housing sections using a suitable
2 1 lifting device.

STEP 2

BILD-14

Remove hex bolts (1) of bolted brake disc/output

flange connection and remove brake disc (2).

STEP 7

3 BILD-02
2 Loosen bolted connection (1) of oil screen sheets.
1

BILD-15

Remove hex bolts (1), washer and O-ring. Remove

output flange (2) and shaft seal. Remove cylinder
bolt with washer (3).
6003-16
STEP 3 STEP 6

1 2

BILD-03 BILD-06

Remove output shaft (1) and lower oil screen sheet Secure all clutches K1, K2, K3 and K4 by using
(2) from housing. 380001557 handle (1).
WARNING: Clutches KV, KR and input shaft (2) are
STEP 4 only secured by the gear chain. Care must be taken
to ensure these non-secured components do not
detach.
2
NOTE: Due to the installation conditions, the
1 removal of single clutches without using the special
tool is not possible.

STEP 7

BILD-04

Remove all rectangular rings (1) from the clutches

and all O-rings (2) from the oil tubes.

STEP 5 1
3
1 4
2
BILD-07

Separate rear housing section including clutches

from front housing section using a suitable lifting
device and attach it to the assembly truck.
1. Clutch KV
2. Input shaft
3. Clutch KR
2 4. Pump shaft
BILD-05
WARNING: Clutches KV, KR and input shaft are only
Use a suitable lifting device to lower rear housing secured by the gear chain. Care must be taken to
section (1) into contact position with front housing ensure these non-secured components do not
section (2). detach.
 6003-17
STEP 8 STEP 10

BILD-08 BILD-10

Remove cylindrical bolts of oil tubes (1) from the front Remove bearing outer rings (arrows) from the front
housing. housing.
NOTE: If contrary to recommendation, the tapered
STEP 9 roller bearings of clutches, input and output are not
replaced, the technician must ensure the previous
pairing (bearing outer ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be
marked.
2
STEP 11

BILD-09

NOTE: The suction tube (1) and the lubrication lines

(2) are rolled in and difficult to remove. In case of
damage, use special tools 380001285 (EU) or 2
380001286 (EU) for fitting or replacing these
components. North American Dealers contact 1
special tools.
BILD-11

Disengage retaining ring (1) and remove pump shafts

(2).
6003-18
STEP 12 STEP 14

1
2

BILD-12 BILD-14

Press ball bearing (1) off the pump shaft. Snap out Remove bearing outer rings (arrows) from the rear
rectangular ring (2). housing.
NOTE: If contrary to recommendation, the tapered
STEP 13 roller bearings of clutches, input and output are not
replaced, the technician must ensure the previous
7 pairing (bearing outer ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be
6 marked.

2 STEP 15

5
3
4 1 1
2

BILD-13

Lift the clutches out of the housing in numerical order

as described in the legend.
1. K1 clutch
2. K2 clutch
3. K3 clutch (Version with emergency steering BILD-15

pump) NOTE: The lubrication lines (1 and 2) are rolled in

and difficult to remove. In case of damage, use
4. K4 clutch
special tool 380001285 (EU) for fitting or replacing
5. KR clutch these components. North American Dealers contact
special tools.
6. KV clutch
7. Input shaft
 6003-19
7.0 Clutches KV/KR/K1/K2/K3/K4 input STEP 3
and output shaft.

STEP 1

2 6

4 5
3
1
BILD-03

7 Pull tapered roller bearing off the shaft using special

tool 380001555.
BILD-01

1. K1 clutch STEP 4
2. K2 clutch 1
3. K3 clutch
4. K4 clutch
5. KR clutch
6. KV clutch
7. Input shaft.

STEP 2
7.1 KV clutch
BILD-04

1 2 Snap out retaining ring (1).

STEP 5

BILD-02
1
Remove stud bolt (1) and snap out piston ring (2).

BILD-05

Pull clutch (1) off the shaft.

NOTE: For disassembly of clutch see Steps 11-16.
6003-20
STEP 6 STEP 9

1 2

BILD- 06 BILD-09

Secure idler gear (1) using a cut-off device and pull it Turn shaft (2) 180 degrees and snap out piston ring
off the clutch shaft. (1).

STEP 7 STEP 10

BILD-07 BILD-10

Snap retaining ring (1) out of the idler gear (2) and Pull tapered roller bearing off shaft with special tool
remove ball bearing (3). 380001555.

STEP 8 STEP 11
1
1

BILD-08 BILD-11

Remove needle cage (1) from the shaft (2). Unsnap snap ring (1).
 6003-21
STEP 12 STEP 15

1
2

BILD-12 BILD-15

Remove end shim (1) and disc set (2) from the disc Using compressed air, remove the piston (1) from the
carrier (3). disc carrier.

STEP 13 STEP 16

1 2

BILD-13 BILD-16

Preload compression spring with special tool Remove both O-rings (1 and 2).
380001556 and unsnap L-ring (1).
STEP 1
STEP 14 7.2 KR clutch

1 1 2

BILD-14
BILD-01
Remove support shim (1), compression spring (2)
Remove stud bolt (1) and snap out piston ring (2).
and washer (3).
6003-22
STEP 2 STEP 5

BILD-02 BILD- 05
Pull tapered roller bearing off the shaft with special Secure idler gear (1) using a cut-off device and pull it
tool 380001555. off the clutch shaft.

STEP 3 STEP 6

1 1

BILD-03 BILD-06
Snap out retaining ring (1). Snap retaining ring (1) out of the idler gear (2) and
remove ball bearing (3).
STEP 4
STEP 7
1

BILD-04

Pull clutch (1) off the shaft. BILD-07

NOTE: For disassembly of clutch see Steps 10-15. Remove needle cage (1) from the shaft (2).
 6003-23
STEP 8 STEP 11

1
1

BILD-08 BILD-11

Turn shaft (2) 180 degrees and snap out piston ring Remove end shim (1) and disc set (2) from the disc
(1). carrier (3).

STEP 9 STEP 12

BILD-09 BILD-12

Pull tapered roller bearing off shaft using special tool Preload compression spring with special tool
380001555. 380001556 and unsnap L-ring (1).

STEP 10 STEP 13

1
1
2

BILD-10 BILD-13

Unsnap snap ring (1). Remove support shim (1), compression spring (2)
and washer (3).
6003-24
STEP 14 STEP 2

BILD-14 BILD-02

Using compressed air, remove the piston (1) from the Pull tapered roller bearing off the shaft with special
disc carrier. tool 380001555.

STEP 15 STEP 3

BILD-15 BILD-03

Remove both O-rings (1 and 2). Snap out retaining ring (1).

STEP 1 STEP 4
7.3 K1 clutch
1

1 2

BILD-04

Remove axial bearing assembly (1).

BILD-01

Remove stud bolt (1) and snap out piston ring (2).
 6003-25
STEP 5 STEP 8

BILD-05 BILD-08

Take off idler gear (1), remove needle cage (2) and Pull tapered roller bearing off the shaft with special
axial bearing assembly (3). tool 380001555.

STEP 6 STEP 9

BILD-06 BILD-09

Pull clutch (1) off the shaft. Unsnap snap ring (1).
NOTE: For disassembly of clutch see Steps 9-14.
STEP 10
STEP 7
1
1

2
3

BILD-10

Remove end shim (1) and disc set (2) from the disc
BILD-07
carrier (3).
Turn shaft (2) 180 degrees and snap out piston ring
(1).
6003-26
STEP 11 STEP 14

1 2

BILD-11 BILD-14

Preload cup springs using special tool 380001556 Remove both O-rings (1 and 2).
and unsnap L-ring (1).
STEP 1
STEP 12 7.4 K2 clutch

1 2
1

BILD-12
BILD-01
Remove cup spring package (1).
Remove stud bolt (1) and snap out piston ring (2).
STEP 13 STEP 2

BILD-13
BILD-02
Using compressed air, remove the piston (1) from the
Pull tapered roller bearing off the shaft using special
disc carrier.
tool 380001555.
 6003-27
STEP 3 STEP 6
1

BILD-03 BILD-06

Snap out retaining ring (1). Pull clutch (1) off the shaft.
NOTE: For disassembly of clutch see Steps 9-14.
STEP 4
1 STEP 7

BILD-04

Remove axial bearing assembly (1).

BILD-07

Turn shaft (2) 180 degrees and snap out piston ring
STEP 5 (1).

STEP 8
1

3
2

BILD-05

Remove idler gear (1), needle cage (2) and axial

bearing assembly (3).
BILD-08

Pull tapered roller bearing off the shaft using special

tool 380001555.
6003-28
STEP 11

1
1

BILD-09

Unsnap snap ring (1). BILD-12

Remove cup spring package (1).

STEP 9
STEP 12
1

2 1

BILD-10

Remove end shim (1) and disc set (2) from the disc BILD-13

carrier (3). Using compressed air, remove the piston (1) from the
disc carrier.
STEP 10
STEP 13

1 2

BILD-11

Preload cup springs using special tool 380001556 BILD-14

and unsnap L-ring (1). Remove both O-rings (1 and 2).

 6003-29
STEP 1 STEP 4
7.5 K3 clutch
1

1
3

BILD-04

Take off idler gear (1), remove needle cage (2) and
BILD-01
axial bearing assembly (3).
Snap out piston ring (1).
STEP 5
STEP 2

BILD-05
BILD-02
Pull clutch (1) off the shaft.
Pull tapered roller bearing off the shaft using special
tool 380001555. NOTE: For disassembly of clutch see Steps 8-13.

STEP 3 STEP 6

1 2
1

BILD-03 BILD-06

Remove axial bearing assembly (1). Remove stud bolt (1) and snap out piston ring (2).
6003-30
STEP 7 STEP 10

BILD-07 BILD-10

Pull tapered roller bearing off the shaft using special Preload cup springs using special tool 380001556
tool 380001555. and unsnap L-ring (1).

STEP 8 STEP 11

1 1

BILD-08 BILD-11

Unsnap snap ring (1). Remove cup spring package (1).

STEP 9 STEP 12

1
2

BILD-09 BILD-12

Remove end shim (1) and disc set (2) from the disc Using compressed air, remove the piston (1) from the
carrier (3). disc carrier.
 6003-31
STEP 13 STEP 3

1
1

BILD-13 BILD-03

Remove both O-rings (1 and 2). Snap out retaining ring (1).

STEP 1 STEP 4
7.6 K4 clutch

1
2

BILD-04

Pull clutch (1) off the shaft.

BILD-01

Remove stud bolt (1) and snap out piston ring (2). NOTE: For disassembly of clutch see Steps 9-14.

STEP 2 STEP 5
1

BILD-02 BILD-05

Pull tapered roller bearing off the shaft using special Remove axial bearing assembly (1) and idler gear
tool 380001555. (2).
6003-32
STEP 6 STEP 9

2 1

BILD-06 BILD-09

Remove needle cage (1) and axial bearing assembly Unsnap snap ring (1).
(2).
NOTE: The gear (3) cannot be removed, it is a STEP 10
shrink fit.
1
STEP 7
1
2

2 BILD-10

Remove end shim (1) and disc set (2) out of the disc
carrier (3).
BILD-07

Turn shaft (2) by 180 degrees and snap out piston STEP 11
ring (1).

STEP 8

BILD-11

Preload cup springs using special tool 380001556

and unsnap L-ring (1).

BILD-08

Pull tapered roller bearing off the shaft using special

tool 380001555.
 6003-33
STEP 12 STEP 1
7.7 Input shaft

2
1

BILD-12

Remove cup spring package (1).

BILD-01

Snap out piston ring (1). Turbine wheel shaft and

STEP 13 drive gear (2) are secured by a snap ring.
NOTE: When separated, the snap ring will be
destroyed.

1 STEP 2

BILD-13

Using compressed air, remove the piston (1) from the

disc carrier.

STEP 14
BILD-02

Pull tapered roller bearing off drive gear using special

tool 380001555.
1

BILD-14

Remove both O-rings (1 and 2).

6003-34
STEP 3

BILD-03

Pull tapered roller bearing off drive gear using special

tool 380001555.
NOTE: It is not possible to separate the input shaft
and gear (1). It is a shrink fit.

STEP 1
7.8 Output shaft

BILD-01

Pull tapered roller bearing off of output shaft using

special tool 380001555 and remove oil sheet (1).

STEP 2

BILD-02

Turn output shaft 180 degrees and pull off tapered

roller bearing using special tool 380001555.
 6003-35

REASSEMBLY
8.0 Clutches KV/KR/K1/K2/K3/K4 input STEP 3
and output shaft
1
STEP 1
8.1KV Clutch

BILD-03

Mount bearing cage (1) onto the shaft and oil it.

STEP 4
BILD-01

Heat bearing to approximately +120° C (+248° F).

3

STEP 2 2

2
1 1

BILD-04

Install ball bearing (2) into the idler gear (1) until
contact occurs and secure it using retaining ring (3).

STEP 5
BILD-02

Mount bearing (1) until contact is made. Adjust

bearing after it cools. Fit rectangular ring (2).
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts. 1

BILD-05

Press pre-assembled idler gear (1) onto the shaft

until contact occurs.
6003-36
STEP 6 STEP 9
4
3
1
2

1
1 S

BILD-06 BILD-09

Place both O-rings (1 and 2) into the piston grooves Mount inner installer (S) onto the disc carrier. Install
and oil them. disc (1), compression spring (2), support shim (3)
and L-ring (4).
NOTE: Check function of the drain valve (see arrow).
The ball must not jam. NOTE: For installation position of support shim and
L-ring see Step 11. (S) Inner installer, see Step 10.
STEP 7
STEP 10

1
S1
S2

BILD-07

Place piston (1) into the disc carrier. BILD-10

Preload compression spring using special tool

NOTE: Observe installation position.
380001556 (S1) and pressure piece (S2), until
L-Ring has engaged into the annular grove.
STEP 8
NOTE: Always use a new L-ring.

BILD-08

Use special tool 380001556 (S) to place piston into

the disc carrier.
 6003-37
STEP 11 STEP 12
1 2 3 1

6
2
3
7

4
4
1
BILD-11 W130R0054

Disc carrier with piston retraction: Install outer and inner discs into the disc carrier (4).
1. Washer 1. Friction disc - coated on one side (2 pcs)
2. Compression spring 2. Outer discs (9 pcs)
3. Support shim 3. Inner discs (10 pcs)
4. L-Ring NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
5. Disc carrier
Number of friction surfaces is 20.
6. Drain valve (piston)
NOTE: Different clutch disc arrangements with
7. Piston with O-Rings relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.

STEP 13

1
2

BILD-15

Mount end plate (1) and secure disc package using

snap ring (2) e.g. thickness = 2.65 mm (0.104
in.)/recommended value.
6003-38
STEP 14 STEP 16

BILD-16 BILD-18

Press on end plate with F (approximately 100 N = 10 Heat clutch to approximately +120° C (+248° F).
kg) and set dial indicator to “zero”.
STEP 17
STEP 15
L R
F

BILD-19

BILD-17 Install clutch until contact is made. Mount inner discs

Then press end plate against the snap ring onto the inner disc carrier using short left/right
(upwards) and read disc clearance. Disc clearance rotations.
should be: 2.45 to 2.75 mm (0.096 to 0.108 in.).
WARNING: Always wear protective gloves to
NOTE: In cases of deviation, the disc clearance prevent burning your hands when handling heated
must be corrected with the appropriate snap ring. parts.
Optional thicknesses range from 2.1 to 4.2 mm (0.08
to 0.17 in.). STEP 18

BILD-20

Secure clutch (1) using retaining ring (2).

 6003-39
STEP 19 STEP 22

BILD-21 BILD-24

Heat bearing inner ring to approximately +120° C Check clutch operation using compressed air at the
(+248° F). hole (see arrow). Closing and opening of the clutch
must be clearly audible.
STEP 20
STEP 23
1 1

BILD-22

Mount bearing (1) until contact is made. Adjust BILD-25

bearing after it cools. Install sealing cap on orifice (1).

WARNING: Always wear protective gloves to NOTE: Wet contact surface with Loctite (Type No.
prevent burning your hands when handling heated 262).
parts.
NOTE: The sealing cap is not mounted on all
versions. For versions concerned, see corresponding
STEP 21 spare parts list.

2
1

BILD-23

Mount stud bolt (1), torque to 17 Nm (150 pound

inches). Fit rectangular ring (2).
6003-40
STEP 1 STEP 4
8.2 KR Clutch
3

BILD-04

Install ball bearing (2) into the idler gear (1) until
BILD-01
contact occurs and secure it using retaining ring (3).
Heat bearing to approximately +120° C (+248° F).
STEP 5
STEP 2

2
1

BILD-05
BILD-02
Press in pre-assembled idler gear (1) onto the shaft
Mount bearing (1) until contact is made. Adjust
until contact occurs.
bearing after it cools. Fit rectangular ring (2).
WARNING: Always wear protective gloves to STEP 6
prevent burning your hands when handling heated
parts.

STEP 3
1
1
3

BILD-06

Place both O-rings (1 and 2) into the piston grooves

and oil them.
NOTE: Check function of the drain valve (3). The ball
BILD-03
must not jam.
Mount needle bearing (1) onto the shaft and oil it.
 6003-41
STEP 7 STEP 10

1 S1
S2

BILD-07 BILD-10

Place piston (1) into the disc carrier. Preload compression spring using special tool
assembly 380001556 (S1) and pressure piece (S2),
NOTE: Observe installation position.
until L-Ring has engaged the annular grove.
STEP 8 NOTE: Always use a new L-ring.

STEP 11
1 2 3
S
5

6
7

4
BILD-08

Use special tool 380001556 (S) to place piston into

the disc carrier. BILD-11

Disc carrier with piston retraction:

STEP 9 1. Washer
4 2. Compression spring
3 3. Support shim

2 4. L-Ring
5. Disc carrier
1 6. Drain valve (piston)

S 7. Piston with O-Rings.

BILD-09

Mount inner installer (S) onto the disc carrier. Install

disc (1), compression spring (2), support shim (3)
and L-ring (4).
NOTE: Installation position support shim and L-ring
see Step 11. (S) Inner installer, see Step 10.
6003-42
STEP 12 STEP 14
1

2
3

4
1
W130R0054 BILD-16

Install outer and inner discs into the disc carrier (4). Press on end plate (F) approximately 100 N = 10 kg
and set dial indicator to “zero”.
1. Friction disc - coated on one side (2 pcs)
2. Outer discs (9 pcs) STEP 15
3. Inner discs (10 pcs)
NOTE: Make sure that the uncoated (blank) side of F
the friction disc (1) is showing towards the piston.
Number of friction surfaces is 20.
NOTE: Different clutch disc arrangements with
relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.

STEP 13 BILD-17

Press end plate against the snap ring (upwards) and

read disc clearance. Disc clearance should be 2.45
1 to 2.75 mm (0.096 to 0.108 in.).
2 NOTE: In cases of deviation, the disc clearance
must be corrected with an appropriate snap ring.
Optional thicknesses range from 2.1 to 4.2 mm (0.08
to 0.17 in.).

BILD-15

Mount end plate (1) and secure disc package using

snap ring (2) e.g. thickness = 2.65 mm (0.104
in.)/recommended value.
 6003-43
STEP 16 STEP 19

BILD-18 BILD-21

Heat clutch to approximately +120° C (+248° F). Heat bearing to approximately +120° C (+248° F).

STEP 17 STEP 20

L R 1

BILD-19 BILD-22

Install clutch until contact is made. Mount inner discs Mount bearing (1) until contact is made. Adjust
onto the inner disc carrier using short left/right bearing after it cools.
rotations.
WARNING: Always wear protective gloves to
WARNING: Always wear protective gloves to prevent burning your hands when handling heated
prevent burning your hands when handling heated parts.
parts.
STEP 21
STEP 18
2
2 1

BILD-23
BILD-20 Mount stud bolt (1) and torque to 17 Nm (150 pound
Secure clutch (1) using retaining ring (2). inches). Fit rectangular ring (2).
6003-44
STEP 22 STEP 1
8.3 Clutch K1

BILD-24

Check clutch operation by using compressed air at

BILD-01
the hole (see arrow). Closing and opening of the
Heat bearing to approximately +120° C (+248° F).
clutch must be clearly audible.

STEP 23 STEP 2
2
1 1

BILD-02
BILD-25

Install sealing cap on orifice (1). Mount bearing (1) until contact is made. Adjust
bearing after it cools. Fit rectangular ring (2).
NOTE: Wet contact surface with Loctite (Type No.
262). WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
NOTE: The sealing cap is not mounted on all parts.
versions. Versions concerned, see corresponding
spare parts list.
 6003-45
STEP 3 STEP 6
2

1
1
3

2 S

BILD-03 BILD_06

Place both O-rings (1 and 2) into the piston grooves Mount inner installer (S) onto the disc carrier. Install
and oil them. cup spring package (1) and L-ring (2).
NOTE: Check function of the drain valve (3). There NOTE: For installation position of cup spring
must be no jamming of the ball. package and L-ring see Step 8. (S) Inner installer,
see Step 7.
STEP 4
STEP 7

S2 S1

BILD-04

Place piston (1) into the disc carrier. BILD-07

Preload cup spring package using special tool

NOTE: Observe installation position.
380001556 (S1) and pressure piece (S2), until
L-Ring has engaged the annular grove.
STEP 5
NOTE: Always use a new L-ring.

BILD-05

Use special tool 380001556 (S) to place piston into

the disc carrier.
6003-46
STEP 8 STEP 10

1 2
1
3 2

BILD-08 BILD-11

Disc carrier with piston retraction: Mount end plate (1) and secure disc package using
snap ring (2) e.g. thickness = 2.65 mm (0.104
1. Cup spring package
in.)/recommended value.
2. L-Ring
3. Disc carrier STEP 11
4. Piston with O-rings

STEP 9 F

3 2

BILD-12

Press on end plate (F) approximately 100 N = 10 kg

4 and set dial indicator to “zero”.
1
W130R0055

Install outer and inner discs into the disc carrier (4).
1. Friction disc - coated on one side (2 pcs)
2. Outer discs (7 pcs)
3. Inner discs (8 pcs)
NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
Number of friction surfaces is 16.
NOTE: Different clutch disc arrangements with
relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.
 6003-47
STEP 12 STEP 14

F
1

BILD-13 BILD-15

Press end plate against the snap ring (upwards) and Install clutch (1) until contact is made.
read disc clearance. Disc clearance should be 2.00
WARNING: Always wear protective gloves to
to 2.30 mm (0.078 to 0.09 in.).
prevent burning your hands when handling heated
NOTE: In cases of deviation, the disc clearance parts.
must be corrected with an appropriate snap ring.
Optional thicknesses range from 2.1 to 4.2 mm (0.08 STEP 15
to 0.17 in.).

STEP 13 2 3

BILD-16

Mount running disc (1), axial cage (2) and axial

washer (3) and oil it.
BILD-14
NOTE: Install chamfer (see arrow) of running disc
Heat clutch to approximately +120° C (+248° F).
(1) showing towards the axial cage.

STEP 16

BILD-17

Mount needle bearing (1) and oil it.

6003-48
STEP 17 STEP 20

L
R

BILD-18 BILD-21

Install (1) idler. Mount inner discs onto the inner disc Heat bearing to approximately +120° C (+248° F).
carrier (idler) by using short left/right rotations.
STEP 21
STEP 18

3 1
2

BILD-22

BILD-19 Mount bearing (1) until contact is made. Adjust

Mount axial washer (1), axial cage (2) and running bearing after it cools.
disc (3) and oil it.
WARNING: Always wear protective gloves to
NOTE: Install chamfer (see arrow) of running disc prevent burning your hands when handling heated
(3) showing towards the axial cage. parts.

STEP 19 STEP 22

2 1 2

BILD-20 BILD-23

Secure idler gear (1) and single parts by using Mount stud bolt (1) and torque to 17 Nm (150 pound
retaining ring (2). inches). Fit rectangular ring (2).
 6003-49
STEP 23 STEP 2
2
1

BILD-24 BILD-02

Check clutch operation by using compressed air at Mount bearing (1) until contact is made. Adjust
the hole (see arrow). Closing and opening of the bearing after it cools. Fit rectangular ring (2).
clutch must be clearly audible.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
STEP 1 parts.
8.4 Clutch K2
STEP 3

BILD-01

Heat bearing to approximately +120° C (+248° F). BILD-03

Place both O-rings (1 and 2) into the piston grooves

and oil them.
NOTE: Check function of the drain valve (3). There
must be no jamming of the ball.
6003-50
STEP 4 STEP 7

1
S2 S1

BILD-04 BILD-07

Place piston (1) into the disc carrier. Preload cup spring package using special tool
380001556 (S1) and pressure piece (S2), until
NOTE: Observe installation position.
L-Ring has engaged into the annular grove.
STEP 5 NOTE: Always use a new L-ring.

STEP 8

1 2
S
3

BILD-05

Use special tool 380001556 (S) to place piston into

the disc carrier. BILD-08

Disc carrier with piston retraction:

STEP 6 1. Cup spring package
2 2. L-Ring
3. Disc carrier
4. Piston with O-rings
1

BILD_06

Mount inner installer (S) onto the disc carrier. Install

cup spring package (1) and L-ring (2).
NOTE: For installation position cup spring package
and L-ring see Step 8. (S) Inner installer, see Step 7.
 6003-51
STEP 9 STEP 11
1
F

3 2

4 1
W130R0056 BILD-12

Install outer and inner discs into the disc carrier (4). Press on end plate with (F) approximately 100 N = 10
kg and set dial indicator to “zero”.
1. Friction disc - coated on one side (2 pcs)
2. Outer discs (7 pcs) STEP 12
3. Inner discs (8 pcs)
NOTE: Make sure that the uncoated (blank) side of F
the friction disc (1) is showing towards the piston.
Number of friction surfaces is 16.
NOTE: Different clutch disc arrangements with
relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.

STEP 10 BILD-13

Press end plate against the snap ring (upwards) and

read disc clearance. Disc clearance should be 2.0 to
2.3 mm (0.078 to 0.09 in.) see Step 9.
1
2 NOTE: In cases of deviation, the disc clearance
must be corrected with an appropriate snap ring.
Optional thicknesses range from 2.1 to 4.2 mm (0.08
to 0.17 in.).

BILD-11

Mount end plate (1) and secure disc package using

snap ring (2) e.g. thickness = 2.65 mm (0.104
in.)/recommended value.
6003-52
STEP 13 STEP 16

BILD-14 BILD-17

Heat clutch to approximately +120° C (+248° F). Mount needle bearing (1) and oil it.

STEP 14 STEP 17
L R
1

BILD-15 BILD-18

Mount clutch (1) until contact is made. Install (1) idler. Mount inner discs onto the inner discs
carrier (idler) by using short left/right rotations.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts. STEP 18
3
STEP 15
2
3
2 1

BILD-19

Mount axial washer (1), axial cage (2) and running

disc (3) and oil it.
BILD-16

Mount running disc (1), axial cage (2) and axial NOTE: Install chamfer (see arrow) of running disc
washer (3) and oil it. (3) showing towards the axial cage.
NOTE: Install chamfer (see arrow) of running disc
(1) showing towards the axial cage.
 6003-53
STEP 19 STEP 22

2 1 2

BILD-20 BILD-23

Secure idler gear (1) and single parts using retaining Mount stud bolt (1) and torque to 17 Nm (150 pound
ring (2). inches). Fit rectangular ring (2).

STEP 20 STEP 23

BILD-21 BILD-24

Heat bearing to approximately +120° C (+248° F). Check clutch operation by using compressed air at
the hole (see arrow). Closing and opening of the
STEP 21 clutch must be clearly audible.

STEP 1
1 8.5 Clutch K3

BILD-22

Mount bearing (1) until contact is made. Adjust

bearing after it cools.
WARNING: Always wear protective gloves to BILD-01

prevent burning your hands when handling heated Heat bearing to approximately +120° C (+248° F).
parts.
6003-54
STEP 2 STEP 4
3 2

1 1

BILD-02 BILD-04

Mount bearing (1) until contact is made. Adjust Place piston (1) into the disc carrier.
bearing after it cools. Fit rectangular ring (2). Mount
NOTE: Observe installation position.
stud bolt and torque to 17 Nm (150 pound inches).
WARNING: Always wear protective gloves to STEP 5
prevent burning your hands when handling heated
parts.

STEP 3
S

3
2 BILD-05

Use special tool 380001556 (S) to place piston into

the disc carrier.

BILD-03 STEP 6
Place both O-rings (1 and 2) into the piston grooves
and oil them. 2
NOTE: Check function of the drain valve (3). There
must be no jamming of the ball.
1

BILD_06

Mount inner installer (S) onto the disc carrier. Install

cup spring package (1) and L-ring (2).
NOTE: For installation position of cup spring
package and L-ring see Step 8. For inner installer
(S), see Step 7.
 6003-55
STEP 7 STEP 9
1

S2 S1
3 2

4 1
BILD-07 W130R0056

Preload cup spring package using special tool Install outer and inner discs into the disc carrier (4).
380001556 (S1) and pressure piece (S2), until
1. Friction disc - coated on one side (2 pcs)
L-Ring has engaged into the annular grove.
2. Outer discs (7 pcs)
NOTE: Always use a new L-ring.
3. Inner discs (8 pcs)
STEP 8 NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
1 2 Number of friction surfaces is 16.
NOTE: Different clutch disc arrangements with
3
relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
4 arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.

STEP 10

BILD-08

Disc carrier with piston retraction: 1

1. Cup spring package 2
2. L-Ring
3. Disc carrier
4. Piston with O-rings.

BILD-11

Mount end plate (1) and secure disc package using

snap ring (2) e.g. thickness = 2.65 mm (0.104
in.)/recommended value.
6003-56
STEP 11 STEP 13

BILD-12 BILD-14

Press on end plate with (F) approximately 100 N = 10 Heat clutch inner diameter to approximately +120° C
kg and set dial indicator to “zero”. (+248° F).

STEP 12 STEP 14

F
1

BILD-13 BILD-15

Press end plate against the snap ring (upwards) and Mount clutch (1) until contact is made.
read disc clearance. Disc clearance should be 2.0 to
WARNING: Always wear protective gloves to
2.3 mm (0.078 to 0.09 in.).
prevent burning your hands when handling heated
NOTE: In cases of deviation, the disc clearance parts.
must be corrected with an appropriate snap ring.
Optional thicknesses range from 2.1 to 4.2 mm (0.08
to 0.17 in.).
 6003-57
STEP 15 STEP 18
3 3
2 2
1 1

BILD-16 BILD-19

Mount running disc (1), axial cage (2) and axial Mount axial washer (1), axial cage (2) and running
washer (3) and oil it. disc (3) and oil it.
NOTE: Install chamfer (see arrow) of running disc NOTE: Install chamfer (see arrow) of running disc
(1) showing towards the axial cage. (3) showing towards the axial cage.

STEP 16 STEP 19

BILD-17 BILD-20

Mount needle bearing (1) and oil it. Make sure that the running disc is flush with the shaft
collar (see arrow) to ensure that all inner discs are
STEP 17 mounted on the idler gear teeth.

STEP 20
1

L R

BILD-18

Install (1) idler. Mount inner discs onto the inner disc
carrier (idler) using short left/right rotations. BILD-21

Heat bearing to approximately +120° C (+248° F).

6003-58
STEP 21 STEP 1
8.6 K4 Clutch
2
1

BILD-22

Mount bearing (1) until contact is made. Adjust

BILD-01
bearing after it cools. Fit rectangular ring (2).
Heat bearing to approximately +120° C (+248° F).
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated STEP 2
parts.

STEP 22 2
1

BILD-02

Mount bearing (1) until contact is made. Adjust

bearing after it cools. Fit angular ring (2).
BILD-23
WARNING: Always wear protective gloves to
Check clutch operation by using compressed air at
prevent burning your hands when handling heated
the hole (see arrow). Closing and opening of the
parts.
clutch must be clearly audible.
 6003-59
STEP 3 STEP 5

2 2
1

BILD-03 BILD-05

Cool shaft (1) to approximately -80° C (-112° F), heat Mount lower axial washer (1), axial needle cage (2)
gear (2) to approximately +120° C (+248° F) and and upper axial washer (1) and oil it.
mount until contact is made.
NOTE: Upper and lower axial washer are identical.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated STEP 6
parts.

STEP 4 1

1
BILD-06

Mount needle bearing (1) and oil it.

BILD-04 STEP 7
Secure gear using retaining ring (1).

BILD-07

Mount idler gear (1).

6003-60
STEP 8 STEP 10

3
2
1
1

BILD-08 BILD-10

Mount axial washer (1), axial needle bearing (2) and Place piston (1) into the disc carrier.
running disc and oil it.
NOTE: Observe installation position.
NOTE: Mount running disc (3) with the chamfer (see
arrow) pointing to the needle cage. STEP 11
STEP 9

3
2

BILD-11

Use special tool 380001556 (S) to place piston into

BILD-09 the disc carrier.
Place both O-rings (1 and 2) into the piston grooves
and oil them. STEP 12
NOTE: Check function of the drain valve (3). There
must be no jamming of the ball. 2

BILD-12

Mount inner installer (S) onto the disc carrier. Install

cup spring package (1) and L-ring (2).
NOTE: For installation position of cup spring
package and L-ring see Step 14. For inner installer,
see Step 13.
 6003-61
STEP 13 STEP 15

S2 2
S1 3

4 1
BILD-13 W130R0057

Preload cup spring package using special tool Install outer and inner discs into the disc carrier (4).
380001556 (S1) and pressure piece (S2), until
1. Friction disc - coated on one side - (2 pcs)
L-Ring has engaged into the annular groove.
2. Inner discs (5 pcs)
NOTE: Always use a new L-ring.
3. Outer discs (4 pcs)
STEP 14 NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
1 2 Number of friction surfaces is 10.
NOTE: Different clutch disc arrangements with
3 relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
4 arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.

STEP 16

BILD-14

Disc carrier with piston retraction: 1

2
1. Cup spring package
2. L-ring
3. Disc carrier
4. Piston with O-rings

BILD-16

Mount end plate (1) and secure disc package using a

snap ring (2) e.g. thickness = 2.65 mm (0.104
in.)/recommended value.
6003-62
STEP 17 STEP 19

BILD-17 BILD-19

Press on end plate with (F) approximately 100 N = 10 Heat clutch inner diameter to approximately +120° C
kg and set dial indicator to “zero”. (+248° F).

STEP 18 STEP 20

F L
R

BILD-18 BILD 20

Press end plate against the snap ring (upwards) and Mount clutch (1) until contact is made. Mount inner
read disc clearance. Disc clearance should be 1.15 discs onto the inner disc carrier using short left/right
to 1.45 mm (0.045 to 0.057 in.) see Step 15. rotations.
NOTE: In cases of deviation, the disc clearance WARNING: Always wear protective gloves to
must be corrected with an appropriate snap ring. prevent burning your hands when handling heated
Optional thickness range from 2.1 to 4.2 mm (0.08 to parts.
0.17 in.).
STEP 21

BILD-21

Secure clutch using retaining ring (1).

 6003-63
STEP 22 STEP 24

BILD-22 BILD-24

Heat bearing inner ring to approximately +120° C Check clutch operation by using compressed air at
(+248° F). the hole (see arrow). Closing and opening of the
clutch must be clearly audible.
STEP 23
STEP 1
3 8.7 Input shaft
2
1
2

1
BILD-23

Mount bearing (1) until contact is made. Adjust

bearing after it cools. Fit rectangular ring (2). Mount
BILD-01
stud bolt (3). Torque to 17 Nm (150 pound inches).
Cool input shaft (1) to approximately -80° C (-112° F)
WARNING: Always wear protective gloves to and heat drive gear (2) to approximately +120° C
prevent burning your hands when handling heated (+248° F). Mount until contact is made.
parts.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated or
cooled parts.
6003-64
STEP 2 STEP 5

BILD-02 BILD-05

Secure drive gear using retaining ring (1). Heat bearing to approximately +120° C (+248° F).

STEP 3 STEP 6

BILD-03 BILD-06

Heat bearing to approximately +120° C (+248° F). Mount bearing (1) until contact is made. Adjust
bearing after it cools.
STEP 4 WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts.

1 STEP 7

2
BILD-04

Mount bearing (1) until contact is made. Adjust

bearing after it cools.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated BILD-07

parts. Install snap ring (1) into the annular groove of the
turbine shaft (2).
 6003-65
STEP 8 STEP 1
8.8 Output Shaft

BILD-08

Mount turbine shaft (1) until the snap ring engages

BILD-01
into the input shaft groove. Snap in and interlock
Heat bearing to approximately +120° C (+248° F).
rectangular ring (2).
NOTE: Turbine shaft is axially secured. STEP 2
STEP 9
3 1

BILD-02

Mount bearing (1) until contact is made. Adjust

BILD-09 bearing after it cools.
Version with lock-up clutch:
WARNING: Always wear protective gloves to
Mount turbine shaft (1) until the snap ring engages prevent burning your hands when handling heated
into the input shaft groove. Snap in and interlock parts.
rectangular ring (2 and 3).
NOTE: Turbine shaft is axially secured. STEP 3

BILD-03

Mount screen sheet (1).

6003-66
STEP 4 9.0 Installation of input shaft, output
shaft, pump shaft (power-take off shaft)
and clutches

STEP 1

BILD-04

Heat bearing to approximately +120° C (+248° F).

2
STEP 5
BILD-01

NOTE: If the suction tube (1) in the front housing is

1 to be replaced, a special rolling tool 380001285 must be
used for assembly. Secure the tube with cylindrical bolt (2).
Torque to 23 Nm (17 pound feet).
NOTE: Oil cylindrical bolt. It is always necessary to
use new cylindrical bolts.

STEP 2

BILD-05

Mount bearing (1) until contact is made. Adjust

bearing after it cools.
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts. 1

BILD-02

NOTE: The lubricating oil tube (1) is supplied as a

complete package with the front housing only. Single
parts delivery are available only upon request.
NOTE: Assembly is only possible with special tool
380001286.
 6003-67
STEP 3 STEP 5

3 3

1 2

1 2

4 4
BILD-03 BILD-05

Mount O-rings into the oil tube annular grooves (1 NOTE: The lubricating oil tubes (1 and 2) are
and 2) and oil them. Then insert tubes into the front supplied as a complete package with the rear
housing. Oil cylindrical bolts (3 and 4) and secure housing. Single parts delivery available only upon
them. Torque to 23 Nm (17 pound feet). request.
NOTE: Always use new cylindrical bolts. NOTE: Assembly is only possible with special tool
380001287.
STEP 4
STEP 6
4
3 1

6 8

7
1 5
2 2

BILD-04

Mount O-rings into the oil tube annular grooves (1 BILD-06

and 2) and oil them. Then insert tubes into the front Insert all bearing outer rings into the bearing holes of
housing. both housing sections. Front housing.
1. Input
2. Output
3. Forward clutch
4. Reverse clutch
5. K1 = 1st gear clutch
6. K2 = 2nd gear clutch
7. K3 = 3rd gear clutch
8. K4 = 4th gear clutch.
NOTE: For installation position, see Step 6 and 7.
6003-68
STEP 7 STEP 9

3 1
4
1
8 6
5 7 2

BILD-07 BILD-09

Rear housing legend see Figure 6. Place bearing Slightly lift drive gear (1) and position K4 clutch (2).
outer rings into the bearing holes using assembly
grease. STEP 10
NOTE: If contrary to manufacturer recommendation,
the tapered roller bearings of clutches, input and
output are not replaced, you must ensure the
previous pairing (bearing inner ring/bearing outer
ring) - see disassembly instructions.
1
STEP 8

1
BILD-10
3
Mount K3 clutch (1).

STEP 11

BILD-08
1
Place KR clutch (1), AN input shaft (2) and KV clutch
(3) into the housing rear section at the same time.
WARNING: Risk of injury.
NOTE: Due to installation conditions, the installation
of single clutches without using the special tool is not
possible.
NOTE: Housing rear section will be removed again
later. BILD-11

Position K2 clutch (1).

 6003-69
STEP 12 STEP 15

1 7 5
2 2
6
1
3

4
S
BILD-12 BILD-15

Slightly lift K4 clutch (1) and position K1 clutch (2). Secure clutches K1 (1), K2 (2), K3 (3) and K4 (4) by
using a special handle tool 380001557 (S). Check all
STEP 13 rectangular rings, grease and align them centrically.
NOTE: This step shows the installation position of
the individual clutches in the rear housing.
WARNING: Clutches KV (5), KR (6) and input shaft
AN (7) are only secured by the gear chain. Care must
2 be taken to ensure these non-secured components
do not detach.

STEP 16
3
1

BILD-13

Press ball bearing (1) onto the pump shaft (2) until
contact is made. Mount rectangular ring (3). Grease
and centrically align rectangular ring.

STEP 14 3
1
2 4
BILD-16

Pivot rear housing 180 degrees by using a suitable

lifting device.
1. Clutch KV
2. Input shaft

1 3. Clutch KR
4. Pump shaft.
2
WARNING: Clutches KV, KR and input shaft (2) are
BILD-14
only secured by the gear chain. Care must be taken
Mount pump shaft (1) until contact is made. Attach to ensure these non-secured components do not
pump shaft using retaining ring (2). detach.
6003-70
STEP 17 STEP 20

4 2 3 1

BILD-17 BILD-20

Use the suitable lifting device to bring the rear Oil cylindrical bolts (1) and use them to attach screen
housing into contact position with the front housing sheet (1). Torque to 23 Nm (17 pound feet). Mount
by cautiously assembling the clutches. Then remove O-rings (2) into the annular grooves of the oil tubes
handles. and oil them. Mount all rectangular rings (4), grease
and align them centrally. Wet mounting face (3) with
STEP 18 sealing agent Loctite (type No. 574).
NOTE: Always use new cylindrical bolts.

STEP 21

BILD-18

Remove the rear housing again.

STEP 19 BILD-21

Carefully bring the front housing into contact position

with the rear housing by using a suitable lifting
device.
2
NOTE: Be sure that both oil tubes are aligned with
the holes in the rear housing.

BILD-19

Position screen sheet (1). Install pre-assembled

output shaft (2).
 6003-71
STEP 22 STEP 24

1 3 1
1 2 1

BILD-22 BILD-24

Fit both cylindrical pins (1) centrically to the mounting Join front and rear housing sections using cylindrical
face bolts (1). Torque to 46 Nm (34 pound feet). Mount
securing plate (2). Mount stud bolts (3) and torque to
STEP 23 15 Nm (133 pound inches).
NOTE: Wet bolt-in thread with Loctite (type No. 243).
S
STEP 25
1 1

BILD-23

Check clearance of the gear drive train. Position

driving element (S) and rotate KV clutch shaft.
Driving element can be fabricated by dealer.
BILD-25

NOTE: If interference of the movable parts (e.g. on The bolt plugs (1) must be mounted with a hydraulic
the screen sheet or on the oil tubes) is found, it must pneumatic pressing tool.
be corrected. Do this step on all clutch shafts.
NOTE: In case of damage the pre-mounted rear
transmission housing must be fully replaced.
6003-72
10.0 Outputs and closure parts pump STEP 3
shaft (PTO-shaft)

STEP 1 1 3
2
10.1 Output flange output side with brake FSG-88

BILD-16

Insert O-ring into the space between output flange

and shaft. Attach output flange (1) using washer (2)
and hex bolts. Oil hex bolts before the assembly.
Torque to 46 Nm (34 pound feet). Mount cylindrical
BILD-14 bolt with washer (3) for stop of the parking brake set
Use driver tool 380001560 (S) to mount shaft seal screw. Tightening torque 48 Nm (35 pound feet).
with the sealing lip showing to the oil sump. Fill space
between sealing lip and dust lip with grease. Wet NOTE: Always use new hex bolts.
outer diameter (rubber-coated) with mineral spirit.
STEP 4
NOTE: Use of specified driver (S) ensures the exact
installation position.
NOTE: For installation position of shaft seal see
Step 4. 2
STEP 2 1
3

1 BILD-17

Secure brake disc (1) at output flange (2) using hex

bolts and washers. Torque to 68 Nm (50 pound feet).
Connect a hand-operated pump at port (see arrow)
and apply approximately 80 bar (1160 PSI) pressure
to the parking brake (3) and bring it in contact
BILD-15
position.
Press screen sheet (1) onto the output flange (2).
Mount output flange (2) until contact is made.
 6003-73
STEP 5 STEP 7
2

BILD-18 BLD-20

Attach parking brake (1) on transmission housing Insert setting gauge on both sides between base disc
using the hex bolt - guide pin (2). Torque to 46 Nm and brake disc and hold in its position. Clearance:
(34 pound feet). 0.5 - 1.5 mm (0.020 - 0.059 in.). Nominal clearance:
1.0 mm (0.039 in.).
STEP 6 NOTE: For all installation, fitting and maintenance
instructions, functional characteristics and setting
specifications of the parking brake, see
manufacturer’s documentation.

STEP 8
10.2 Output flange on converter side (Standard
versions)

BILD-19
S
Secure hex nut on brake caliper using the open end
wrench insert. Torque to 300 Nm (221 pound feet).

BILD-26

Use driver tool 380001560 (S) to mount shaft seal,

with the sealing lip showing to the oil sump.
NOTE: Use of the specified driver (S) ensures the
exact installation position.
NOTE: Fill space between sealing lip and dust lip
with grease.
NOTE: For installation position shaft seal see Step
34.
6003-74
STEP 9 STEP 11

2 3

1 3
1
4

2
5
BILD-27 BILD-29

1. Shaft seal Insert O-ring into the space between output flange
and shaft. Secure output flange (1) using washer (2)
2. Gearbox housing - rear section
and hex bolts (3). Oil hex bolts before the assembly.
3. Roller bearing Torque to 34 Nm (25 pound feet).
4. Output shaft NOTE: Always use new hex bolts.
5. Screen sheet

STEP 10
2

BILD-28

Press screen sheet (1) onto the input flange (2).

Mount output flange (2) until contact is made.
 6003-75
11.0 Reassembly: Engine connection, oil STEP 3
pressure pump, converter back-pressure
valve and temperature sensor
(measuring point “63” after the converter
1
as described in the specifications,
pressure checks and troubleshooting
section of the manual)

STEP 1
11.1 Converter back-pressure valve

1 BILD-03

Mount temperature sensor (1) with O-ring. Torque to

25 Nm (18 pound feet).
2 NOTE: For version without a temperature sensor, fit
5 3
a plug (1) with O-ring and torque to 25 Nm (18 pound
feet).

STEP 4
4 11.2 Oil pressure pump

BILD-01

The Step shows the single parts of the converter 3

back-pressure valve.
1. Oil feed housing
2. Piston 1 2
3. Compression spring
4. Pressure plate
S S
5. Locking plate.
NOTE: Install pressure plate (4), with the pin (6 mm
diameter) facing towards the locking plate (1).
BILD-04

Insert pressure relief valve (1) into the housing hole

STEP 2 until contact is made. Mount two M8 adjusting bolts
(S) and position gasket (2) and oil feed housing (3).
Use assembly grease.
NOTE: The pressure relief valve is not mounted on
2 all versions. Versions concerned, see the
corresponding spare parts list.
1

BILD-02

Assemble single parts, preload them with

screwdriver (1) and secure them with the locking
plate (2).
6003-76
STEP 5 STEP 8

1
1

BILD-05 BILD-08

Install two adjusting bolts (S) and mount stator shaft Position control disc and secure it radially using two
(1). cylindrical bolts (1). Place O-ring (2) into the annular
groove and oil it.
NOTE: Pay attention to radial installation position.
NOTE: Do not tighten the cylindrical bolts - only turn
STEP 6 them in until contact is made and then turn them
back by approximately 1/2 a turn. Pay attention to the
installation position of the control disc in figure.

STEP 9

BILD-06

Install outer rotor with the chamfer (see arrow) facing

downwards.
2
NOTE: If there are wear marks in the pump housing
BILD-09
or on the control disc, replace the pump assembly.
With the sealing lip positioned facing downward,
carefully insert the shaft seal (1) into the pump
STEP 7 housing with suitable driver (2) until contact is made.
NOTE: Wet outer diameter of shaft seal with mineral
spirits.

BILD-07

Install inner rotor with the teeth (see arrow) facing

upwards.
 6003-77
STEP 10 STEP 13

2 1
1 2
4 2
3

BILD-10 BILD-13

Oil sliding bearing (see arrow) before assembly. Secure oil feed housing (1) equally using Torx bolts
Mount inner installer (S) onto the stator shaft. Mount (2). Torque to 23 Nm (17 pound feet). Secure plate
pre-assembled transmission pump (1). (3) using cylindrical bolts (4). Torque to 46 Nm (34
pound feet).
NOTE: Pay attention to radial installation position.
STEP 14
STEP 11
1
2

BILD-14
BILD-11
Secure converter bell housing (1) using hex bolts (2).
Mount pre-assembled pump with driver (S) until
Torque to 65 Nm (48 pound feet).
contact is made.

STEP 12

2
1

BILD-12

Grease O-rings and fit them to the cylindrical bolts

(1). Secure transmission pump (2) using cylindrical
bolts. Torque to 46 Nm (34 pound feet).
6003-78
STEP 15 STEP 17
11.3 Engine connection (remote mount)
1
2
1
2
3

BILD-20

Install ball bearing (1) and secure it using V-ring (2).

BILD-18

Bolt input shaft (1) to flex plate (2) using hex bolts (3).
Torque to 115 Nm (85 pound feet). STEP 18
NOTE: Wet threads of hex bolts with Loctite (Type
No. 262). S
STEP 16

1 2 1

BILD-21

Put cover (1) onto the converter and press it until

contact is made.
NOTE: Support the pressure sleeve (S) on the
bearing inner ring.
BILD-19

Secure flex plate (1) to converter (3) using hex bolts

(2). Torque to 115 Nm (85 pound feet). STEP 19
NOTE: Wet threads of hex bolts with Loctite (Type
No. 262).

BILD-22

Press screen sheet (1) onto the input flange (2).

 6003-79
STEP 20 STEP 22

1 3

BILD-23 BILD-25

Heat flange inner diameter to approximately +120° C Secure input flange (3) using washer (1) and hex
(+248° F). bolts (2). Oil hex bolts before assembly. Torque to 34
Nm (25 pound feet).
STEP 21 NOTE: Always use new hex bolts.

1 STEP 23

BILD-24
2
Mount input flange (1) until contact is made.
WARNING: Always wear protective gloves to BILD-26

prevent burning your hands when handling heated Position converter using a suitable lifting device until
parts. the cover (1) is in contact with the converter bell
housing (2).
6003-80
STEP 24 STEP 2

1 1

2
3

BILD-27 BILD-02

Bolt converter bell housing (1) to cover (2) using Attach cover using hex bolts (1). Torque to 23 Nm (17
cylindrical bolts and hex nuts (3). Torque to 46 Nm pound feet).
(34 pound feet).
NOTE: Pay attention to radial installation position
markings made during disassembly (see arrows).
12.0 Reassembly - Emergency steering
pump

STEP 1
12.1 Version without emergency steering pump

1
S

BILD-01

Install adjusting bolts (S) and assemble seal (1) and

cover (2).
 6003-81
13.0 Reassembly: Inductive sensor, Hall STEP 2
sensor, breather, oil filler and oil drain
plug 4
STEP 1
1 2 3 4
2

3 5
1
BILD-02

Mount oil drain plug with O-ring (1) and torque to 80

Nm (59 pound feet). Attach oil level tube (2) with seal
6 to the housing front section and secure it using hex
bolts (3). - torque to 34 Nm (25 pound feet). Fasten
dipstick (4) in oil level tube. Attach identification plate
(5) to the housing front section.
NOTE: Use Loctite (type No. MS 9360).
7
5

9 8
BILD-01

Mount inductive sensors (1,2 and 3) with O-rings and

torque to 30 Nm (22 pound feet).
1. Inductive sensor - turbine speed
2. Inductive sensor - speed/central gear chain
3. Inductive sensor - engine speed.
Mount breather (4) and torque to 12 Nm (106 pound
inches). Mount speed sensor (Hall sensor) - output
speed (5) with O-ring. Secure it using a cylindrical
bolt (6) and torque to 23 Nm (17 pound feet). Mount
plug (7) with O-ring and torque to 80 Nm (59 pound
feet). Attach cover (8) with seal to the housing front
section securing it with hex bolts (9), torque to 23 Nm
(17 pound feet).
6003-82

14.0 Reassembly Electro-hydraulic

control with proportional valves

STEP 1

Main pressure valve 16+2 bar Pressure reducing valve 9 bar Wiring harness

A A

B
B
Cover Cover

Housing Valve block Housing

CHAPTER 14 - FIG. 1.PNG

Electro-hydraulic Control
NOTE: Different versions regarding the wiring
harness position are possible. Please observe the
vehicle manufacturer’s specifications.
The following sketches show the sectional views of
the electro-hydraulic control.
 6003-83

STEP 2
Proportional valve P5

Vibration damper

Pressure controller
Follow-on slide

CHAPTER 14 - FIG. 2.PNG

STEP 3
Main pressure valve 16+2 bar Valve block Wiring harness

Pressure reducing valve 9 bar

Duct plate
CHAPTER 14 - FIG. 3.PNG

Main Pressure Valve

STEP 4
14.1 Fitting of electric control

1 1

BILD-04

NOTE: Check all single parts for damage and

replace if required. Ensure free travel of the moving
parts in the valve block before installation. Pistons
can be exchanged individually. Before installation, oil
single parts.
With the concave side facing upward, insert orifice
(1) until contact is made.
6003-84
STEP 5 STEP 7

2
1

3 S
S

2
1
BILD-05 BILD-07

NOTE: See arrows for installation position. Fit adjusting bolts 380001577 (S). Mount seal (1) and
housing (2). Then position housing equally using the
This Step shows the following single parts:
adjusting bolts until contact is made.
1. Pressure reducing valve (1x, piston and
compression spring) STEP 8
2. Vibration damper (3x, piston and compression
spring) 1
3. Follow-on slide (3x, piston and compression
spring)

STEP 6

BILD-08

Bring housing (1) into contact position using the Torx

bolts. This preloads the pistons, allowing removal of
the cylindrical pins (assembly aid).
S
STEP 9
BILD-06

Install the single parts shown in Step 5. Preload 1

compression springs of the follow-on slides and
temporarily secure pistons using 5.0 mm diameter
cylindrical pins (S).

BILD-09

Secure housing using the Torx bolts (1) and torque to

5.5 Nm (49 pound inches).
 6003-85
STEP 10 STEP 12
1 3

2 1

BILD-10 BILD-12

Mount pressure controllers with O-ring (1) and Install the single parts shown in Step 11. Preload the
secure them using securing plates (2) and Torx bolts compression springs of the follow-on slides and
(3). Torque to 5.5 Nm (49 pound inches). temporarily fasten the pistons using the 5.0 mm
diameter cylindrical pins (S).
NOTE: Install securing plate with the claw side
facing downward. Pay attention to the radial Install two adjusting bolts (S). Assemble flat gasket
installation position of pressure controllers. (1) and housing cover. Place the housing cover
equally until contact by using the adjusting bolts.
STEP 11
STEP 13

1
1

3 2
BILD-11

Preassemble the opposite side with the following BILD-13

single parts: Preload the pistons with Torx bolts and remove the
cylindrical pins (assembly aid) again. Then secure
1. Main pressure valve (1x, Piston and
the housing cover using Torx bolts (1). Torque to 5.5
compression spring)
Nm (49 pound inches).
2. Vibration damper (3x, Piston and compression
spring)
3. Follow-on slide (3x, Piston and compression
spring).
6003-86
STEP 14 STEP 16

1 1

BILD-14 BILD-16

Mount the pressure regulators with O-ring (1) and Install flat gasket (1) and assemble the plug socket
fasten them using securing plates and cap screws. with the slot facing the lug of the cover until it makes
Torque to 5.5 Nm (49 pound inches). contact. Secure the cover using cap screws and
torque to 5.5 Nm (49 pound inches).
NOTE: Install the securing plate with the neck facing
downward. Observe radial installation position of the
pressure regulators. STEP 17

STEP 15 1

BILD-17

Secure the wiring harness using the retaining clamp

(1). Install the opposite cover.
BILD-15

Assemble the wiring harness (1) and connect the NOTE: For version with torque converter lock-up
pressure regulators. clutch solenoid valve, go to Steps 29 & 30.
NOTE: See Step 1 for installation position of
pressure regulators. Pay attention to the installation STEP 18
position of the wiring harness - see markings made
during disassembly. S

BILD-18

Install two adjusting bolts (S).

 6003-87
STEP 19 STEP 21

1 1 1 2

BILD-19 BILD-21

Flush-mount screens (1) into the holes of the sealing Position duct plate (1) and secure it equally using
plate, see arrows. Torx bolts (2). Torque to 10.5 Nm (93 pound inches).
NOTE: Pay attention to the installation position, -
screens should face upwards toward the duct plate. STEP 22

STEP 20
1
2 3

BILD-22

Install bolt plugs with O-rings (1) and torque them to

6 Nm (53 pound inches).
BILD-20

Attach sealing plate (1) and duct plate (2). Screens

(3) should face upward. STEP 23
NOTE: Do not re-assemble the seal plate after
opening the threaded joint shift unit/duct plate. In
case of repair, always mount a new seal plate.

BILD-23

Insert converter safety valve (1) into the housing hole

until contact is made.
6003-88
STEP 24 STEP 26

2 1
1

2
3 4

BILD-24 BILD-26

Mount stud bolts (1) and torque to 15 Nm (133 pound Mount compression spring (4), piston (3) and switch
inches). (2) with new O-ring. Torque to 30 Nm (22 pound feet).
NOTE: Wet bolt-in thread with Loctite (Type No. 1. Filter differential pressure valve
243).
2. Switch with O-ring
Position seal (2) and duct plate (3) on the rear
3. Piston
housing until contact is made.
4. Compression spring
NOTE: Use assembly grease.
STEP 27
STEP 25
S

2
4
1
3

1
BILD-27
BILD-25
Fit two adjusting bolts (S). Mount sealing plate (1)
Secure duct plate (1) using Torx bolts (2) and hex
and electro-hydraulic control unit (2).
nuts (3). Torque to 23 Nm (17 pound inches). Mount
plug (4) with new O-ring and torque to 30 Nm (22 NOTE: Do not re-assemble the seal plate after
pound feet). opening the threaded joint of the shift unit/gearbox
housing. In the case of repair, a new seal plate must
be mounted.
 6003-89
STEP 28 STEP 30

3 1

4
2

BILD-28 BILD-30

Secure electro-hydraulic control unit (1) evenly using Secure pressure controller (1) using cylindrical bolts
Torx bolts (2) and torque them to 9.5 Nm (84 pound (2) and torque to 10 Nm (89 pound inches). Fit bolt
inches). necks (3) with O-ring and torque to 25 Nm (18 pound
feet). Fit plug (4) with O-ring and torque to 10 Nm (89
NOTE: For version with torque converter lock-up
pound inches).
clutch solenoid valve, go to Steps 31 and 32.
NOTE: Go back to Step 18.
STEP 29
14.2 Version with torque converter lock-up clutch STEP 31
solenoid valve Pipe - System pressure to lock-up clutch valve.

3
2 1

BILD-29 BILD-31

Position seal (1) and secure connecting housing (2) Secure pipe (1) with hollow bolt (2) and bolt nut (3).
using Torx bolts (3). Tightening torque 5.5 Nm (49 Fit O-ring on to hollow bolt (2), insert it into the eye of
pound inches). the pipe and torque to 45 Nm (33 pound feet). Attach
bolt nut (3) and torque to 35 Nm (26 pound feet).
NOTE: Pay attention to installation position of
connection housing, see markings applied during
disassembly.
6003-90
STEP 32 STEP 34
Pipe - System pressure from lock-up clutch valve
to lock-up clutch.

3 BILD-34

Install new filter element.

BILD-32 NOTE: Before putting the transmission into
Insert screw-in sleeve (1) and torque to 45 Nm (33 operation, fill it with oil according to operators
pound feet). manual.
NOTE: Wet bolt-in thread with Loctite (Type No.
243).
Secure pipe (2) with nuts (3 and 4). Torque nut (3) to
35 Nm (26 pound feet). Torque nut (4) to 45 Nm (33
pound feet).

STEP 33
14.3 Fitting of filter (pressure filter)

BILD-33

Secure filter head (1) with new O-rings to the rear

housing using Torx bolts (2). Torque to 34 Nm (25
pound feet).
Section
6004

6004
FRONT AXLE
6004-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REPLACing HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal and Disassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Brake Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Brake Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal and Disassembly Differential Locking version DHL-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Reassembly Differential locking version DHL-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adjust Disc Clearance of Differential Lock (100% lock for DHL-1200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Setting Backlash and Bearing Preload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Contact Pattern Check of Bevel Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Leakage Test of DHL (100% lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Shaft Seal / Imput Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
 6004-3

SPECIFICATIONS

W130C Axle Options LSD (*) HD (**)

Multitrac Axle Tipe MT-L3075II MT-L3065II MT-L3075II MT-L3075II

Position Front Axle Rear Axle Front Axle Rear Axle

Differential Limited Slip Differential Differential Locking Differential Open

Yoke DS1480 DS1480 DS1480 DS1480

Flange to Flange (mm) 1984 1984 1984 1984

Axle Ratio 21.53 21.53 21.53 21.53

Ratio Beverl Gear 3.36 3.36 3.36 3.36

Ratio Planetary Drive 6.4 6.4 6.4 6.4

Differential version DZ1200 DZ1200 DHL1200 D1200

Differential type Limited Slip Differential Differential Locking Differential Open

Axle Installation Dimension Spring pad Above center pivot Spring pad Above center pivot
8x27, 788-1018.4 200 8x27, 788-1018.4 200

Output Shaft 12xM22x1.5; threads 12xM22x1.5; threads 12xM22x1.5; studs 12xM22x1.5; studs
PCD 425 PCD 425 PCD 425 PCD 425

Sealing Lip Seal Lip Seal Metal Face Seal Metal Face Seal

Brake 4 x Paper Jinmyung 4 x Paper Jinmyung 4 x Sinter 4 x Sinter

Oil Volume (liters/U.S. Quarts) 22 (23.2) 22 (23.2) 22 (23.2) 22 (23.2)

* Limited Slip Differential

** Heavy Duty

SPECIFICATIONS
Brake Wear Measurement..................................................................................................... 4.0 mm Max (0.16 inch)
Sun Gear Shaft End Play ............................................................................................................1.00 mm (0.04 inch)
Drive Pinion Rolling Torque................................................................................... 1.1 to 2.3 Nm (9.7 to 20.4 lb-inch)

SPECIAL TORQUES
Bolts Securing Brake Housing to Axle Housing...................................................................390 Nm (288 pound feet)
Wheel End Retainer Bolts ...................................................................................................500 Nm (369 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads)..................................................700 Nm (516 pound feet)
Bolts Securing Differential Housing to Axle Housing...........................................................390 Nm (288 pound feet)
Bolts Securing Differential Cover and Ring Gear ................................................................410 Nm (302 pound feet)
Nut for Securing Brake Tube to Axle Housing.......................................................................100 Nm (74 pound feet)
Brake Tube to Axle Housing Fitting .......................................................................................100 Nm (74 pound feet)
Brake Tube Axle Housing Fitting .............................................................................................36 Nm (27 pound feet)
Breather Plug...........................................................................................................................50 Nm (37 pound feet)
Oil Drain Plugs (Outputs).........................................................................................................50 Nm (37 pound feet)
Oil Fill Plug / Dipstick...............................................................................................................50 Nm (37 pound feet)
Brake Lining Check Plug .........................................................................................................50 Nm (37 pound feet)
Brake Bleeder Valve.................................................................................................................6 Nm (4.4 pound feet)
Brake Return Spring Retainer Bolts ........................................................................................34 Nm (25 pound feet)
6004-4

GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased

BS01D011 BS01D009
COAST SIDE (CONCAVE)

BS01D013
COAST SIDE (CONCAVE)
BS01D012
DRIVE SIDE (CONVEX)

BS01D014
DRIVE SIDE (CONVEX)
 6004-5
Pinion Distance Must Be Decreased

BS01D016

BS01D010 DRIVE SIDE (CONVEX)

BS01D015
COAST SIDE (CONCAVE)
6004-6

LUBRICATION

3 3

1
2
3 3

8 7

5 6 4
6 5
9 4 9

W110R563

1. OIL DRAIN HOLE (AXLE HOUSING) 4. BRAKE BLEEDER 7. PLUG

2. OIL DRAIN HOLE (OUTPUTS) 5. CONNECTION DIFF. LOCK AND BREATHER 8. OIL FILLER AND OVERFLOW
3. OIL FILL PLUG & DIPSTICK 6. BRAKE INLET 9. WEAR CHECK DISC BRAKE
NOTE: Rear axle shown. Refer to section 1002 of this service manual for proper lubricant.

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BD07N211-01 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

BD06G004-01

Use lifting bracket, to hold wheel end. Loosen and

remove the bolts and washers.

STEP 4
2
BD08A277-01

Fasten axle on a stand. 1

STEP 2

BD07N013-01

Carefully pull the wheel end from the axle housing.

Remove and discard O-ring (1) from axle housing
wheel end and O-ring from brake port (2).

STEP 5
W110R567

BD06G005-01

Mount the wheel end on a stand.

W110R568

Remove drain plugs and drain oil from axle housing.

6004-8
STEP 6 STEP 9

BD07N113-01 BD07N110-01

Remove sun gear from the planetary gears. Do not Remove the end shim from the brake housing.
loose the shim (s) located in the sun gear shaft.
STEP 10
STEP 7

BD07N109-01

BD07N112-01 Remove plate from brake housing.

Remove snap ring on all three planetary gears.
STEP 11
STEP 8

BD07N108-01
BD07N045-01 Remove brake disk from brake housing.
Use an acceptable tool and remove planetary gear
and bearing, repeat procedure for the other two
gears.
 6004-9
STEP 12 STEP 15

BD07N107-01

Remove brake plate from brake housing. BD07N093-01

Remove the four bolts holding the wheel end to the

STEP 13 output shaft of the carrier.
Repeat Steps 11, and 12 to remove the remaining
brake plates, and friction plates. STEP 16

STEP 14

BD07N090-01

Remove the retainer from the wheel end.

BD07N097-01

STEP 17

BD07N094-01

Pry the cover off from the output shaft. Remove and
BD07N089-01
discard O-ring from cover.
Attach an acceptable lifting device to the wheel end
and remove the wheel end of axle from the brake
housing.
6004-10
STEP 18 STEP 20

BD07N087-01 BD07N047-01

Attach an acceptable lifting device to the brake Inspect the carrier output shaft bearing. If damaged
housing and remove from the carrier. score with a die grinder and remove bearing cage.
Then score bearing with die grinder and break with a
STEP 19 hammer and chisel.

STEP 21

BD07N046-01

BD07N035-01

Remove the face seal ring metal ring from the wheel
end shaft using a pry bar.

BD06G015-01

Inspect the stop pin (plug) for wear. If necessary drill

a hole into the pin, use acceptable tool and remove
the pin.
 6004-11
STEP 22 STEP 25

BD07N052-01
BD06G022

Inspect bearing on wheel end shaft. If damaged Remove return spring from the brake housing.
score with a die grinder and remove bearing cage.
Then score bearing with die grinder and break with a STEP 26
hammer and chisel.

STEP 23

BD07N055-01

Remove shim from the brake housing.

STEP 27
BD07N049-01

Remove six bolts from the return spring retainer.

STEP 24

BD07N056-01

Pry brake piston from the brake housing alternate

sides in order to raise piston evenly.

BD07N054-01

Remove return spring retainer.

6004-12
STEP 28 STEP 31

BD07N059-01 BD07N063-01

Remove brake piston from brake housing. Remove upper seal from break housing.

STEP 29 STEP 32

BD07N065-01
BD07N067-01

Remove wear ring from brake housing. Remove lower seal, located in the same groove as
lower back-up ring from the brake housing.
STEP 30
STEP 33

BD07N064-01
BD07N066-01
Remove upper back-up ring, located in same groove
as upper seal from the brake housing. Remove lower back-up ring from the brake housing.
 6004-13
STEP 34 Cleaning and Inspection
IMPORTANT: Do not use compressed air to dry bearings.
Allow bearings to air dry.

STEP 37
Clean all parts except friction plates in brake disc
pack using cleaning solvent. WEAR FACE
PROTECTION WHEN USING COMPRESSED AIR.
Use compressed air to clear passages in planetary
ring gear and brake housing.

STEP 38
Inspect bearing rollers for pitting, scoring,
BD07N079-01
deformation, or other damage. Check inner face and
Drive out the outer bearing cup on the brake housing. bearing cage for deformation, dents, and other
da mag e. Ch eck associated b earing cup s fo r
STEP 35 scratches, grooves, or cracks. Check bearings for
rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth,
replace the bearing.

STEP 39
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
NOTE: If a bearing or bearing cup requires replacement,
the associated part must also be replaced.

STEP 40
BD07N080-01
Check planetary ring gear, planetary gears, and
Flip brake housing over and pry out face seal. planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of
STEP 36 these conditions are seen. Check planetary carrier
shaft splines for broken, cracked, or twisted
condition. Replace if necessary.

STEP 41
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.

BD07N081-01

Drive out inner bearing from the brake housing.

6004-14

Assembly STEP 44
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 42
WARNING: Always wear heat protective gloves
to prevent burning your hand when handling
heated parts.
SM121A

BD07N038-01

Apply Loctite 574 to the seal ring mounting surface.

STEP 45
WARNING: Always wear heat protective gloves
to prevent burning your hand when handling
heated parts.
SM121A

BD07N040-01

Heat the wheel end shaft outer bearing to 120qC

(248qF) 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.

STEP 43

BD07N039-01

Heat the seal ring to approximately 120° C (248° F),

place the face seal ring on the wheel end shaft.

BD07N037-01

Clean mounting surface of seal ring area on wheel

end.
 6004-15
STEP 46 STEP 48
WARNING: Always wear gloves to prevent
frostbite to your hands when handling frozen parts.
SM118A

BD06G084-01

Use acceptable tool to drive seal ring into position on

hub.
NOTE: Be sure the sealing ring is fully seated. BD07N082-01

Place outer bearing cup in dry ice for several hours to

STEP 47 freeze. Install the outer bearing cup into the brake
housing until seated against the shoulder in the
WARNING: Always wear gloves to prevent brake housing.
frostbite to your hands when handling frozen parts.
SM118A STEP 49

BD07N083-01 BD06G032-01
Place inner bearing cup in dry ice for several hours to
freeze. Install the inner bearing cup into the brake A A
housing until seated against the shoulder in the
brake housing. 1
A

BS00M073

1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
6004-16
Wet the outer diameter of the face seal with a STEP 52
solution of 50% water and 50% mineral spirits. Use
suitable tool to install the face seal with the seal lip
positioned as shown. Apply grease to seal as
indicated by (A) above.

STEP 50

BD07N072-01

Install the lower seal (2) in the same groove as the

lower back-up ring (1). Make sure seal is installed as
shown in Step 56.

STEP 53
BD07N069-01

Clean seal grooves in brake housing with solvent.

STEP 51

BD07N074-01

Install the upper seal (4) into the brake housing.

Make sure seal is installed as shown in Step 56.

BD07N070-01 STEP 54
Install the lower back-up ring (1) into the brake
housing.

BD07N075-01

Install upper back-up ring (5) into the same groove

as the upper seal.
 6004-17
STEP 55 STEP 57

BD07N077-01 BD07N086-01

Clean the groove of the brake housing with cleaning Drive the adjustment pins flush with the surface of
solvent. Install wear ring (6) into the top groove of the the brake piston.
brake housing.
NOTE: Orientation of brake piston when driving in pins.
IMPORTANT: Ensure correct installation position of wear
ring end points must be in the 12 o’clock position in the STEP 58
axle when installed in the machine in the area of brake oil
supply and vent hole.
NOTE: Make sure that the wear ring is installed correctly
in the groove around the entire circumference of the brake
housing. Then apply Loctite 415 at its end points.

STEP 56

6
BD07N061-01
5

BC08A246
WEAR RING, BACK-UP RINGS AND SEAL LOCATION
BD07N062-01
1. LOWER BACK-UP RING 4. UPPER SEAL
Apply oil on the sliding surface of the brake piston,
2. LOWER SEAL 5. UPPER BACK-UP RING
3. BRAKE HOUSING 6. WEAR RING
Carefully install piston in the brake housing.

NOTE: Install the back-up rings and seals in the grooves

of the brake housing as shown in the illustration above.
6004-18
STEP 59 STEP 62

BD07N057-01 BD00M285

Install shim into the brake housing. Install the six bolts into the return spring retainer and
tighten to 34 Nm (25.1 pound feet).
STEP 60
STEP 63
WARNING: Always wear heat protective gloves
to prevent burning your hand when handling
heated parts.
SM121A

BD00M283

Install return spring in the brake housing. Install with

the tapered end facing upward.

STEP 61

BD07N048-01

Heat the carrier output shaft to 120qC (248qF) in a

bearing oven. Wearing heat resistant gloves or
mittens, install the bearing on the shaft until the
bearing is against the carrier gear.

BD07N054-01

Install the return spring retainer into the brake

housing.
 6004-19
STEP 64 STEP 67

BD06G053-01 BD07N089-01

Install a new stop pin if it was removed, damaged or Attach an acceptable lifting device to the wheel end
worn. and install the wheel end on to the brake housing. A
slight rotation of the wheel end maybe necessary to
STEP 65 align the splines on the carrier output shaft.

STEP 68

BD08A441-01

Coat the spline of the carrier output shaft with Loctite

767 antiseize lubricant.
BD07N090-01

Install the retainer into the wheel end on the output

STEP 66 shaft of the carrier.

BD07N087-01

Attach an acceptable lifting device to the brake

housing and insert the brake housing on to the
carrier output shaft.
6004-20
STEP 69 STEP 70

BD07N095-01
BD07N092-01

Install the four new bolts holding the wheel end to the
output shaft of the carrier. Tighten the bolts to a
torque of 500 Nm (368.8 pound feet). Rotate brake
housing several times in both directions and recheck
torque.
IMPORTANT: Do not reuse locking bolts, just one time
installation is permitted.

BD07N096-01

Install a new O-ring on the cover and use a mallet

and install the cover into the wheel end.

6
5
2 4
3

2
1

8
BS08A216
BRAKE DISC ASSEMBLY LAYOUT

1. END SHIM 3. BRAKE PLATE (THICK) 5. RETURN SPRING 7. BOLT (QUANTITY 6)

2. PLATE (2.0 MM) 4. SPRING RETAINER 6. SHIM 8. BRAKE DISC
 6004-21
STEP 71 STEP 73

BD07N109-01
BD07N107-01

Install 2.0 mm plate (2) into the brake housing.

STEP 72

BD07N108-01

Install a brake plate (3) and brake disk (8) into brake
housing alternately as shown on page 20 until all the
brake discs (8) are installed.
BD07N108-01

Install brake disk (8) into the brake housing. STEP 74

BD07N107-01

Install last 2.0 mm plate (2) into the brake housing.

6004-22
STEP 75 STEP 77

BD07N110-01 BD07N112-01

Install end shim (1) on top of the 2.0 mm plate (2). Install the snap rings on planetary gear shafts with
snap ring pliers.
STEP 76
WARNING: Always wear heat protective gloves
to prevent burning your hand when handling
heated parts.
SM121A

BD08B032-01

Heat the sun gears to 120qC (248qF) in a bearing

oven. Wearing heat resistant gloves or mittens,
install the sun gears on the shaft until the bearing is
against the carrier gear.
 6004-23
Sun Gear Shaft End Play Adjustment STEP 81
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 78

2 BD08B033-01

Install the sun gear onto the stub shaft with out the
shims.

STEP 82

BD07N013-01
Install a new O-ring onto the axle housing (2) and a
new O-ring in brake port (1) in axle housing.

STEP 79

BD08B034-01

Determine dimension B from the face of the sun gear

to the mounting face of the axle housing.
Example:
Dimension B . . . . . . . . . . . . 100.20 mm (3.95 inch)

STEP 83
BD08B036-01
Take a measurement from the straight edge to the Subtract dimension A from dimension B. Then
face of the brake housing, the difference between subtract 1.30 mm (0.05 inch) from the difference. The
this measurement and the next measurement will be difference is the required shim size.
dimension A. Example:
Mount the sun gear into the planet gears. Then, Dimension B 100.20 mm (3.94 inch)
determine dimension A, from the inner face of the Dimension A  97.90 mm (3.85 inch)
sun gear to the face of the brake housing. Difference 2.30 mm (0.09 inch)
Example: Required end play 1.30 mm (0.05 inch)
Dimension A . . . . . . . . . . . . . . 97.90 mm (3.85 inch) Difference = shim
1.00 mm (0.04 inch)
size
STEP 80
Install the stub shaft in the spline of the axle bevel
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear.
6004-24
STEP 84 STEP 87

BD08B035-01 BD07N212-01

Install the sun gear shaft into the stub shaft with the Remove dip stick from axle housing. Refill the axle
determined shim set. (size as determined in Step 83) with 22 Liters (23.2 quarts) of Transaxle fluid (SAE
into the sun gear shaft with grease. 80W-140).

STEP 85 STEP 88

BD06G072-01

Use lifting bracket, and install the assembled wheel BD07N213-01

end onto the axle housing. Insert dip stick back into the axle but do not screw in
set it off on the edge fill hole, oil level should be
NOTE: Turn the input flange to align splines of the stub
between upper and lower level on the dip stick.
shaft into the sun gear.
Install plug into axle housing and torque plug to
50 Nm (36.9 pound feet).
STEP 86

BD02D154-01

Install the washers and bolts to secure the wheel end

to the axle housing. Tighten the bolts to a torque of
390 Nm (287.7 pound feet).
 6004-25

BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) High Pressure Test
PRESSURE IN THE FOLLOWING STEPS. If the maximum
pressure of 100 bar (1450 psi) is exceeded, the piston will
STEP 91
move too much changing the gripping rings adjustment. If
the gripping rings adjustment changes, the wheel end must Operate the hand pump to increase pressure to 100
be removed and disassembled and the gripping rings bar (1450 psi) maximum. Close connection to hand
adjusted to the correct dimension. pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 3% or
3 bar (43.5 psi).
STEP 89
Low Pressure Test
STEP 92
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period there should
be no pressure drop.

BD00M305

Connect a hand pump with pressure gauge to the

brake port as shown above. Fill the hand pump with
hydraulic oil.

STEP 90

BD07N208-01

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.
6004-26

REPLACING HUB SEAL

Removal STEP 95
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 93

BD07N094-01

Remove and discard the O-ring.

STEP 96

BD06G074-01

Remove drain plug and drain oil from the brake

housing.

STEP 94

BD07N093-01

Remove the four bolts from the carrier output shaft.

STEP 97

BD07N097-01

Use pry bar and remove the end cover.

BD07N090-01

Remove the retainer from the wheel end.

 6004-27
STEP 98 Installation
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 101

BD06G078-01

Use lifting bracket, to hold wheel end. Separate the

output shaft using a puller.

STEP 99

BD06G081-01

A A

A 1

BD06G079-01

Use a pry bar and remove the seal from the brake
housing.

STEP 100
BS00M073

1. FACE SEAL 2. BRAKE HOUSING A. GREASE

Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use
appropriate tool to install the face seal with the seal
lip positioned as shown. Apply grease to seal as
indicated by (A) above.

BD07N035-01

Inspect the metal face seal ring for damage or wear

marks where the seal makes contact, if required
remove the bushing.
6004-28
STEP 102 STEP 105

BD07N037-01 BD06G084-01

Clean the seal ring mounting surface with solvent. Use suitable tool and drive the metal face seal ring
into position onto the hub.
STEP 103 NOTE: Be sure the sealing ring is properly seated.

STEP 106

BD06G082
Apply Loctite 574 to the seal ring mounting surface.
BD06G086-01
STEP 104 Grease the seal lip of the shaft seal, use lifting
bracket, and install the wheel end onto the brake
WARNING: Always wear heat protective gloves housing.
to prevent burning your hand when handling
heated parts. STEP 107
SM121A

BD07N090-01
Install the retainer on the wheel end.
BD07N039-01
Heat the meal face seal ring to 120° C (248° F),
place the face seal ring onto the wheel end shaft.
 6004-29
STEP 108 STEP 111

BD07N092-01 BD07N212-01
Install the four bolts and tighten to a torque of Remove the dip stick from the axle housing. Refill the
500 Nm (369 pound feet). Rotate brake housing axle with 22 Liters (23.2 quarts) of the proper
several times in both directions and recheck torque. Transaxle fluid (SAE 80W-140).

STEP 109 STEP 112

BD07N095-01
BD07N213-01
Install a new O-ring on the wheel end cover.
Insert dip stick back into the axle but do not screw in
set it off on the edge fill hole, oil level should be
STEP 110 between upper and lower level on the dip stick.
Install plug into axle housing and torque plug to
50 Nm (36.9 pound feet).

BD02D053-01

Install the wheel end cover into the wheel end.

6004-30

DIFFERENTIAL

Removal and Disassembly Limited STEP 114

Slip Differential version DZ-1200
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 113

BD06G126-01

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.

W110R567
STEP 115

BD06G127-01
W110R568

Remove drain plugs and drain oil from axle. Connect lifting bracket to the differential and remove
the differential from axle housing.
NOTE: Make sure that the right axle stub shaft releases
from the differential.
 6004-31

Disassembly Limited Slip STEP 119

Version DZ-1200
STEP 116

BD07N162-01

Remove the ring gear from the differential housing.

BD01F075-01
STEP 120
If required, remove the bearing from the housing
cover using appropriate tools.

STEP 117

BD07N159-01

BD07N165-01

Place the differential in a press to prevent it from

turning. Remove the bolts.
STEP 118

BD07N148-01

Remove the outer set of clutch plates, thrust washer,

and bevel gear from the differential housing.

BD07N163-01

Remove the housing cover from the differential

housing.
6004-32
STEP 121 STEP 123

BD07N145-01 BD07N136-01

Remove the differential shaft from the differential

Drive both roll pins out of the differential housing and
housing.
remove pins.
STEP 124
STEP 122

BD07N131-01
BD07N140-01
Remove the two bevel gears and thrust washers
from the differential housing.

BD07N139-01

NOTE: Remove the two differential half shafts, bevel

gears and thrust washers from the differential housing.
 6004-33
STEP 125 STEP 127

BD07N129-01 BD06G131-01

Pull the bearing cups and shims from both axle

housings.
NOTE: Make sure to identify the shims into which axle
housing they were removed.

BD07N114-01

Remove the inner set of clutch plates, thrust washer,

and bevel gear from the differential housing.

STEP 126

BD07N104-01

If required, remove bearing from differential housing

using a bearing puller and a press.
6004-34

8
6 7
5
3
2
1

10

11
12
3
14
11
15
8
16
13
2 10
4
9

BS08A334
LIMITED SLIP DIFFERENTIAL ASSEMBLY EXPLODED VIEW

1. INNER BEVEL GEAR AXLE 5. DIFFERENTIAL 9. THRUST WASHER 13. OUTER BEVEL GEAR
2. THRUST WASHER (COPPER COLOR) 6. ROLL PIN 10. SPIDER GEAR 14. RING GEAR
3. REACTION PLATES 7. ROLL PIN 11. HALF SHAFT 15. COVER DIFFERENTIAL
4. FRICTION PLATES 8. BEARING 12. SHAFT 16. BOLT
 6004-35

Reassembly Limited Slip STEP 131

Differential version DZ-1200
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 128

BD07N119-01

Install one friction plate on the inner bevel gear.

STEP 132

BD07N105-01

Install bearing on differential housing using a press.

STEP 129
Check reaction plates, friction plates and thrust
washers for damage or wear, replace if necessary.
NOTE: Be sure to apply oil to all parts before assembly.
BD07N120-01

STEP 130 Install one friction plate on the inner bevel gear.

STEP 133

BD07N118-01

Install the thrust washer (copper color) on the inner

bevel gear. BD07N122-01

NOTE: Clutch plates must be installed on the inner bevel Install two reaction plates on the inner bevel gear.
gear in the correct order, refer to illustration on
page 34.
6004-36
STEP 134 STEP 137

BD07N124-01 BD07N127-01

Install two friction plates on the inner bevel gear. Install one reaction plate on the inner bevel gear.
STEP 138
STEP 135

BD07N128-01
BD07N125-01
Align all tabs of reaction plates on the inner bevel
Install one reaction plate on the inner bevel gear. gear.

STEP 136

BD07N126-01

Install one friction plate on the inner bevel gear.

 6004-37
STEP 139 STEP 141

BD07N129-01 BD07N136-01

BD07N130-01 BD07N137-01

Install the clutch pack and inner bevel gear assembly Install the full differential shaft into the housing
into the differential housing. through both thrust washers and spider gears
installed in the previous step. Make sure position of
hole in center of differential shaft is horizontal to the
STEP 140
differential housing.

1 STEP 142

2 1

BD07N131-01

1. THRUST WASHER 2. SPIDER GEAR

Install a thrust washer (1) and spider gear (2) into the BD07N139-01
differential housing. Install another thrust washer (1) 1. THRUST WASHER 2. SPIDER GEAR
and spider gear (2) directly across from the first.
Make sure to install in the correct location for the full Install a thrust washer (1) and spider gear (2) into the
differential shaft. differential housing. Install another thrust washer (1)
and spider gear (2) directly across.
NOTE: The torsional stop (tab) on the thrust washer must
be positioned upwards see image above.
6004-38
STEP 143 STEP 145

BD07N140-01 BD07N142-01

Install new roll pins into differential housing.

2 NOTE: Use new roll pins only.

STEP 146

BD07N138-01

Install both differential half shafts into housing

through thrust washers and spider gears installed in
previous step. The tapered end of half shafts (1)
insert into the hole in center of differential shaft.
BD07N144-01
Make sure the holes on the other end of the half
shafts (2) align with the holes in the differential Drive the new roll pins into differential housing to
housing (3). secure half shafts.

STEP 144 STEP 147

BD07N149-01
BD07N138-01

Spider gear assembly installed in differential Install the thrust washer (copper color) on the outer
housing. bevel gear.
NOTE: Clutch plates must be installed on the outer bevel
gear in the correct order, refer to illustration on page 34.
 6004-39
STEP 148 STEP 151

BD07N150-01 BD07N155-01

Install one reaction plate on the outer bevel gear. Install two friction plates on the outer bevel gear.

STEP 149 STEP 152

BD07N151-01 BD07N156-01

Install one friction plate on the outer bevel gear. Install one reaction plate on the outer bevel gear.

STEP 150

BD07N153-01

Install two reaction plates on the outer bevel gear.

6004-40
STEP 153 STEP 156

BD07N156-01 BD07N160-01

Install one friction plate on the outer bevel gear. Clean ring gear mounting surface on differential
housing.
STEP 154
STEP 157

BD07N158-01

Align all tabs of reaction plates on the outer bevel BD07N161-01

gear. Clean mating surfaces of ring gear and differential

cover.
STEP 155 NOTE: The ring gear and the drive pinion are a matched
gear set and cannot be serviced separately.

STEP 158

BD07N159-01

Install the clutch pack and outer bevel gear assembly

into the differential housing.
BD07N162-01

Install ring gear on differential housing.

NOTE: Make sure to align bolt holes when installing ring
gear and differential cover.
 6004-41
STEP 159 Drive Pinion Removal
NOTE: Ring and drive pinion are matched set and can not
be serviced separately.

STEP 162

BD07N163-01

NOTE: Install cover on differential housing.

STEP 160
BD07N168-01

Heat locknut securing flange with a hot air blower to

loosen Loctite, approximately 120° C (248° F)

STEP 163

BD07N166-01

Place the differential in a press to prevent it from

turning. Install new bolts and tighten to a torque of
410 Nm (302.4 pound feet).
NOTE: Use new locking bolts do not reuse old bolts.

STEP 161 BD07N169-01

If bearing was removed from differential cover install Use suitable tool to hold input flange. Hold flange
bearing using a press. using holding tool and remove lock nut and washer.
Remove holding tool from flange.
6004-42
STEP 164 STEP 167

BD07N181-01
BD07N173-01 Drive inner bearing cup from the differential housing.
Remove the input flange from the drive pinion and
seal. STEP 168
STEP 165

BD06G141-01

Remove inner bearing cup and shim from differential

housing.
BD07N174-01

Press the input pinion out of the housing. STEP 169

STEP 166

BD07N175-01

BD07N183-01
Remove the spacer ring from the drive pinion.
Drive outer bearing cup from the differential housing.
 6004-43
STEP 170 Brake Tube Removal
STEP 171

BD06G167

Remove inner bearing from the drive pinion using a

suitable tool and a press. BD07N030-01

Remove the plug with the breather installed from the

axle housing on the differential end.

STEP 172

BD07N001-01

Remove fitting from the brake tube on the axle

housing on the differential end of the axle.
6004-44
STEP 173 STEP 174

BD07N004-01 BD07N008-01

BD07N006-01 BD07N010-01

Loosen and remove the nut holding the brake tube to Loosen the brake tube at wheel end of axle housing
the axle housing on the differential end of the axle. then remove the brake tube from the axle housing.

STEP 175

BD07N015-01

Remove the fitting on the wheel end of the axle

housing.
NOTE: Repeat steps 171 through 174 for the other side of
the axle.
 6004-45

Brake Tube Installation

6 1
5 4 3 2

BS08B043

1. HEXAGON NUT 100 NM (73.8 LB.-FT.) 3. BRAKE TUBE 5. SCREW NUT 100 NM (73.8 LB.-FT.)
2. O-RING 4. AXLE HOUSING 6. SCREW CONNECTOR 36 NM (26.6 LB.-FT.)

STEP 176 STEP 177

BD07N017-01 BD07N018-01

Install a new O-rig on the fitting removed from the Install the connector in the axle and tighten to a
wheel end of the axle. torque of 36 Nm (26.6 pound feet).
6004-46
STEP 178 STEP 180

BD00M343-01 BD07N006-01

Install a new O-ring in the groove of the brake tube

fitting.

STEP 179

BD07N005-01

Install the nut to secure the brake tube. Tighten the

nut to a torque of 100 Nm (73.8 pound feet).

BD07N010-01 STEP 181

Install the brake tube in axle housing.

BD07N009-01
Connect opposite end of brake tube to connector
installed in wheel end. Tighten brake tube nut to 100
Nm (73.8 pound feet).
IMPORTANT: Use the two wrench tightening method to
prevent the connector in axle from turning.
NOTE: Do steps 176 through 181 for the other wheel end.
 6004-47
STEP 182 STEP 183

1
2
3

BD00M347-01 BD07N003-01
BREATHER VENT EXPLODED VIEW Install the plug in axle housing. Tighten plug to a
torque of 50 Nm (36.9 pound feet). Tighten breather
1. O-RING 2. PLUG 3. BREATHER
valve to standard torque specification.
Remove and discard O-ring (1) from plug (2) and
install a new O-ring. Install breather (3) in plug. Drive Pinion Installation
STEP 184

BD06G137-01

Find and record the housing dimension “X” located

inside the differential housing where the pinion shaft
is located.
Dimension X (Example).......205.30 (8.08 inch)
6004-48
STEP 185 STEP 187
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)
Calculation example B:
205.30 mm
Dimension X
-------(8.080 inch)
204.08 mm
Dimension Y
BD06G138-01 -------(8.034 inch)
Measure the thickness of the inner bearing and Difference = shim 1.22 mm
record its measurement, dimension “I”. thickness ------(0.046 inch)
Dimension I (Example)..... 36.13 mm (1.422 inch)
NOTE: Deduct the thickness of the gauge blocks being Shims are available in 0.10 mm (0.004 inch), round up or
used to support the bearing from the overall measurement. down to the next available shim thickness, s = 1.20 (0.044
IE: overall measurement 106.13 mm (4.178 inch) inch).
minus gauge block thickness 70 mm (2.756 inch) will equal
dimension I. STEP 188

STEP 186

1
1

3
2 BD06G140-01

NOTE: Heat the bearing hole to approximately 120°

BD06G139-01 C (248° F) and install the outer bearing cup until
1. MATING NUMBER (MARKED MANUALLY) contact is made using an acceptable tool.
2. PINION BASIC DIMENSION (STAMPED)
3. PINION DISTANCE DEVIATION + OR - (MARKED
MANUALLY)

Distance deviation is indicated in 1/100 mm. If no

distance deviation is indicated the pinion basic
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)
 6004-49
STEP 189 STEP 190
WARNING: Always wear heat protective gloves WARNING: Always wear heat protective gloves
to prevent burning your hand when handling to prevent burning your hand when handling
heated parts. heated parts.
SM121A SM121A

BD06G141-01 BD07N178-01

Heat the pinion inner bearing to 120° C (248° F) in a

bearing oven. Wearing heat resistance gloves or
mittens, install the bearing on the pinion shaft until
contact.
After installing bearing on pinion shaft, allow the bearing to
cool to ambient temperature.

Drive Pinion Bearing Rolling

Torque Adjustment
STEP 191
BD06G142-01

Heat the inner bearing hole on the differential

housing to approximately 120° C (248° F). Install the
shim set determined in Step 187 in the bearing bore
and press the bearing cup into to the bearing hole
using a suitable tool.

BD07N175-01

Install a 9.03 mm (0.35 inch) thick spacer on the

pinion shaft.
6004-50
STEP 192 STEP 194
WARNING: Always wear heat protective gloves
to prevent burning your hand when handling
heated parts.
SM121A

BD06G147-01

Install the input flange on the pinion shaft.

STEP 195
BD07N186-01

Heat the pinion shaft outer bearing to 120° C

(248° F) in a bearing oven. Wearing heat resistance
gloves or mittens, install the bearing on the pinion
shaft until contact.
Prior to mounting the input flange and tightening the nut,
allow the bearing to cool to ambient temperature.

STEP 193

BD07N171-01

BD06G146-01

Press the dust shield on the input flange.

BD07N170-01

Install the washer and nut on the pinion shaft.

 6004-51
STEP 196 STEP 197

BD07N169-01 BD07N204-01

Use a suitable tool to hold input flange. Hold flange Check the rolling torque of the drive pinion bearing.
using holding tool and tighten nut to a torque of 700 The rolling torque should be 1.1 to 2.3 Nm (9.7 to
Nm (515 pound feet). Remove holding wrench. 20.4 pound-inch). If rolling torque is too low, install a
thinner spacer (Step 191); if rolling torque is too high,
When tightening rotate the pinion shaft in both directions install a thicker spacer (Step 191).
several times.
STEP 198
Remove the nut and input yoke from the drive pinion
shaft.
6004-52

Setting Backlash and Bearing Preload

Deviation Value -20 -10 0 +10 +20
1.20 mm 1.10 mm 1.00 mm 0.90 mm 0.80
Shim A
(0.047 inch) (0.043 inch) (0.039 inch) (0.035 inch (0.032 inch)
0.80 mm 0.90 mm 1.00 mm 1.10 1.20
Shim B
(0.032 inch) (0.035 inch) (0.039 inch) (0.043 inch) (0.047 inch)

STEP 199 STEP 200

1 2

A B

BD06G163-01

Record the deviation value from side of 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 mm (0.035 inch) 4
BC06G004
Shim B = 1.10 mm (0.043 inch)
1. DIFFERENTIAL 5. AXLE HOUSING
2. DRIVE HOUSING A. RING GEAR SIDE
3. AXLE HOUSING B. CARRIER SIDE
4. INPUT PINION

STEP 201

BD06G164-01

Insert shim A- 0.90 mm (0.354 inch) and install the

bearing outer ring with a suitable tool until seated in
axle housing.
 6004-53
STEP 202 STEP 205

BD06G165-01

Insert shim B- 1.10 mm (0.043 inch) and install the BD07N202-01

bearing outer ring with a suitable tool until seated in Position the axle housing on the drive housing, install
axle housing. 4 bolts, top center, bottom center, front center, rear
center, torque bolts evenly to 390 Nm (285 pound
Contact Pattern Check feet).

STEP 203 STEP 206

BD06G166-01 BD06G169-01

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 204 compare the contact pattern with examples on page
4 and page 5.
If the tooth contact pattern differs, the wrong shim size was
selected in Step 187. Remove differential and repeat Steps
184 though 187.

BD07N199-01

Position the differential assembly in the axle drive

housing.
6004-54

Installation STEP 209

STEP 207

BD06G171-01

Loosen and remove the nut and input flange.

BD07N199-01

Position the differential assembly in the axle drive STEP 210

housing.

STEP 208

BD06G172

Install the shaft seal with the sealing lip towards oil
sump using appropriate tool.
BD06G170-01 NOTE: Wet the outer diameter of the seal with a solution
Install a new O-ring on the axle housing. Position the of 50% water and 50% mineral spirits. Fill the space
axle housing on the drive housing. between the sealing and dust lip with grease.

BDO7N207-01

Install bolts and torque bolts evenly to 290 Nm

(215 pound feet).
 6004-55
STEP 211 STEP 213

BD06G173-01 BD07N213-01

Install the input flange. Using a suitable holding tool, Insert dip stick back into the axle but do not screw in
on input flange. Apply Loctite No. 262, on the threads set it off on the edge fill hole, oil level should be
of the locknut. Install the washer and locknut by between upper and lower level on the dip stick.
hand. Hold flange using holding tool and tighten nut Install plug into axle housing and torque plug to
to a torque of 700 Nm (516 pound feet). 50 Nm (36.9 pound feet).
NOTE: Rotate the input pinion several times in both
directions when tightening.

STEP 212

BD07N212-01

Remove the dip stick from the axle housing. Refill the
axle with 22 Liters (23.2 quarts) of Transaxle fluid
(SAE 80W-140).
6004-56

DIFFERENTIAL

Removal and Disassembly STEP 2

Differential Locking version
DHL-1200
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

BD06G126-01

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.

W110R567

W110R568

Remove drain plugs and drain oil from axle.

 6004-57

Disassembly STEP 6

STEP 3

W110R474

Remove axial roller ring (could get stuck on piston).

W110R471

Remove bearing outer ring and shim behind (rolling STEP 7

torque differential bearing) out of axle housing.
NOTE: Mark shim (position/bearing allocation) –
assembly aid.

STEP 4

W110R475

Lift differential assy out of axle drive housing.

STEP 8

W110R472

Remove O-ring (arrow).

Pull piston out of axle housing hole.

STEP 5

W110R476

Pull both bearing inner rings off the differential.

W110R473

Remove O-rings (arrows) from piston.

6004-58
STEP 9 STEP 11

W110R477 W110R479

Hold differential by means of a press (for this Compensate spring preload of lid by means of the
purpose place pressure piece– see arrow) and press and remove retaining ring.
loosen lid screws. Remove releasing components (retaining ring,
sliding sleeve and compression spring).
NOTE: Locking screws – permitted for one-time use only.
STEP 12
STEP 10

W110R480
W110R478
Remove disc package and disc carrier.
Remove lid and loose parts.
1 = Lid
2 = Cage
3 = Lever (12x)
4 = Pressure piece
5 = Cylindrical pins (6x)
 6004-59
STEP 13 STEP 15

W110R481 W110R483

Remove crown wheel, axle bevel gear, thrust washer 1 = Differential carrier
and constant spacer. 2 = Slotted pin (2x)
3 = Slotted pin (2x)
1 = Differential carrier
4 = Spider shaft (split version)
2 = Crown wheel
5 = Spider shaft (one-piece)
3 = Constant spacer
6 = Spider gear (4x)
4 = Thrust washer
7 = Thrust washer (4x)
5 = Axle bevel gear
8 = Axle bevel gear
9 = Constant spacer
STEP 14 10 = Outer disc
11 = Thrust washer

W110R482

Force slotted pin (fixing) out of both spider shaft

halves (split version), then remove both spider shaft
halves in arrow direction and take components (see
figure no. W110R483) out of differential carrier.
6004-60
STEP 16 STEP 17

W110R484 W110R485

Pull out stub shaft, if required. Pull bearing outer ring out of hole by means of striker
and remove shim behind (backlash).
NOTE: Pay attention to releasing sun gear shaft with
inserted shim sun gear shaft – clearance). Mark allocation NOTE: Mark shim (position/bearing allocation) –
of shim versus sun gear shaft/stub shaft and output side – assembly aid.
assembly aid.
 6004-61

W110R564
DIFFERENTIAL LOCKING ASSEMBLY

1. DIFFERENTIAL, CASE 12. PIN 23. O-RING

2. DISC O. CLUTCH 13. DISC. CLUTCH OUTER 1.2 mm 24. RING
3. DIFFERENTIAL, RING 14. DISC. CLUTCH OUTER 1.3 mm 25. BEARING, ROLLER CAGE
4. WASHER THRUST 15. DISC. CLUTCH OUTER 1.4 mm 26. SLEEVE
5. GEAR, BEVEL, AXLE 16. DISC. CLUTCH INNER 27. SPRING, COMPRESSION
6. GEAR, BEVEL, DIFFERENTIAL 17. DISC. CLUTCH OUTER 28. RING, LOCKING
7. WASHER THRUST 18. LEVER 29. SLEEVE, ACTUATOR
8. AXLE DIFFERENTIAL 19. DIFFERENTIAL, CAGE 30. COUPLING, SPLINED
9. AXLE, DIFF. SHORT 20. DIFFERENTIAL, COVER 31. SNAP RING
10. PIN, SLOTTED 21. SCREW, HEX SOC 32. BEARING, ROLLER
11. PIN, SLOT 22. PISTON 33. BEARING, ROLLER, TAPERED
6004-62

REASSEMBLY

Differential locking version STEP 19

DHL-1200
(DHL = Differential hydr. powershiftable)

W110R488

Insert steel outer disc (2) and thrust washer (3) into
differential carrier (1).
W110R486 NOTE: Pay attention to installation position of outer disc
A = Differential – part (standard version) and thrust washer – see position/figure.
B = DHL – part (Diff.-hydr.-powershiftable 100% lock)
STEP 20
STEP 18

W110R489
W110R487 Insert axle bevel gear.
Insert constant spacer into differential carrier.
 6004-63
STEP 21 STEP 23

W110R490 W110R492

Legend to figure-no. W110R490 … figure-no. Install split spider shaft (4) with spider gears (2) and
W110R491: thrust washers (3).
Differential spider - single parts: NOTE: Insert thrust washers with tabs showing upwards
- see arrow - and being located in recess.
1 = Spider shaft (one part)
2 = Spider gear (4x) NOTE: Pay attention to installation position of spider
3 = Thrust washer (4x) shaft/halves - slotted pin/location holes of spider shaft
4 = Spider shaft (split version) towards diff. carrier.
5 = Slotted pin (2x)
6 = Slotted pin (2x) STEP 24

STEP 22

W110R493

Fix spider shaft half (arrows) with double-slotted

W110R491 pins.
Insert one-part spider shaft (1) into hole/differential
NOTE: Install double-slotted pins – always with slots in a
(without slotted pin location hole) thereby mounting
180° offset position to each other.
two spider gears (2) with thrust washers (3).
NOTE: Insert thrust washers with tabs showing upwards
- see arrow - and being located in recess.
6004-64
STEP 25 STEP 27

W110R494 W110R496

Place second axle bevel gear into the differential Install two adjusting screws (M 16) - see arrows - and
carrier. press crown wheel to contact position.
For input version “with” bevel gear set only – see
STEP 26 specification in the corresponding spare parts list:
If a bevel gear set is specified, the pairing
number/crown wheel (e.g. “7”) must be identical with
pairing number/input pinion.

STEP 28

W110R495

Place thrust washer (2) and constant spacer (3) into

the differential carrier (1).
NOTE: Pay attention to installation position of thrust
washer and constant spacer – see position/figure.
W110R497

Place differential lid over the sliding sleeve with

mounted compression spring (arrow).
 6004-65
STEP 29 STEP 31

W110R498 W110R500

Fix lid by means of a press and snap retaining ring Place cage (arrow) and position lever in cage with
into groove of sliding sleeve. grease (assembly aid).
NOTE: Pay attention to installation position of levers -
STEP 30 also see detailed sketch no. W110R499.

STEP 32

W110R499

Place lid on pressure piece (5, see arrow).

NOTE: Ensure that lid is only supported on the pressure W110R501

piece (5), but never on the sliding sleeve. Place cylindrical pins (for outer disc fixing) into the lid
with grease (assembly aid).
Legend to detailed sketch:

1 = Lid
2 = Pressure piece
3 = Sliding sleeve
4 = Compression spring
5 = Pressure piece
Insert pressure piece (2) - pay attention to installation
position.
6004-66
STEP 33 STEP 35

W110R502 W110R504

Equipment of the disc package (number and Insert disc package into the lid considering the
arrangement of the individual discs). required arrangement – see figure-no. W110R502.
Legend to sketch no. W110R502 …. figure-no. NOTE: Pay attention to radial installation position of the
W110R504: outer disc - Locating grooves (arrow 1) of the outer disc to
be positioned over the cylindrical pins (arrow 2).
1 = Outer disc (s = constant 4.0 mm)
2 = Outer discs (s = optional 1.2/1.3/1.4 mm)
3 = Inner discs STEP 36
NOTE: Possible other versions could show a deviating
equipment (number and arrangement of the individual
discs). The illustrations in the respective spare parts list
forms the basis for the required equipment.

STEP 34

W110R505

Install snap ring (arrow) in the annular groove of the

disc carrier and insert preassembled disc carrier so
that all inner discs are mounted.

W110R503

Ensure a correct contact position of pressure piece,

cage and levers.
Insert outer disc (1. s = constant 4.00 mm) in the
preassembled lid.
NOTE: Pay attention to radial installation position of the
outer disc - locating grooves (arrow 1) of the outer disc to
be positioned over the cylindrical pins (arrow 2).
 6004-67

Adjust disc clearance of

differential lock (100% lock) for
DHL-1200
(DHL = Differential hydr. powershiftable)

STEP 37

W110R506

Legend to sketch no. W110R506 … figure no.

W110R507:
1 = Lid
2 = Pressure piece - 5870 100 072
3 = Pressure piece - 5870 100 078
4 = Load cell - 5870 700 004
5 = Disc carrier
6 = Disc package
7 = Sliding sleeve
F = 50 + 30 KN
X = Disc clearance (specified = 0.8 ± 0.1 mm)
ATTENTION: Ensure that lid (1) is only supported on
pressure piece (2), but never on the sliding sleeve (7).
ATTENTION: Ensure that pressure piece (3) is seated
only on disc package (6), but not on disc carrier (5).
6004-68
STEP 38 STEP 40

W110R507 W110R509

Adjust disc clearance "X" = 0.8 ± 0.1 mm: Tilt differential by 180° - keeping the contact position
of differential carrier and lid.
Apply “F“ = 50 + 30 KN on disc package (pos. 6 - see
sketch no. 63) by means of a press and load cell (4) Find reference dimension - front face/lid to front
as well as pressure piece (3). face/crown wheel.
Find dimension “X“ - from locating face lid/crown Refer.dimension (for correctly positioned parts) =
wheel to disc package (contact face of upper inner app. 39.50 mm.
disc).
Dimension “X“ e.g.........................................0.80 mm STEP 41
NOTE: If the required disc clearance (0.8 ± 0.1 mm) is not
achieved, use suitable outer disc(s) (s = optional) for
correction.

STEP 39

W110R510

Fix differential with pressure piece (arrow) by means

of a press and install lid with “new“ locking screws.
NOTE: Locking screws - permitted for one-time use only.
Tightening torque (M16 x 1.5/12.9) ............ = 410 Nm
W110R508

Mount pre-assembled differential carrier until contact

with lid is obtained.
 6004-69
STEP 42

W110R511

Place differential on the pressure piece (arrow).

NOTE: Ensure that differential is supported on pressure
piece /lid, but not on the sliding sleeve.
Press bearing inner ring to contact position.

STEP 43

W110R512

Use suitable support (arrow) for temporarily mounted

bearing inner ring, Roller bearing cage - risk of
damage.
Press bearing inner ring on crown wheel side to
contact position.
6004-70

Setting Backlash and Bearing STEP 45

Preload
STEP 44

W110R514

Legend to sketch no. W110R514:

W110R513

Read crown wheel labeling (test dimension) from 1 = Crown-wheel

crown wheel rear side. 2 = Differential carrier
3 = Tapered roller bearing (differential carrier side)
Determine required shims by means of the read 4 = Tapered roller bearing (crown-wheel side)
value (crown wheel) and the relating 5 = Input pinion
specifications of the following table: 6 = Axle drive housing
Test dimension, e.g. „77“ mm is stamped on the 7 = Axle housing (differential carrier side)
crownwheel rear side, without + or – deviation, which 8 = Axle housing (crown-wheel side)
corresponds to the real value/test dimension „77“ in
the following table. The required shims according to
this real value/test dimension are allocated in the
following table.
Any + or – deviation from the test dimension due to
production is manually applied on the crown wheel
rear side (e.g. - 20 or - 10 or 10). The required shims
according to this real value/test dimension are
allocated in the following table.

Table - shims for differential DHL-1200 in ZF-axle MT-L 3065 II

Crown wheel labeling 77 and corrective value -20 -10 - 10
Results in ---> real value/test dimension 76.80 76.90 77.0 77.10

Required shim thickness

0.80 0.90 1.00 1.10
Shim/differential carrier side

Required shim thickness

1.20 1.10 1.00 0.90
Shim/crown-wheel side
 6004-71
STEP 46 STEP 49

W110R515 W110R518

Oil both O-rings (arrows) and insert in annular Insert determined shim (e.g. s = 1.00 mm) and
grooves of piston. bearing outer ring into hole of axle housing on
differential carrier side.
STEP 47

W110R516

Oil sealing faces and insert pre-assembled piston

into hole of axle housing.

STEP 48

W110R517

Insert determined shim (e.g. s = 1.00 mm) and

bearing outer ring into hole of axle housing on crown
wheel side.
6004-72

Contact Pattern Check of Bevel STEP 53

Gear Set
STEP 50

W110R522

Bring axle housing to contact position by means of

hex. screw and temporarily fix it.
W110R519 Rotate differential several times in both directions -
Cover some tooth flanks of crown wheel with marking roller setting (also see figure no W110R523).
ink (contact pattern check). Tightening torque (M 18/10.9) .................... = 390 Nm

STEP 51 STEP 54

W110R520
W110R523
Insert pre-assembled differential. Roll input pinion over crown wheel in both directions
(coast - drive flank meshing - contact pattern).
STEP 52

W110R521

Position axle housing/crown wheel side (without

O-ring) on axle drive housing -pay attention to radiale
installation position.
 6004-73
STEP 55 STEP 57

W110R524 W110R526

Disassemble differential. Insert preassembled stub shafts into both outputs

Compare contact pattern to examples - see chapter (considering allocation to the correct output side).
„0“, page 0/4 … 0/5.
NOTE: If contact pattern differs considerably, use a STEP 58
suitable shim for correction.

STEP 56

W110R527

Remount differential - by mounting stub shaft into

gearing of axle bevel gear (differential).
W110R525

If disassembled: STEP 59
Insert shim(s) (2) into sun gear shaft (1) and mount
stub shaft (3).

W110R528

Position axial roller ring on differential and fix by

means of grease (assembly aid).
6004-74
STEP 60 Leakage Test of DHL (100% lock)
STEP 62

W110R529

Oil O-ring (arrow) and mount it.

Position complete axle half on the axle drive housing W110R531
- by mounting the stub shaft into the gearing of the Prior to starting the test, bleed pressure chamber and
axle bevel gear (differential). then apply 100 % lock several times.
NOTE: Pay attention to radial installation position of Build up test pressure p = 25 bar and close locking
output towards axle drive housing. valve of the HP pump.

STEP 61 No measurable pressure drop is permissible

during a 5-minute test.

W110R530

Fix axle housing finally by means of hex. screws.

Rotate differential several times in both directions -
roller setting!
Tightening torque (M 18/10.9) .................... = 390 Nm
 6004-75

Shaft Seal / Imput Flange STEP 65

STEP 63

W110R534

Insert shaft seal (1), considering the required

W110R532
installation position (dimension “X“) – see detailed
Remove flange. sketches no. W110R535.
Contact face (outer diameter) of shaft seal:
STEP 64 - if rubber-coated: wet with spirit, (assembly aid)
- if made of metal: apply sealing agent (Loctite no.
574). Grease the shaft seal around the sealing and
dust lip. (Grease e.g."PETAMO GHY 133 N"ZF-order
no. 0671 190 099).
NOTE: Ensure plane installation position of shaft seal -
use the specified driver tool to obtain an exact installation
position of the shaft seal.

W110R533

For new parts assembly only:

Mount protection plate on screen sheet on input
flange and bring to contact position.
NOTE: Pay attention to installation position of screen
sheet - also see sketch no. W110R535.
6004-76
STEP 66

W110R535

Detailed sketch “Z“:

Legend to sketch no. W110R535:
1 = Shaft seal
2 = Protection plate
3 = Input flange
4 = Tapered roller bearing
5 = Input pinion
6 = Axle drive housing
X = Install. dim. 16.6 ± 0.2 mm

STEP 67

W110R536

Mount flange, fix with washer and hex. nut.

During tightening, rotate pinion several times in both
directions (roller setting).
NOTE: Install hex. nut with locking compound
(Loctite-Nr. 262).
Tightening torque (M36x1,5) ...................... = 700 Nm
Section
6004

6004
REAR AXLE
6004-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REPLACE HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal and Disassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassembly Differential Version D-1200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Reassembly Differential Version D-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Brake Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Brake Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pivot Pin Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pivot Pin Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
 6004-3

SPECIFICATIONS
Brake Wear Measurement.............................................................................................................4.0 mm (0.16 inch)
Sun Gear Shaft End Play ....................................................................................0.5 to 2.00 mm (0.02 to 0.079 inch)
Drive Pinion Rolling Torque......................................................................... 1.1 to 2.3 Nm (9.75 to 20 pound inches)

W130C Axle Options LSD (*) HD (**)

Multitrac Axle Tipe MT-L3075II MT-L3065II MT-L3075II MT-L3075II

Position Front Axle Rear Axle Front Axle Rear Axle

Differential Limited Slip Differential Differential Locking Differential Open

Yoke DS1480 DS1480 DS1480 DS1480

Flange to Flange (mm) 1984 1984 1984 1984

Axle Ratio 21.53 21.53 21.53 21.53

Ratio Beverl Gear 3.36 3.36 3.36 3.36

Ratio Planetary Drive 6.4 6.4 6.4 6.4

Differential version DZ1200 DZ1200 DHL1200 D1200

Differential type Limited Slip Differential Differential Locking Differential Open

Axle Installation Dimension Spring pad Above center pivot Spring pad Above center pivot
8x27, 788-1018.4 200 8x27, 788-1018.4 200

Output Shaft 12xM22x1.5; threads 12xM22x1.5; threads 12xM22x1.5; studs 12xM22x1.5; studs
PCD 425 PCD 425 PCD 425 PCD 425

Sealing Lip Seal Lip Seal Metal Face Seal Metal Face Seal

Brake 4 x Paper Jinmyung 4 x Paper Jinmyung 4 x Sinter 4 x Sinter

Oil Volume (liters/U.S. Quarts) 22 (23.2) 22 (23.2) 22 (23.2) 22 (23.2)

* Limited Slip Differential

** Heavy Duty

SPECIAL TORQUES
Bolts Securing Brake Housing to Axle Housing...................................................................390 Nm (288 pound feet)
Wheel End Retainer Bolts ...................................................................................................500 Nm (369 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads)..................................................700 Nm (516 pound feet)
Bolts Securing Differential Housing to Axle Housing...........................................................390 Nm (288 pound feet)
Bolts Securing Differential Cover and Ring Gear ................................................................410 Nm (302 pound feet)
Nut for Securing Brake Tube to Axle Housing.......................................................................100 Nm (74 pound feet)
Brake Tube to Axle Housing Fitting .......................................................................................100 Nm (74 pound feet)
Brake Tube Axle Housing Fitting .............................................................................................36 Nm (27 pound feet)
Oil Drain Plugs (Outputs).........................................................................................................50 Nm (37 pound feet)
Oil Fill Plug/Dipstick.................................................................................................................50 Nm (37 pound feet)
Brake Lining Check Plug .........................................................................................................50 Nm (37 pound feet)
Brake Bleeder...........................................................................................................................6 Nm (4.4 pound feet)
Brake Return Spring Retainer Bolts ........................................................................................34 Nm (25 pound feet)
6004-4

GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased

BS01D011 BS01D009
COAST SIDE (CONCAVE)

BS01D013
COAST SIDE (CONCAVE)
BS01D012
DRIVE SIDE (CONVEX)

BS01D014
DRIVE SIDE (CONVEX)
 6004-5
Pinion Distance Must Be Decreased

BS01D016

BS01D010 DRIVE SIDE (CONVEX)

BS01D015
COAST SIDE (CONCAVE)
6004-6

LUBRICATION

3 10 3

3
1
2
3

8 7
6 5 5 6 4
4
W110R565

1. OIL DRAIN HOLE (AXLE HOUSING) 5. BREATHER 9. WEAR CHECK DISK BRAKE
2. OIL DRAIN HOLE (OUTPUTS) 6. BRAKE INLET 10. GREASE NIPPLE
3. OIL FILL PLUG & OIL LEVEL CHECK 7. PLUG
4. BRAKE BLEEDER 8. OIL FILLER & OVER FLOW
NOTE: Refer to section 1002 of this service manual for proper lubricant.

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BD07N211-01 BS08B041

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 (X) using a thickness gauge. If dimension (X) 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 (37 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

BD06G004-01

Using acceptable lifting equipment to hold wheel

end. Loosen and remove the bolts and washers.

STEP 4

BD06G001-01

Fasten axle on a stand.

STEP 2

BD06G072

Carefully pull the wheel end from the axle housing.

NOTE: Pay attention for shim(s) that are placed between
the sun gear and stub shaft. Mark location of shim(s) to aid
in assembly.

STEP 5
BD06G002-01

BD07N013-01

BD06G003-01 Remove and discard the O-ring from the brake port
Remove drain plugs and drain oil from axle housing. (1) and axle housing (2).
6004-8
STEP 6 STEP 9

BD06G005-01
BD07N045-01
Mount the wheel end on a stand or suitable work Using a suitable puller remove the three planetary
bench. gears.

STEP 7 STEP 10

BD07N113-01
BD07N110-01
Remove the shim(s) from the sun gear shaft. Remove the steel end shim from brake housing.
Pull the sun gear shaft out of the planetary gears and
remove.
NOTE: Mark location of shim(s) to aid in assembly.

STEP 8

BD07N112-01

Using snap ring pliers remove the retaining rings

from the three planetary gears.
 6004-9
STEP 11 STEP 13

BD07N094-01

BD07N107-01 Remove and discard O-ring.

STEP 14

BD07N108-01

Remove the reaction and friction brake plates BD07N093-01

alternately until all brake plates have been removed. Remove the wheel end retainer bolts.

STEP 12 STEP 15

BD07N090-01

BD07N097-01
Remove the wheel end retainer.
Remover cover from wheel end.
6004-10
STEP 16 STEP 18

BD07N089-01 BD07N046-01

Use acceptable lifting equipment and lift the wheel

end from the brake housing.

STEP 17

BD06G015-01

Inspect the stop pin for wear, if necessary drill a hole

into the pin, use 380001545 adapter and 380001582
BD00M251
striker and remove the pin.
Use acceptable lifting equipment and lift the brake
housing from the planetary carrier. STEP 19

BD07N047-01

Inspect wheel bearing, if bearing needs replaced cut

bearing cage with a die-grinder and remove cage.
Score the bearing surface with a die-grinder and
break bearing from planetary carrier using a hammer
and chisel.
 6004-11
STEP 20 STEP 23

BD07N049-01 BD07N056-01

Loosen and remove the six bolts that secure the Carefully pry brake piston up, alternate sides in order
return spring retainer to the brake housing. to raise piston evenly.

STEP 21 STEP 24

BD07N051-01 BD07N059-01

Remove the retainer and return spring from the brake Once brake piston is free remove from housing.
housing.
STEP 25
STEP 22

BD07N067-01
BD07N055-01 Remove and discard the wear ring from top groove in
Remove the shim from the brake housing. brake housing.
6004-12
STEP 26 STEP 29

BD07N064-01 BD07N066-01

Remove and discard the upper back up ring from the Remove and discard the lower back up ring from the
brake housing. brake housing.

STEP 27 STEP 30

BD07N063-01 BD07N079-01
Remove and discard the upper piston seal from the Inspect outer bearing cup, if worn or damaged drive
brake housing. outer bearing cup from brake housing and discard.

STEP 28 STEP 31

BD07N065-01
BD07N081-01
Remove and discard the lower piston seal from the Inspect inner bearing cup, if worn or damaged drive
brake housing. inner bearing cup from brake housing and discard.
 6004-13
STEP 32 STEP 34

BD07N080-01 BD07N036-01

Remove and discard the face seal from brake Remove the metal face seal ring and discard.
housing.
STEP 35
STEP 33

BD07N033-01
BD07N035-01
Inspect wheel end bearing, if bearing needs replaced
Inspect the metal face seal ring, if worn or damaged cut bearing cage with a die-grinder and remove cage.
loosen from wheel end shaft using a pry bar. Score the bearing surface with a die-grinder and
break bearing from wheel end shaft using a hammer
and chisel.
6004-14

Cleaning and Inspection Assembly

IMPORTANT: Do not use compressed air to dry bearings. NOTE: Tools and axle shown in the following
Allow bearings to air dry. photographs may appear slightly different than the tools
and axle you may have. The use of the tools and
STEP 36 disassembly/assembly of axle is the same regardless of
Clean all parts except friction plates in brake disc appearance.
pack using cleaning solvent. WEAR FACE
PROTECTION WHEN USING COMPRESSED AIR. STEP 41
Use compressed air to clear passages in planetary
WARNING: Always wear heat protective
ring gear and brake housing.
gloves to prevent burning your hand when
handling heated parts.
STEP 37 SM121A
Inspect bearing rollers for pitting, scoring,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
dam age . Ch eck a ssociated be aring cup s for
scratches, grooves, or cracks. Check bearings for
rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth,
replace the bearing.

STEP 38
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
BD07N040-01
NOTE: If a bearing or bearing cup requires replacement,
Heat the wheel end shaft outer bearing to 120qC
the associated part must also be replaced.
(248qF) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
STEP 39 end shaft until the bearing is against the shoulder on
Check planetary ring gear, planetary gears, and the wheel end shaft.
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of STEP 42
these conditions are seen. Check planetary carrier
shaft splines for broken, cracked, or twisted
condition. Replace if necessary.

STEP 40
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.

BD07N037-01

Clean the seal ring mounting surface with solvent.

 6004-15
STEP 43 STEP 45

BD07N038-01 BD06G084-01

Apply Loctite 574 to the seal ring mounting surface. Use special tool 380001566 and drive the sealing
ring into position onto the hub.
NOTE: Only use the special tool to install the sealing ring
STEP 44
to ensure proper seating.
WARNING: Always wear heat protective
gloves to prevent burning your hand when STEP 46
handling heated parts.
SM121A
WARNING: Always wear gloves to prevent
frostbite to your hands when handling frozen
parts.
SM118A

BD07N039-01

Heat the metal face seal ring to approximately 120°

C (248° F), place the face seal ring on the wheel end
BD07N083-01
shaft.
Freeze new inner bearing cup in dry ice for several
hours. Install bearing cup in brake housing.
6004-16
STEP 47 STEP 49
WARNING: Always wear gloves to prevent
frostbite to your hands when handling frozen
parts.
SM118A

BD07N069-01

Clean the seal grooves of the brake housing with

solvent.

BD07N082-01
STEP 50
Freeze new outer bearing cup in dry ice for several
hours. Install bearing cup in brake housing.

STEP 48

BD07N070-01

BD06G032-01
6

A A 5 7

A 1
4

2 3
2
1
BC08A246

BS00M073 WEAR RING, BACK-UP RINGS AND PISTON SEAL LOCATION

1. FACE SEAL 2. BRAKE HOUSING A GREASE 1. LOWER BACK-UP RING 5. UPPER BACK-UP RING
Wet the outer diameter of the face seal with a 2. LOWER PISTON SEAL 6. WEAR RING
solution of 50% water and 50% mineral spirits. Use a 3. BRAKE HOUSING 7. BRAKE PISTON
4. UPPER PISTON SEAL
suitable seal installer to install the face seal with the
seal lip positioned as shown. Apply grease to seal as Install the lower back-up ring (1) in the brake
indicated by (A) above. housing.
 6004-17
STEP 51 STEP 54

BD07N077-01
BD07N072-01

Install the lower piston seal (2) in the brake housing, Install the wear ring (6) in the top groove of the brake
make sure the groove in the seal is facing upwards. housing. End points of the wear ring must be
installed in the 12 o’clock (top) position of the brake
STEP 52 housing. Make sure the wear ring is installed
completely in its groove in the brake housing.
NOTE: Apply Loctite 415 to the end points of the wear
ring.

STEP 55

BD07N074-01

Install the upper piston seal (4) in the brake housing,

make sure the groove in the seal is facing
downwards.

STEP 53 BD07N086-01

Set the slack adjuster pins on the brake piston by

driving them in until they are flush with the pin mount.

BD07N075-01

Install the upper back up ring (5) in the brake

housing.
6004-18
STEP 56 STEP 59

BD07N061-01 BD07N052-01

Apply oil on the sliding surface of the piston, back-up Install the brake return spring, make sure that the
rings, seals and wear ring. Carefully install piston in tapered end of the spring is facing up.
the brake housing.
STEP 60
STEP 57

BD07N054-01
BD07N062-01 Install the brake spring retainer.
Using a plastic mallet fully seat the brake piston.
Strike piston on alternate sides to seat piston evenly. STEP 61

STEP 58

BD07N057-01 BD07N050-01

Apply oil to both sides of return spring shim and Install the six retainer bolts and tighten to a torque of
install in brake housing. 34 Nm (25 pound feet).
 6004-19
STEP 62 STEP 64

BD00M251
BD06G053-01
Use acceptable lifting equipment and lower the brake
If stop pin was removed, drive a new stop pin into the housing onto the planetary carrier.
planetary carrier until contact.
STEP 65
STEP 63 Coat the splines of the planetary carrier shaft with
WARNING: Always wear heat protective Loctite No. 767 antiseize lubricant.
gloves to prevent burning your hand when
handling heated parts. STEP 66
SM121A

BD07N089-01

BD07N046-01 Using acceptable lifting equipment lower the wheel

If inner wheel bearing was removed, heat the wheel end onto the brake housing. A slight rotation of the
bearing to 120q C (248q F) in a bearing oven. wheel end may be necessary in order align the
Wearing heat resistant gloves or mittens, install the splines of the carrier shaft with the splines in the
bearing on the planetary carrier until the bearing is wheel end.
against the shoulder on the carrier shaft.
6004-20
STEP 67 STEP 69

BD07N095-01
BD07N090-01 Install a new O-ring on the wheel end cover.
Install the wheel end retainer.
STEP 70
STEP 68

BD07N096-01
BD07N092-01 Install the cover on the wheel end.
Install new bolts, evenly tighten the four bolts in a
cross pattern to a torque of 500 Nm (369 pound feet).
While tightening bolts rotate the brake housing
several time in both directions.
NOTE: Use only new bolts.
 6004-21

6 7
2 5

2
1

BS08A216
BRAKE PLATE AND RETURN SPRING PARTS LOCATION

1. END SHIM 5. RETURN SPRING RETAINER

2. THIN REACTION PLATE (2.0 MM) 6. RETURN SPRING
3. THICK REACTION PLATE 7. SHIM
4. FRICTION BRAKE DISC 8. RETAINER BOLT (6)

STEP 71 STEP 72

BD07N108-01
BD07N107-01 Install a friction brake disc into the brake housing.
Install a thin (2.0 MM) reaction brake plate into the
brake housing.
NOTE: Refer to Illustration above for correct brake plate
installation.
6004-22
STEP 73 STEP 75

BD07N107-01 BD07N110-01

Install the end shim into the brake housing.

STEP 76
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

BD07N108-01

Install a thick reaction brake plate and then another

friction brake disc. Repeat this step until all thick
reaction plates and friction brake discs have been
installed.

STEP 74

BD08B032-01

Heat the three planetary gears to 120qC (248qF) in a

bearing oven. Wearing heat resistant gloves or
mittens, install the planetary gears on the planetary
carrier.

BD07N107-01

Install a thin (2 mm) reaction plate.

 6004-23
STEP 77 STEP 79

BD07N112-01 BD08B036-01

Install the three planetary gear retaining rings with Take a measurement from the straight edge to the
snap ring pliers. face of the brake housing, the difference between
this measurement and the next measurement will be
dimension A.
Sun Gear Shaft End Play Adjustment Measure from the stop pin to the face of the brake
housing.
STEP 78 Example:
Dimension A . . . . . . . . . . . . . 21.25 mm (0.84 inch)
3 4
STEP 80
Install the stub shaft in the spline of the axle bevel
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear.

STEP 81

1 2 5 6 7
BS08B042

1. PLANETARY CARRIER 5. SUN GEAR SHAFT

2. STOP PIN 6. SHIM(S)
3. BRAKE HOUSING 7. STUB SHAFT
4. AXLE HOUSING
BD08B033-01

Install the sun gear on the stub shaft (without shim)

until contact.
6004-24
STEP 82 STEP 84

BD08B034-01
BD07N113-01
Determine dimension B from the mounting face of
the axle housing to the face of the sun gear.
Example:
Dimension B . . . . . . . . . . . . . . . . 19 mm (0.75 inch)

STEP 83
Subtract dimension A from dimension B. Then
subtract 1.25 mm (0.05 inch) from the difference. The
difference is the required shim size.
Example:
Dimension A 21.25 mm (0.84 inch)
Dimension B  19.00 mm (0.75 inch)
BD08B035-01
Difference 2.25 mm (0.09 inch)
Install the sun gear shaft into the planetary gears.
Required end play 1.25 mm (0.05 inch) Install the shim set (size as determined in Step 83)
Difference = shim into the sun gear shaft with grease.
1.00 mm (0.04 inch)
size
STEP 85

BD07N013-01

Install a new O-ring in brake port (1), and a new

O-ring on the axle housing (2).
 6004-25
STEP 86 STEP 89

BD06G072-01

Using acceptable lifting equipment, install the BD06G003-01

assembled wheel end onto the axle housing. Install axle drain plug in differential housing and
torque to 50 Nm (37 pound feet).
NOTE: Turn the input flange to align splines of the stub
shaft into the sun gear.
STEP 90
STEP 87

BD07N212-01

Remove dip stick from axle housing and wipe clean.

BD02D154-01
Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of STEP 91
390Nm (288 pound feet).

STEP 88

BD07N213-01

To check oil level, do not screw in dip stick, but bring

it into contact with the face of the axle housing.
BD06G002-01
Remove dip stick, oil level should be between upper
Install drain plug in wheel end and torque to 50 Nm and lower marks on dip stick. Add Transaxle Fluid
(37 pound feet). (SAE 80W-140) as needed.
Install dip stick and torque to 50 Nm (37 pound feet).
6004-26

BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) High Pressure Test
PRESSURE IN THE FOLLOWING STEPS. If the maximum
pressure of 100 bar (1450 psi) is exceeded damage to
STEP 94
brake piston seals may occur.
Operate the hand pump to increase pressure to 100
bar (1450 psi) maximum. Close connection to hand
STEP 92
pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 3 bar (44
psi).

Low Pressure Test

STEP 95
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.

BD07N209-01

Connect a hand pump with pressure gauge to the

brake port as shown above.

STEP 93

BD07N208-01

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.
Torque brake bleeder to 6 Nm (4.4 pound feet)
 6004-27

REPLACE HUB SEAL

Removal STEP 98
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 96

BD07N094-01

Remove and discard O-ring.

STEP 99

BD06G002-01

Remove drain plug and drain oil from the brake

housing.

STEP 97

BD07N093-01

Loosen and remove the wheel end retainer bolts.

STEP 100

BD06G075-01

Use a pry bar and remove the end cover.

BD07N090-01

Remove the wheel end retainer.

6004-28

Installation
STEP 103

BD06G078-01

Use acceptable lifting equipment to hold the wheel

end. Separate the output shaft using a puller.
BD06G081-01

STEP 101
A A

A 1

BD06G079-01 BS00M073
Use a pry bar and remove the face seal from the 1. FACE SEAL
brake housing and discard. 2. BRAKE HOUSING
A FILL WITH GREASE
STEP 102 Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use a
suitable seal installer to install the face seal with the
seal lip positioned as shown. Apply grease to seal as
indicated by (A) above.

BD07N035-01

Inspect the metal face seal ring for damage or wear,

if required remove the seal ring and discard.
 6004-29
STEP 104 STEP 107

BD07N037-01 BD06G084-01

Clean the seal ring mounting surface with solvent. Use special tool 380001566 and drive the sealing
ring into position onto the hub.
STEP 105 NOTE: Only use special tool to install the sealing ring to
ensure proper seating.

STEP 108

BD07N038-01
Apply Loctite 574 to the seal ring mounting surface.

STEP 106 BD06G086-01

Use acceptable lifting equipment and install the
WARNING: Always wear heat protective
wheel end onto the brake housing.
gloves to prevent burning your hand when
handling heated parts.
SM121A
STEP 109

BD06G088
BD07N039-01
Install the wheel end retainer.
Heat the metal face seal ring to approximately 120°
C (248° F), place the face seal ring onto the wheel
end shaft.
6004-30
STEP 110 STEP 113

BD07N092-01 BD06G002-01
Install new bolts, evenly tighten the four bolts in a
Install drain plug on brake housing and torque to 50
cross pattern to a torque of 500 Nm (369 pound feet).
Nm (37 pound feet).
While tightening bolts rotate the brake housing
several time in both directions.
STEP 114
NOTE: Use only new bolts.

STEP 111

BD07N212-01

Remove dip stick from axle housing and wipe clean.

BD07N095-01
Install a new O-ring on the wheel end cover.
STEP 115
STEP 112

BD07N213-01

To check oil level, do not screw in dip stick, but bring

BD02D053-01
it into contact with the face of the axle housing.
Install the wheel end cover into the wheel end.
Remove dip stick, oil level should be between upper
and lower marks on dip stick. Add Transaxle Fluid
(SAE 80W-140) as needed.
Install dip stick and torque to 50 Nm (37 pound feet).
 6004-31

DIFFERENTIAL

LIMITED SLIP DIFFERENTIAL VERSION DZ-1200

Removal/Disassembly STEP 117
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 116

BD06G126-01

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.
BD06G002-01
STEP 118

BD06G003-01

Remove drain plugs and drain oil from axle. BD06G127-01

Connect suitable lifting equipment to the differential

and remove the differential from axle housing.
NOTE: Make sure that the right axle stub shaft
releases from the differential.
6004-32
STEP 119 STEP 122

BD01F075-01 BD07N162-01
If required, remove the bearing from the housing Remove the ring gear from the differential housing.
cover using a suitable puller.
STEP 120 STEP 123

BD07N165-01 BD07N159-01

Place the differential in a press to prevent it from

turning. Remove the bolts.

STEP 121

BD07N148-01

Remove the outer set of clutch plates, thrust washer,

and bevel gear from the differential housing.

BD07N163-01

Remove the housing cover from the differential

housing.
 6004-33
STEP 124 STEP 125

BD07N145-01 BD07N140-01

3
2 2

1 1
BD07N139-01

Remove the two differential half shafts, spider gears

and thrust washers from the differential housing.
4
STEP 126

BS08B044

1. ROLL PIN SET

2. DIFFERENTIAL HALF SHAFT
3. DIFFERENTIAL SHAFT
4. DIFFERENTIAL HOUSING
Drive both roll pin sets (1) out of the differential
housing (4) to remove the diferential half shafts (2).

BD07N136-01

Remove the differential shaft from the differential

housing.
6004-34
STEP 127 STEP 129

BD07N131-01 BD07N104-01

Remove the remaining two spider gears and thrust If required, remove bearing from differential housing
washers from the differential housing. using a suitable puller and a press.

STEP 128 STEP 130

BD07N129-01 BD06G131-01

Pull the bearing cups and shims from both axle

housings.
NOTE: Make sure to identify the shims into which
axle housing they were removed.

BD07N114-01

Remove the inner set of clutch plates, thrust washer,

and bevel gear from the differential housing.
 6004-35

W11R556
LIMITED SLIP DIFFERENTIAL ASSEMBLY

1. DIFFERENTIAL, CASE 5. DISC, INNER CLUTCH (8x) 9. WASHER THRUST (4x) 13. PIN, SLOT (2x)
2. DISC, OUTER CLUTCH 1.8 mm 6. WASHER THRUST (2x) 10. AXLE, DIFFERENTIAL 14. COVER HOUSING
3. DISC, OUTER CLUTCH 1.9 mm 7. GEAR, BEVEL, AXLE (2x) 11. AXLE, DIFF, SHORT (2x) 15. BOLT (12x)
4. DISC, OUTER CLUTCH 2.0 mm 8. GEAR, BEVEL, DIFF. (4x) 12. PIN, SLOTTED (2x) 16. BEARING, ROLLER
6004-36

Reassembly Limited Slip Differential Version DZ-1200

STEP 131 STEP 134

BD07N119-01
BD07N105-01
Install one reaction plate on the inner bevel gear.
Install bearing on differential housing using a press.
STEP 135
STEP 132
Check reaction plates, friction plates and thrust
washers for damage or wear, replace if necessary.
NOTE: Be sure to apply oil to all parts before assembly.

STEP 133

BD07N120-01

Install one friction plate on the inner bevel gear.

STEP 136

BD07N118-01

Install the (copper color) thrust washer on the inner

bevel gear.
NOTE: Clutch plates must be installed on the inner bevel
gear in the correct order, refer to illustration on page 35.

BD07N122-01

Install two reaction plates on the inner bevel gear.

 6004-37
STEP 137 STEP 140

BD07N124-01 BD07N127-01

Install two friction plates on the inner bevel gear. Install one reaction plate on the inner bevel gear.

STEP 138 STEP 141

BD07N125-01 BD07N128-01

Install one reaction plate on the inner bevel gear. Align all tabs of reaction plates on the inner bevel
gear.
STEP 139

BD07N126-01

Install one friction plate on the inner bevel gear.

6004-38
STEP 142 STEP 144

BD07N129-01 BD07N136-01

BD07N130-01 BD07N137-01

Install the clutch pack and inner bevel gear assembly Install the full differential shaft into the housing
into the differential housing. through both thrust washers and spider gears
installed in the previous step. Make sure position of
STEP 143 hole in center of differential shaft is horizontal to the
differential housing.
1
STEP 145

2
1

BD07N131-01

1. THRUST WASHER 2. SPIDER GEAR

Install a thrust washer (1) and spider gear (2) into the
BD07N139-01
differential housing. Install another thrust washer (1)
and spider gear (2) directly across from the first. 1. THRUST WASHER 2. SPIDER GEAR
Make sure to install in the correct location for the full Install a thrust washer (1) and spider gear (2) into the
differential shaft. differential housing. Install another thrust washer (1)
and spider gear (2) directly across.
NOTE: The stop tab on the thrust washers must face
upwards.
 6004-39
STEP 146 STEP 148

BD07N140-01 BD07N144-01

2
3
2 2

1 1
BD07N138-01

Install both differential half shafts into housing

through thrust washers and spider gears installed in
previous step. The tapered end of half shafts (1) 4
insert into the hole in center of differential shaft.
Make sure the holes on the other end of the half
shafts (2) align with the holes in the differential
housing (3). BS08B044

1. ROLL PIN SET

2. DIFFERENTIAL HALF SHAFT
STEP 147
3. DIFFERENTIAL SHAFT
4. DIFFERENTIAL HOUSING
Drive new roll pins (1) into the differential housing to
secure half shafts.
NOTE: Use new roll pins only.

BD07N138-01

Spider gear assembly installed in differential

housing.
6004-40
STEP 149 STEP 152

BD07N149-01 BD07N153-01

Install the (copper color) thrust washer on the outer Install two reaction plates on the outer bevel gear.
bevel gear.
NOTE: Clutch plates must be installed on the outer bevel STEP 153
gear in the correct order, refer to illustration on page 35.

STEP 150

BD07N155-01

Install two friction plates on the outer bevel gear.

BD07N150-01
STEP 154
Install one reaction plate on the outer bevel gear.

STEP 151

BD07N156-01

Install one reaction plate on the outer bevel gear.

BD07N151-01

Install one friction plate on the outer bevel gear.

 6004-41
STEP 155 STEP 158

BD07N156-01 BD07N160-01

Install one friction plate on the outer bevel gear. Clean ring gear mounting surface on differential
housing.
STEP 156
STEP 159

BD07N158-01

Align all tabs of reaction plates on the outer bevel BD07N161-01

gear. Clean mating surfaces of ring gear and differential

cover.
STEP 157 NOTE: The ring gear and the drive pinion are a matched
gear set and cannot be serviced separately.

STEP 160

BD07N159-01

Install the clutch pack and outer bevel gear assembly

into the differential housing.
BD07N162-01

Install ring gear on differential housing.

NOTE: Make sure to align bolt holes when installing ring
gear and differential cover.
6004-42
STEP 161 Disassembly
Differential version D-1200
STEP 164

BD07N163-01

Install cover on differential housing.

STEP 162
BD06G127-01

Lift differential assy out of axle drive housing.

STEP 165

BD07N166-01

Place the differential in a press to prevent it from

turning. Install new bolts and tighten to a torque of
410 Nm (302 pound feet).
BD01F075-01
NOTE: Use new bolts only.
Pull both taper roller bearings off the differential carrier.

STEP 163 STEP 166

BD08B037-011 BD07N165-01

If bearing was removed from differential cover install Hold differential by means of a press. Loosen locking
bearing using a press. screws and remove lid.
NOTE: Locking screws - permitted for one-time use only.
 6004-43
STEP 167 STEP 169

W110R537 W110R539

Insert some locking screws, position pressure plate Force slotted pin (fixing) out of both spider shaft
and press differential carrier off the crown wheel. halves (split version), then remove both spider shaft
halves in arrow direction and take components (see
STEP 168 figure no. W110R540) out of differential carrier.

STEP 170

W110R538

Remove axle bevel gear, thrust washer and constant

spacer. W110R540

STD differential assembly

1 = Differential carrier
2 = Crown wheel 1 = Differential carrier
3 = Constant spacer 2 = Slotted pin (2x)
4 = Thrust washer 3 = Slotted pin (2x)
5 = Axle bevel gear 4 = Spider shaft (split version)
5 = Spider shaft (one-piece)
6 = Thrust washer (4x)
7 = Spider gear (4x)
8 = Axle bevel gear
9 = Constant spacer
10 = Outer disc
11 = Thrust washer

STEP 171
Pull bearing outer ring out of hole by means of the
striker and remove shim behind (backlash).
NOTE: Mark shim (position/bearing allocation) –
assembly aid.
6004-44
STEP 172

BD06G131-01

Remove O-ring (arrow).

Remove bearing outer ring and shim behind (rolling
torque differential bearing) from axle housing.
NOTE: Mark shim (position/bearing allocation) –
assembly aid.

W110R541

1. DIFFERENTIAL , CASE 6. GEAR, BEVEL, DIFF. 11. PIN SLOT.

2. DISC O. CLUTCH 7. WASHER THRUST 12. COVER HOUSING
3. DIFFERENTIAL, RING 8. AXLE, DIFFERENTIAL 13. BOLT
4. WASHER THRUST 9. AXLE, DIFFERENTIAL SHORT 14. BEARING, ROLLER
5. GEAR, BEVEL, AXLE 10. PIN, SLOTTED SPRING 5X50
 6004-45

Reassembly STEP 175

Differential version D-1200

STEP 173

W110R544

Insert steel outer disc (2) and thrust washer (3) into
the differential carrier (1).
NOTE: Pay attention to installation position of outer disc
W110R542 and thrust washer – see position/figure.
Illustration in figure no. 14 shows differential version
D-1200 = standard version. STEP 176
STEP 174

W110R545

Insert axle bevel gear.

W110R543

Insert constant spacer into differential carrier.

6004-46
STEP 177 STEP 179

W110R546 W110R548

Legend to figure-no. W110R536 … figure-no. Install split spider shaft (4) with spider gears (2) and
W110R549: thrust washers (3).
Differential spider – single parts: NOTE: Insert thrust washers with tabs showing upwards
1 = Spider shaft (one part) - see arrow - and being located in recess.
2 = Spider gear (4x)
NOTE: Pay attention to installation position of spider
3 = Thrust washer (4x)
shaft/halves - slotted pin/location holes of spider shaft
4 = Spider shaft (split version)
towards diff. carrier.
5 = Slotted pin (2x)
6 = Slotted pin (2x)
STEP 180
STEP 178

W110R549

Fix spider shaft half (arrows) with double-slotted

W110R547
pins.
Insert one-part spider shaft (1) into hole/differential
(without slotted pin location hole) thereby mounting NOTE: Install double-slotted pins - always with slots in a
two spider gears (2) with thrust washers (3). 180° offset position to each other.
NOTE: Insert thrust washers with tabs showing upwards
- see arrow - and being located in recess.
 6004-47
STEP 181 STEP 183

W110R550 W110R552

Insert second axle bevel gear into differential carrier. Install two adjusting screws (M 16) - see arrows - and
press crown wheel to contact position.
STEP 182 For input version “with” bevel gear set only - see
specification in the corresponding spare parts list: If a
bevel gear set is specified, the pairing number/crown
wheel (e.g. “7”) must be identical with pairing
number/input pinion.

STEP 184

W110R551

Insert thrust washer (2) and constant spacer (3) into

differential carrier (1) .
NOTE: Pay attention to installation position of thrust
washer and constant spacer – see position/figure.

W110R553

Mount housing lid.

6004-48
STEP 185 Drive Pinion Removal
NOTE: The ring gear and the drive pinion are a matched
gear set and cannot be serviced separately.
STEP 187
Heat lock nut securing flange with a hot air blower to
loosen Loctite, approximately 120° C (248° F).

STEP 188

W110R554

Fix differential by means of a press and fix lid with

“new” locking screws.
NOTE: Locking screws - permitted for one-time use only.
Tightening torque (M16 x 1.5/12.9) ............ = 410 Nm

STEP 186
BD06G132-01

Install holding wrench on input flange. Hold flange

and remove lock nut and washer. Remove holding
tool from flange.

STEP 189

W110R555

Press both bearing inner rings to contact position.

NOTE: Use suitable support (arrow) for provisionally
mounted bearing ring, roller bearing cage – risk of damage.

BD07N173-011

Remove the input flange from the drive pinion.

 6004-49
STEP 190 STEP 193

BD06G133-01 BD07N181-01

Remove the shaft seal from the axle drive housing. Drive inner bearing cup from the differential housing.

STEP 191 STEP 194

BD06G134-01 BD06G141-01

Press the input pinion out of the housing. Remove inner bearing cup and shim from differential
housing.
STEP 192 NOTE: Mark shim and bearing cup location to aid in
assembly.

STEP 195

BD07N183-01

Drive outer bearing cup from the differential housing.

BD07N175-01

Remove the spacer ring from the drive pinion.

6004-50
STEP 196 Brake Tube Removal
STEP 197

BD07N176-01

Remove inner bearing from the drive pinion using a

suitable puller and a press. BD07N030-01

Remove the plug with the breather installed from the

axle housing.

STEP 198

BD07N001-01

Remove fitting from the brake tube on the axle

housing.
 6004-51
STEP 199 STEP 201

BD07N004-01 BD07N010-01

Remove the brake tube from the axle housing.

STEP 202

BD07N006-01

Loosen and remove the nut holding the brake tube

connector to the axle housing.
BD07N015-01
STEP 200 Loosen and remove brake tube fitting inside axle
housing.

STEP 203

BD07N008-01

Loosen the opposite end of brake tube from fitting

inside axle housing.
BD07N017-01

Remove and discard O-ring from fitting.

NOTE: Repeat steps 197 through 203 for the other side of
the axle
6004-52

Brake Tube Installation

2 6
4 5 2
3

BS08B043
BRAKE TUBE PARTS LOCATION

1. BRAKE TUBE FITTING 36NM (27 POUND FEET) 4. AXLE HOUSING

2. O-RING 5. BRAKE TUBE
3. BRAKE TUBE THREADED NUT 100NM (74 POUND FEET) 6. HEXAGON NUT 100NM (74 POUND FEET)

STEP 204 STEP 205

BD07N017-01 BD07N018-01

Install a new O-ring on the brake tube fitting. Install the fitting in the axle and tighten to a torque of
36 Nm (27 pound feet)
 6004-53
STEP 206 STEP 208

BD00M343-01 BD07N006-01

Install a new O-ring in the groove of the brake tube.

STEP 207

BD07N005-01

Install the nut to secure the brake tube. Tighten the

nut to a torque of 100 Nm (74 pound feet).
BD07N010-01

Install the brake tube in axle housing. STEP 209

BD07N009-01
Connect the opposite end of brake tube to the fitting
installed in axle housing. Hold fitting with a wrench
and tighten brake tube to a torque of 100 Nm (74
pound feet).
NOTE: Do steps 204 through 209 for the other wheel end.
6004-54
STEP 210 Pivot Pin Bushing Removal
STEP 212
1
2
3 A

1
BD00M347-01
BD01D499-01
BREATHER VENT EXPLODED VIEW
1. DIFFERENTIAL HOUSING PIVOT PIN BUSHING
1. O-RING 2. PLUG 3. BREATHER A. THRUST SURFACE
Remove and discard O-ring (1) from plug (2) and Inspect pivot pin bushings (1) in differential housing
install a new O-ring. Install breather (3) in plug and for cracks, breaks, deformation, or other damage.
tighten to general bolt torque specifications. Check oil splash grooves for scoring or chipping.
Check for scoring on thrust surface (A). If bushings
STEP 211 require replacement, do Steps 213 through 221.

STEP 213

BD07N003-01
BD07N193-01
Install the breather plug in axle housing and tighten Support left axle housing and wheel end with a
to general bolt torque specifications. suitable stand. Using acceptable lifting equipment to
support differential housing, remove bolts and
remove from left axle housing.

STEP 214

BD07N194-01

Remove and discard O-ring from axle housing.

 6004-55
STEP 215 STEP 217

BD08B006-01
BS08B045

Cut a slot in the pivot bushing.

STEP 216

BD08B007-01

Using a suitable length and diameter rod and spacer,

press bushing out of differential housing.

BD08B005-01 Repeat Steps 215 and 217 to remove the other pivot
Put differential housing in hydraulic press. Make sure bushing.
housing is properly supported.
6004-56

Pivot Pin Bushing Installation STEP 219

WARNING: Always wear gloves to prevent

frostbite to your hands when handling frozen
parts.
SM118A

STEP 218

A
1 BD07N194-01

Install a new O-ring on the left axle housing.

STEP 220

2
BD01D495-01

2
A

BD07N193-01

Position differential housing with left axle housing

and install bolts.
1
STEP 221
BD01D499-01

1. DIFFERENTIAL HOUSING PIVOT PIN BUSHING

2. CENTER OF DIFFERENTIAL HOUSING
A. GROOVE
Freeze new bushing in dry ice for several hours.
Install bushing in differential housing with groove (A)
on circumference of bushing facing center of housing
Install bushing against shoulder in housing.
Repeat Step 218 to install the other pivot bushing.

BD07N197-01

Torque bolts evenly to 390 Nm (288 pound feet).

 6004-57

Drive Pinion Installation STEP 224

STEP 222

2
3
BD06G139-01
1. MATING NUMBER (MARKED MANUALLY)
2. PINION BASIC DIMENSION (STAMPED)
BD06G137-01
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 223 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 225
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
BD06G138-01
------(8.034 inch)
Measure the thickness of the inner bearing and Calculation example B:
record its measurement, dimension “I”.
205.30 mm
Dimension I (Example) . . . . . 36.13 mm (1.422 inch) Dimension X
-------(8.080 inch)
NOTE: Deduct the thickness of the gauge blocks being 204.08 mm
Dimension Y
used to support the bearing from the overall measurement, -------(8.034 inch)
IE: overall measurement 106.13 mm (4.178 inch) Difference = shim 1.22 mm
minus gauge block thickness 70 mm (2.756 inch) will equal thickness ------(0.046 inch)
dimension I.

NOTE: Shims are available in 0.10 mm (0.004 inch),

round up or down to the next available shim thickness, s =
1.20 (0.044 inch)
6004-58
STEP 226 STEP 228
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

BD06G140-01

Heat the bearing hole to approximately 120° C (248°

F) and install the outer bearing cup until contact is
made using a suitable diver.

STEP 227 BD07N178-01

Heat the pinion inner bearing to 120° C (248° F) in a

bearing oven. Wearing heat resistance gloves or
mittens, install the bearing on the pinion shaft until
contact.
NOTE: After installing bearing on pinion shaft, allow the
bearing to cool to ambient temperature.

BD06G141-01

BD06G142-01

Heat the inner bearing hole on the differential

housing to approximately 120° C (248° F). Install the
shim set determined in Step 225 in the bearing bore
and pull the bearing cup into to the bearing hole
using a suitable tool.
 6004-59

Drive Pinion Bearing Rolling STEP 231

Torque Adjustment
STEP 229

BD06G146-01

Press the dust shield on the input flange.

BD07N175-01
STEP 232
Install a 9.03 mm (0.35 inch) thick spacer on the
pinion shaft.

STEP 230
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A

BD06G147-01

Install the input flange on the pinion shaft.

STEP 233
Put the washer and nut in place on the pinion shaft.

BD06G145-01

Heat the pinion shaft outer bearing to 120° C (248°

F) in a bearing oven. Wearing heat resistance gloves
or mittens, install the bearing on the pinion shaft until
contact.
NOTE: Prior to mounting the input flange and tightening
the nut, allow the bearing to cool to ambient temperature.
6004-60
STEP 234 STEP 235

BD06G132-01 BD06G148-01

Install a holding wrench on input flange. Hold flange Check the rolling torque of the drive pinion bearing.
and tighten nut to a torque of 700 Nm (516 pound The rolling torque should be 1.1 to 2.3 Nm (9.75 to
feet). Remove holding wrench. 20 lb-inch). If rolling torque is too low, install a thinner
spacer (Step 229); if rolling torque is too high, install
NOTE: When tightening rotate the pinion shaft in both
a thicker spacer (Step 229).
directions several times.
STEP 236
Remove the nut and input yoke from the drive pinion
shaft.
 6004-61

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 237 STEP 239

BD06G164-01

BD06G163-01 Insert shim A (0.90 mm) and install the bearing cup
Record the deviation value from side of ring gear, the using a suitable driver until seated in axle housing.
value will be a + or -, use the table to determine shim
thicknesses needed. STEP 240
Example: Deviation value of +10 requires the
following shims:
Shim A = 0.90
Shim B = 1.10

STEP 238

1 2

A B
BD06G165-01

Insert shim B (1.10 mm) and install the bearing cup

using a suitable driver until seated in axle housing.

5 3
4
BC06G004

1. DIFFERENTIAL 5. AXLE HOUSING

2. DRIVE HOUSING A. RING GEAR SIDE
3. AXLE HOUSING B. CARRIER SIDE
4. INPUT PINION
6004-62

Contact Pattern Check STEP 244

STEP 241

BD06G169-01

Roll the input pinion several times in both directions

BD06G166-01
over the ring gear. Remove the differential and
Apply marking ink on several teeth of the ring gear. compare the contact pattern with examples on page
4 and page 5.
STEP 242 NOTE: If the tooth contact pattern differs, the wrong shim
size was used in Step 227. Remove differential and repeat
Steps 222 though 227.

BD06G167-01

Position the differential assembly in the axle drive

housing.

STEP 243

BD06G168-01

Position the axle housing on the drive housing, install

4 bolts, top center, bottom center, front center, rear
center, torque bolts evenly to 390 Nm (288 pound
feet).
 6004-63

Installation STEP 248

STEP 245

BD06G171-01

Loosen and remove the nut and input flange.

BD06G167-01

Position the differential assembly in the axle drive STEP 249

housing.

STEP 246

BD06G172

Install the shaft seal with the sealing lip towards oil
sump using suitable seal installer.
BD06G170-01 NOTE: Wet the outer diameter of the seal with a solution
Install a new O-ring on the axle housing. of 50% water and 50% mineral spirits. Fill the space
between the sealing and dust lip with grease.
STEP 247

BD07N207-01

Position the axle housing on the differential housing,

install bolts and torque bolts evenly to 390 Nm (288
pound feet).
6004-64
STEP 250 STEP 252

BD06G173-01 BD06G002-01

Install the input flange. Install holding wrench 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.

STEP 251

BD06G003-01

Install axle drain plugs and torque to 50 Nm (37

pound feet).

BD08B004-01

Check optional axle pivot stop plates for wear or

damage, replace if required. Torque bolts to general
bolt torque specifications.
 6004-65
STEP 253 STEP 254

BD07N212-01 BD07N213-01

Remove dip stick from axle housing and fill with 22 To check oil level, do not screw in dip stick, but bring
Liters (23.2 U.S. Quarts) of Transaxle Fluid (SAE it into contact with the face of the axle housing.
80W-140). Remove dip stick, oil level should be between upper
and lower marks on dip stick.
Install dip stick and torque to 50 Nm (37 pound feet).
6004-66
NOTES
 Section
6005

DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL

JOINTS

6005
6005-2

TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
 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 Coupler Bolts (821F/921F 5-Speed Transmission) ..........86 to 126 Nm (63 to 93 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)
6005-4

FRONT DRIVE SHAFT

Removal STEP 5
Loosen the set screws that secure the center bearing
NOTE: The 921F Series machines use mechanical
to the front drive shaft.
style yokes (no bearing straps) and may appear
different from the machine pictured.
STEP 6
STEP 1 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
the front axle and remove the front drive shaft from
the machine.
NOTE: If necessary, use a brass hammer to drive
the front drive shaft out of the center bearing.

BD03A183
Remove the lock nut that fastens the yoke to the front
drive shaft.

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.

STEP 4
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
 6005-5

FRONT DRIVE SHAFT

Installation STEP 14
NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear
different from the machine pictured.

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.
BD03A183
STEP 11
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.

STEP 16

BD03A167

Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
75 to 81 Nm (55 to 60 pound feet).

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 BD03A166
the alignment marks made during removal are Install the bolts and straps that fasten the front drive
aligned. shaft to the center drive shaft. Tighten the bolts to a
NOTE: If a new front drive shaft has been installed, torque of 75 to 81 Nm (55 to 60 pound feet).
make sure the yoke being installed is 90° to the yoke
on the other end of the front drive shaft.
6005-6

CENTER BEARING

Removal STEP 19
NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear
different from the machine pictured.

STEP 17

BD03A183
Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.

STEP 20
Make an alignment mark on the yoke and the front
BD03A166
drive shaft to be sure that the yoke is installed
Loosen and remove the bolts and straps that fasten
correctly.
the center drive shaft to the front drive shaft.

STEP 18 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.

STEP 23
Loosen the set screws that secure the center bearing
to the front drive shaft.
BD03A183
Loosen and remove the lubrication hose from the
center bearing.
 6005-7
STEP 24

BD03A183

Loosen and remove the bolts, washers and nuts that

fasten the bearing housing to the front frame.

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.
6005-8

CENTER BEARING

Installation STEP 29
NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear
different from the machine pictured.
NOTE: The center bearing and the bearing housing
are not serviced separately. If the center bearing is
worn or damaged or if the bearing housing is
cracked, a new center bearing and bearing housing
must be used.

STEP 26
Apply antiseize compound to the bearing area of the
BC05M214
front drive shaft.
Turn the set screw down to the shaft and then back it
off 1/4th turn and lock it with the jam nut. Repeat the
STEP 27 procedure with the other set screw.
Install the bearing housing so that the lubrication
fitting is at the top.
STEP 30
Apply antiseize compound to the splines on the front
STEP 28 drive shaft. Install the yoke to the front drive shaft,
making sure the alignment marks made during
removal are aligned.

STEP 31

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).
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).
 6005-9
STEP 32

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.

STEP 34
Lubricate the center bearing with the grease
specified in Section 1002.
6005-10

CENTER DRIVE SHAFT

Removal Installation
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.

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.
 6005-11

REAR DRIVE SHAFT

Removal Installation
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.

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.
6005-12

ENGINE DRIVE SHAFT

Removal Installation
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.

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

Install new bolts that fasten the engine drive shaft to

BD03A172
the engine. Tighten bolts to a torque of 53 to 62 Nm
Loosen, remove and discard the bolts that fasten the
(39 to 46 pound feet). For 821F/921F machines
engine drive shaft to the engine.
equipped with 5-Speed transmissions, tighten bolts
to a torque of 86 to 126 Nm (63 to 93 lb ft.).
STEP 49
Remove the engine drive shaft from the machine. NOTE: The bolts that fasten the engine drive shaft to
the engine must be replaced when removed.
 6005-13

UNIVERSAL JOINTS

Removal Installation
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.
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.
6005-14
NOTES
 Section
6006

WHEELS AND TIRES

6006
6006-2

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

WHEELS AND BOLTS

General Information Torque Specification

The wheel bolts must be tightened after every 20 Tighten the wheel bolts to 278 Nm (205 lb ft.) in the
hours of operation until the wheel bolts stay tight: sequence shown in Figure 1 or Figure 2. Then use a
final torque of 640 - 720 Nm (475 - 530 lb ft.) in the
A. If the machine is new.
same sequence.
B. If a wheel has been removed and installed.

FRONT TIRE PRESSURES

23.5 x 25 12 ply L2 .............................................................................................................................345 kPa(50 psi)
23.5 x 25 12 ply L3 ............................................................................................................................345 kPa (50 psi)
23.5R25 L2 ....................................................................................................................... 276 - 448 kPa (40 - 65 psi)
23.5R25 Radial L3............................................................................................................ 276 - 448 kPa (40 - 65 psi)

REAR TIRE PRESSURES

23.5 x 25 12 ply L2 .............................................................................................................................276 kPa(40 psi)
23.5 x 25 12 ply L3 ............................................................................................................................276 kPa (40 psi)
23.5R25 L2 ......................................................................................................................... 207 - 276kPa (30 - 40psi)
23.5R25 Radial L3............................................................................................................... 207 - 276kPa (30 - 40psi

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.
6006-4

INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and
axle flange are clean and free of dirt and grease.
2. Install the wheel, hardened washers and wheel
bolts or nuts depending on axle configuration.
The 621F Heavy Duty axles have wheel studs on
the axles and use wheel nuts.
3. Use a hand wrench (not an impact) to tighten the
wheel b olts to pu ll the wheel against the
planetary housing. DO NOT use an impact
wrench to tighten the wheel bolts.
4. Tighten the wheel bolts to 298 Nm (220 lb ft.) in
the sequence shown in Figure 1. Then tighten to
final torque of 640 - 720 Nm (475 - 530 lb ft.).

1
10 8

6 12

3
4

11 5

7 9
2
B0987A88.TIF
FIGURE 1. 621F SERIES WHEEL NUT/BOLT TORQUE
SEQUENCE

Stud Mounted Wheels (If equipped)

Machines equipped with optional heavy duty axles
have a stud mounted wheel. The heavy duty axle
incorporates a stud and nut assembly.
Torque Rates
First tighten nuts/bolts using correct sequence.
Initially tighten to 298 Nm (220 lb ft.) Then tighten to
final torque of 640 - 720 Nm (475 - 530 lb ft.).
 SECTION INDEX

BRAKES

Section Title Section Number

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
 7001-3

1 5
6

2
8

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 621F STANDARD AXLES
7001-4

9
5

1 6

10

2 8

BC05M136

1. FRONT AXLE 6. REAR ACCUMULATOR

2. REAR AXLE 7. BRAKE PUMP
3. BRAKE VALVE 8. CONNECTOR TO FAN VALVE
9. FRONT AXLE DAMPING
4. PARKING BRAKE ACCUMULATOR
ACCUMULATOR
5. FRONT ACCUMULATOR 10. REAR AXLE DAMPING ACCUMULATOR
COMPONENT LOCATION ILLUSTRATION 621F HEAVY DUTY AXLES
 7001-5

BRAKE VALVE

Removal Installation
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 6.
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
illustration on page 6.
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).
7001-6

9 4

2
7

8
5
6

10
3
W130R0058

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
 7001-7

SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

Removal 18. Disconnect the hose from brake damping

accumulators (9) and (10). See illustration on
NOTE: 621F machines equipped with Heavy Duty Axles page 4.
include brake Damping Accumulators located on the front
axle (9) and frame (10). See illustration on page 4. 19. Remove brake damping accumulators from
machine.
1. Park the machine on a level surface and lower
the loader bucket to the floor. Stop the engine. 20. Install plugs in hoses.

2. Put blocks on both sides of each tire to prevent Installation

machine movement.
NOTE: 621F machines equipped with Heavy Duty Axles
3. Make sure the service brake accumulators (1),
include brake Damping Accumulators located on the front
the parking brake accumulator (2), and brake
axle (9) and frame (10). See illustration on page 4.
damping accumulators (9) and (10) are
completely discharged. Push down and release 1. Mount the accumulators (1) in the accumulators
the brake pedal at least 30. clamps (7), do not tighten clamps at this time.
Refer to illustration on page 8.
4. Turn the master disconnect switch to the OFF
position. 2. Connect the tubes to both brake accumulators
(1) and tighten.
5. Remove the left cab skirt located under the cab
or canopy to gain access to accumulators. 3. Tighten accumulator clamp studs (7) to 17Nm
(13 pound feet).
6. To release the pressure on the parking brake
accumulator, the line at the accumulator must be 4. Install the parking brake accumulator (2) into the
SLOWLY cracked open. A pan will be needed to bracket.
catch the hydraulic oil.
5. Install the nut (3) and tighten.
7. Connect a drain hose to the quick disconnect
6. Connect the line to the parking brake
couplings in each brake circuit to release any
accumulator (2).
pressure in the brake circuit.
7. Install the brake damping accumulators (9) and
8. Clean the brake accumulators (1), parking brake
(10).
accumulator (2), brake damping accumulators
(9) and (10) and lines. Refer to illustrations on 8. Connect the lines to the brake damping
pages 4 and 8. accumulators (9) and (10).
9. Put identification tags on the line that is 9. Stop the vacuum pump and remove.
connected to the parking brake accumulator (2).
10. Install the left cab skirt.
10. Connect a vacuum pump to the hydraulic
11. Turn the master disconnect switch to the ON
reservoir. Start the vacuum pump.
position.
11. Disconnect the tubes from both brake
12. Bleed the brake system. See Section 7002.
accumulators (1).
13. Refer to Section 7008 and perform the Parking
12. Loosen the clamp stud (8) on the accumulator
Brake Test Procedure.
clamp (7).
14. Check the hydraulic reservoir oil level and add oil
13. Remove the accumulators (1) from the
as required. See Section 1002 for the correct oil.
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.
7001-8

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
 7001-9

BRAKE PUMP

Removal Installation
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
illustration on page 10.
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 10. 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).
6. Connect a vacuum pump to the hydraulic
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.
7001-10

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
 7002
Section
7002

HYDRAULIC BRAKE TROUBLESHOOTING

7002-2

ABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
 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
380001767 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 warning switches and replace as
ports.
needed.
4. Make sure that the pressure gauge hoses are
9. As the lowest pressure reaches 106 to 115 bar
long enough so the gauges can be read while
(1530 to 1670 psi) the brake warning lamp and
sitting in the operators seat.
alarm buzzer must actuate. If the warning lamp
NOTE: The gauges can not be connected to the test and alarm buzzer fail to work, test the low brake
ports if hydraulic pressure remains in the system. pressure warning switches and electrical circuit.
If the warning lamp and alarm buzzer actuate at
5. Start the engine. Run the engine at low idle while
a higher or lower pressure than specified, test
reading the pressure gauges. The alarms
the low brake pressure warning switches and
(buzzer, master warning light and brake pressure
replace as needed.
warning light) should shut off when the
accumulator with the lowest pressure reaches 10. After the low brake pressure light activates, 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.
moving and open valve D to charge the
3. Connect the nitrogen charging kit to a dry accumulator.
nitrogen tank.
7. After the accumulator stops charging, turn the
4. Slowly turn valve A clockwise and read gauge E stem out of valve F until the stem stops moving.
until the pressure is 48 to 59 bar (700 to 850 psi).
8. Close valve B and disconnect the nitrogen
Stop turning valve A.
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
Install the guard and cap screws on the
accumulator.
7002-6

BLEEDING THE BRAKE SYSTEM

1. Check the level of hydraulic fluid in the reservoir. 8. Start the engine and run at low idle.
Add fluid to the reservoir if necessary.
9. Push the brake pedal all the way down and
IMPORTANT: If machine is equipped with slowly release for one cycle.
quick-attached components, disconnect them from
10. Close all four wheel end bleed screws.
machine prior to proceeding.
11. Fully depress the brake pedal three times in 5
second cycles.
12. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
bubbles). Close the bleed screw.
13. Open the bleed screw on the right front axle.
Repeat step 12.
1 14. Open the bleed screw on the left rear axle.
Repeat step 12.
15. Open the bleed screw on the right rear axle.
BD03A092
Repeat step 12.
1. SAFETY LINK 16. Replace all bleed screws, caps and plugs.
17. Check the hydraulic fluid and add as necessary.
2. Raise loader arms and install the safety link (1)
for safe access to the front axle bleed screws.
3. Apply the parking brake.
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
5. Connect two 207 bar (3000 psi) pressure gauges
to the front brake accumulator test port (4) and 12. If the pressures are not within the specified
the rear brake accumulator test port (3). range, it will be necessary to adjust the
modulation pressures.
7002-8

Adjusting the Brake Modulation 1. Remove the tamper evident cover (1).
Pressure NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
NOTE: The adjusting bolt to adjust the modulation pressure is adjusted.
pressure is located under the cab, under the brake
pedal. 2. Turn the adjusting bolt 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 11 in the Testing the
Brake Modulation Pressure procedure.
4. Repeat these steps until the brake modulation
pressure is within the specified range.

BD00N121
 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).
1. ARTICULATION LOCK
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).
5. Connect two 207 bar (3000 psi) pressure gauges
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
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

Disassembly Assembly
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
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

380001767 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
380001676 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, turn adjusting bolt

counterclockwise until the brake pads are loose.

STEP 8

BD01F143

Install the articulation lock.

STEP 4
Place the master disconnect switch in the OFF
position.

STEP 5 BD03A186
Remove the retainer pin and brake pin.
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP 9
STEP 6

BD03A187
Remove the two brake pads from the parking brake
BD03A184 assembly.
Loosen and remove the cover from the parking
brake.
7008-4

Inspection STEP 14
Disengage the parking brake.
STEP 10 NOTE: Hydraulic pressure will not be applied to the
Clean and inspect all parts for wear and damage. parking brake until the parking brake rocker switch is
Inspect the brake disc for wear and damage. turned off, the service brakes applied and the
transmission is put into gear.
Replace all parts that are worn or damaged.
A. Place the parking brake rocker switch in the
OFF position.
Assembly
B. Apply the service brake and put the machine
STEP 11 into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.

STEP 15

BD03A187

Install the two brake pads in the parking brake

assembly.

STEP 12

BD0CA185

Turn the adjusting bolt clockwise until both brake

pads contact the brake disc, then turn the adjusting
bolt counterclockwise one turn. Tighten the jam nut
to secure the adjusting bolt.

STEP 16
Install the cover on the parking brake.

STEP 17
Perform the Parking Brake Test Procedure as
BD03A186
described in this section.
Install the brake pins and retainer pins.
STEP 18
STEP 13
Return the articulation lock to the operating position.
Place the master disconnect switch to the on
position. Start the machine and run the engine at low
idle with the bucket resting on the ground.
IMPORTANT: It will be necessary to have an
assistant help for this procedure. An operator must
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.
 7008-5

PARKING BRAKE TEST PROCEDURE

STEP 19 STEP 24
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 20
Start the machine and run the engine at low idle in
third gear neutral.
RCPH10WH381BAH

Use up or down arrow and highlight test park brake

STEP 21 and press the confirm key to enter selection.
Place the Transmission-Auto switch to the manual
position.

STEP 22
Place the Parking Brake switch to the ON position.

STEP 23

BD06F143

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
BD06F141 the monitor will display the condition that needs
Press and hold the enter key for 2 to 3 seconds until corrected prior to proceeding.
the instrument cluster monitor display changes to the
select screen. STEP 25
Monitor will display Test Park Brake Ready.

STEP 26
Shift the gear selector into third gear forward and
slowly increase the engine speed to wide open
throttle.

STEP 27
Verify that the machine does not move.

STEP 28
Reduce the engine speed to low idle and return the
transmission neutral.
7008-6
STEP 29
Shift the gear selector to third gear reverse and
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 to neutral.

STEP 32

BD06F141

Press the escape switch on the key pad to exit the

test mode.

STEP 33
If any machine movement was detected, the parking
brake must be adjusted, see procedures this section.
 SECTION INDEX

HYDRAULICS

Section Title Section Number

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
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 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
 8001-3

LOADER CONTROL VALVE

Removal STEP 5

STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.

STEP 2

BD06F213

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

Raise the lift arms and install the safety link on the lift STEP 7
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
Place the master disconnect switch in the OFF
position.
BD00M041-00

Loosen and remove the bolts and washers that

fasten the access cover plate for the loader control
valve. Remove the cover plate.
8001-4

5
9 3 4

6
2

W130R0059

1. HOSE PILOT TILT RIGHT 4. HOSE PILOT LIFT LEFT (RED-BLACK) 7. HOSE PILOT PRESSURE
(ORANGE-BLACK)
2. HOSE PILOT 3 SPOOL RIGHT 5. HOSE PILOT 3 SPOOL LEFT 8. HOSE PILOT ACCUMULATOR
(RED-WHITE) (YELLOW-WHITE)
3. HOSE PILOT TILT LEFT 6. HOSE PILOT LIFT RIGHT 9. CONTROL VALVE 3 SPOOL
(GREEN-BLACK) (YELLOW-BLACK)
HYDRAULIC VALVE PILOT LINE CONNECTIONS
 8001-5

8
4

3 8

2
1

W130R0061

1. TUBE LIFT HEAD END PLATED 4. HOSE TILT CYLINDER LEFT SIDE 7. HOSE LIFT LEFT SIDE
2. TUBE TILT ROD END PLATED 5. LOADER VALVE 8. TILT CYLINDER
3. HOSE TILT CYLINDER RIGHT SIDE 6. HOSE LIFT RIGHT SIDE 9. LIFT CYLINDER
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
Loosen and remove lines (6 and 7). Install a plug in
each line and a cap on each fitting.

STEP 13
Loosen and remove supply and return lines. Install a
plug in each line and a cap on each fitting.
W130R0060

STEP 14 Install and align the loader control valve with the
Attach proper lifting equipment to lift loader control valve mounting plate.
valve.
STEP 17
STEP 15 Install the bolts and washers that fasten the loader
control valve to the valve mounting plate. Tighten the
bolts.

STEP 18
Tighten the left lift cylinder lines (6 and 7).

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
W130R0060
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
Park the machine on a level surface and lower the
bucket to the floor. 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. 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
STEP 41 Installation
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
Place the master disconnect switch in the ON
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

1 2 3

8
7 5 4
6
BS07D291

1. ORANGE BLACK 4. YELLOW WHITE 7. RED BLACK

2. YELLOW BLACK 5. PILOT PRESSURE HOSE 8. PILOT TANK HOSE
3. RED WHITE 6. GREEN BLACK
JOYSTICK AND 1 LEVER HOSE COLOR CODING
8001-12

1 2 3 4

8 7 6 5

BS07D290

1. RED WHITE 4. PILOT TANK HOSE 7. GREEN BLACK

2. ORANGE BLACK 5. PILOT PRESSURE HOSE 8. YELLOW WHITE
3. YELLOW BLACK 6. RED BLACK
3 LEVER HOSE COLOR CODING
 8001-13

5
3
3
2
2
5
1
6 6
1

BS07D292

1. ORANGE BLACK 1. ORANGE BLACK

2. YELLOW BLACK 2. YELLOW BLACK
3. PILOT TANK HOSE 3. GREEN BLACK
4. PILOT PRESSURE HOSE 4. PILOT PRESSURE HOSE
5. RED BLACK 5. RED BLACK
6. GREEN BLACK 6. PILOT TANK HOSE
2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING
8001-14

HYDRAULIC PUMP

Removal STEP 63

STEP 59
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.

STEP 60
Place the master disconnect switch in the OFF
position.

STEP 61
Drain the hydraulic reservoir then refer to Section
9007 and remove the ROPS cab or ROPS canopy. BD01D329

Loosen and remove the bolts holding the bracket for

STEP 62 the hydraulic hoses. Slide the bracket up to gain
enough clearance for the hydraulic pump to be
removed.

3 1

1
2 4
BD01D303

1. BOLTS (4) 3. SUCTION HOSE

2. CASE DRAIN HOSE 4. HYDRAULIC PUMP
A. Loosen and remove the four bolts (1)
connecting the suction hose (3) to the
hydraulic pump (4).
B. Tag and disconnect the case drain hose (2)
from the top of the hydraulic pump (4).
C. Plug all lines and cap all fittings.
 8001-15
STEP 64 STEP 66

2
4
1
3
BD01D308 BD01D307

1. BOLTS (4) 3. PRESSURE HOSE Loosen and remove the two bolts that fasten the
2. LOAD SENSING HOSE 4. HYDRAULIC PUMP hydraulic pump to the transmission.
A. Loosen and remove the four bolts (1)
connecting the pressure hose (3) to the STEP 67
hydraulic pump (4). Remove the hydraulic pump from the machine.
B. Tag and disconnect the load sensing hose (2)
from the hydraulic pump (4). STEP 68
C. Plug all lines and cap all fittings.

STEP 65

BD01D335

Remove and discard the O-ring from the hydraulic

pump.

BD01D333

Use proper lifting device to strap and support the

hydraulic pump.
8001-16

Installation STEP 72

STEP 69

BD01D308

1. PRESSURE HOSE
BD01D335 2. HYDRAULIC PUMP
3. LOAD SENSING HOSE
Use proper lifting device to lift and support the
hydraulic pump. Install a new O-ring on the hydraulic A. Install the pressure hose (1) to the hydraulic
pump. pump (2).
B. Install the load sensing hose (3) to the
STEP 70 hydraulic pump (2).

STEP 73

1
2

BD01D334 3
Install the hydraulic pump on the transmission.
BD01D303
STEP 71 1. SUCTION HOSE
2. HYDRAULIC PUMP
3. CASE DRAIN HOSE
A. Install the suction hose (1) to the hydraulic
pump (2).
B. Install the case drain hose (3) to the hydraulic
pump (2).

BD01D307

Install the two bolts that fasten the hydraulic pump to

the transmission. Tighten the two bolts to a torque of
335 to 375 Nm (245 to 275 lb ft).
 8001-17
STEP 74 STEP 77
Place the master disconnect switch in the ON
position.

STEP 78
Start the engine and run the engine at low idle for two
minutes.
NOTE: If any unusual vibration is heard coming from the
pump, stop the machine immediately and check for
obstructions in the pump suction line.

STEP 79
Stop the engine and check for hydraulic oil leakage
BD01D329
at the hydraulic pump.
Install the bracket holding the hydraulic hoses.
Tighten the bolts.
STEP 80
Check the level of the hydraulic oil in the reservoir
STEP 75
and add hydraulic oil as required.
See Section 9007 for installing the ROPS cab or
ROPS canopy.

STEP 76
Fill the hydraulic reservoir with hydraulic oil. See
Section 1002 for correct oil type.
8001-18

LIFT CYLINDERS

Removal STEP 85

STEP 81
Park the machine on a level surface and lower the
bucket to the floor. 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 82 BD01D709

Relieve the pressure in the ride control accumulator Loosen and remove the bolt, washer and spacer that
with the manual bleeder valve located at the rear of hold the pivot pin for the yoke.
the front chassis.
STEP 86
STEP 83
Loosen the filler cap on the hydraulic reservoir to
release any pressure.

STEP 84

BD01D711

Use a proper lifting device and secure a strap around

the lift cylinder.

STEP 87
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.
 8001-19
STEP 88 Installation
STEP 91
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.

STEP 92

BD01D710

Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.

STEP 89

BD01D714

Use a proper lifting device and position the lift

cylinder on the machine.

STEP 93

BD01D713

Remove the pivot pin from the closed end of the lift
cylinder.

STEP 90
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.
8001-20
STEP 94 STEP 97

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 98
STEP 95

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 99
STEP 96 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 100
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 101
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the
hydraulic reservoir.
 8001-21

BUCKET CYLINDER - Z-BAR LOADER

Removal STEP 106

STEP 102
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.

STEP 103
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.

STEP 104
BD01D695

Loosen and remove the two bolts that fasten the

mounting bracket to the machine. Remove the
mounting bracket.

STEP 107

BD01D694

Disconnect the proximity switch connector from the

wiring harness connector.

STEP 105

BD01D697

Loosen and remove the two bolts that fasten the

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.

BD01D696

Loosen and remove the two bolts that fasten the

target bar to the mounting bracket. Remove the
target bar.
8001-22
STEP 108 STEP 111

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 112
STEP 109

BD01D704
BD01D700 Remove the pivot pin from the head end of the
Use acceptable equipment to hold the bucket bucket cylinder.
cylinder.
NOTE: It is not necessary to remove the grease line from
the pivot pin unless the pivot pin is to be replaced.
STEP 110
STEP 113

BD01D698

Loosen and remove the bolt, washer and spacer that

BD01D706
fasten the pivot pin from both ends of the bucket
Raise the bucket cylinder and remove the cylinder
cylinder.
from the machine.
 8001-23

Installation STEP 118

STEP 114
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.

STEP 115

BD01D699

Connect the hoses to each side of the bucket

cylinder.

STEP 119
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 116 STEP 120

Install the pivot pin and stop the engine.

STEP 121

BD01D704

Install the pivot pin to the head end of the bucket

cylinder.
BD01D698

STEP 117 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.
8001-24
STEP 122 STEP 125

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 123 STEP 126

See Section 9006 for the adjustment procedure for
adjusting the proximity switch.

STEP 127
Start and run the engine at low idle.

STEP 128
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.

STEP 129
Lubricate the pivot pins with molydisulfide grease.
BD01D695

Install the two bolts for the mounting bracket for the STEP 130
target bar.
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
STEP 124 hydraulic reservoir.

BD01D696

Install the two bolts that fasten the target bar to the
mounting bracket.
 8001-25

OIL COOLER

Removal STEP 136

STEP 131
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.

STEP 132
Place the master disconnect switch in the OFF
position.

STEP 133
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 134
STEP 137

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 135
Loosen the filler cap on the hydraulic reservoir to
STEP 138
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.
8001-26

Installation STEP 142

STEP 139

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 143
tighten the two mounting nuts. Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 140
STEP 144
Place the master disconnect switch in the ON
position.

STEP 145
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 146
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 147
the cooling frame Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
STEP 141

BD03A154

Connect the hose to the top of the oil cooler.

 8001-27

RIDE CONTROL ACCUMULATOR

Removal STEP 151

Loosen the filler cap on the hydraulic reservoir to
STEP 148 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 152
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 149

BD07N615-01
Disconnect the hose from the elbow at the bottom of
the ride control accumulator. Install a plug in the
hose and a cap on the fitting.

STEP 153

BD01F143-01

Put the articulation lock in the LOCKED position.

STEP 150

BD07N616-01
Loosen and remove the nuts and washers from the
top U-bolt. Remove the U-bolt.

BD06F213

Relieve the pressure in the ride control accumulator

with the manual bleeder valve located on the bottom
of the ride control valve. Remove the plug and turn
the valve two turns counter-clockwise.
8001-28
STEP 154 Installation
STEP 155
Place the ride control accumulator in position on the
front frame.

STEP 156

BD07N615-01
Loosen and remove the two bolts that fasten the
accumulator lower bracket to the frame. Remove the
ride control accumulator from the machine.

BD07N615-01

Install the two bolts that fasten the accumulator lower

bracket to the front frame. Tighten the bolts.

STEP 157

BD07N616-01

Install the U-bolt, washers and nuts. Tighten the nuts.

 8001-29
STEP 158 STEP 160

BD07N615-01 BD06F213

Remove the caps and plugs and install the hose on Tighten the accumulator manual bleeder valve
the elbow at the bottom of the ride control located on the bottom of the ride control valve to a
accumulator. torque of 3.5 Nm (31 lb-in). Install the plug and
torque to 7 Nm (62 lb-in).
STEP 159
Turn off and disconnect the vacuum pump from the STEP 161
hydraulic reservoir. Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.

STEP 162
Put the articulation lock in the OPERATING position.

STEP 163
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
hydraulic reservoir.
8001-30

RIDE CONTROL VALVE

Removal STEP 166

Loosen the filler cap on the hydraulic reservoir to
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
IMPORTANT: With the engine NOT running, pump the
Place the master disconnect switch in the OFF
brake repeatedly to be sure the brake accumulators have no
position.
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 STEP 168
control circuit, turn ignition switch OFF. Disconnect the electrical connector on top of the ride
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
BD06F213 Remove and discard all O-rings.
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.
 8001-31

Installation STEP 178

Connect the electrical connector to the ride control
STEP 173 valve.
Install the ride control valve in position on the front
frame. STEP 179
Turn off the vacuum pump and disconnect from the
STEP 174 hydraulic reservoir.
Install the washers and bolts through the frame and
into the ride control valve. Tighten the bolts. STEP 180
Place the master disconnect switch in the ON
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
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
hydraulic reservoir.
BD06F213

Tighten the accumulator manual bleeder valve STEP 184

located on the top of the ride control valve to a torque Refer to Section 8002 and perform the Ride Control
of 3.5 Nm (31 lb-in). Install the plug and torque to Test Procedure.
7 Nm (62 lb-in).

STEP 176
Lubricate and install new O-rings.

STEP 177
Connect the hoses to the ride control valve.
8001-32

FAN REVERSING VALVE

Removal STEP 188

STEP 185
Park the machine on a level surface and lower the
bucket to the ground. 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 2
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
1
control circuit, turn ignition switch OFF.

STEP 186 BD03A174

Loosen the filler cap on the hydraulic reservoir to Tag and disconnect the fan forward hose (1) from the
release the air pressure in the reservoir. Connect a fan reversing valve. Install a plug in the hose and a
vacuum pump to the hydraulic reservoir, turn on the cap on the fitting. Tag and disconnect the fan reverse
pump. hose (2) from the fan reversing valve. Install a plug in
the hose and a cap on the fitting.
STEP 187
STEP 189

3
4

BD03A173
BD03A174

Disconnect the electrical connector for the fan Tag and disconnect the fan valve return hose (3)
reversing valve. from the fan reversing valve. Install a plug in the hose
and a cap on the fitting. Tag and disconnect the fan
valve supply hose (4) from the fan reversing valve.
Install a plug in the hose and a cap on the fitting.

STEP 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.
 8001-33

Installation STEP 198

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
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.

STEP 200
3 Check the level of the hydraulic oil in the reservoir.
4

BD03A173
STEP 201
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
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
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.
8001-34

THERMAL VALVE

Removal Installation
STEP 204 STEP 208
Park the machine on a level surface and lower the Place the thermal valve into position on the machine.
bucket to the ground. Stop the engine and apply the
parking brake. STEP 209
IMPORTANT: With the engine NOT running, pump the Lubricate and install new O-rings in the fittings.
brake repeatedly to be sure the brake accumulators have no
hydraulic pressure, put the ignition switch in the ON STEP 210
position then move the loader control valve back and forth Install the bolts, washers and nuts. Tighten the nuts.
several times to release any hydraulic pressure in the pilot
control circuit, turn ignition switch OFF. STEP 211
Connect the hoses to the thermal valve, remove and
STEP 205 discard tags.
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a STEP 212
vacuum pump to the hydraulic reservoir, turn on the
Turn off the vacuum pump and disconnect from the
pump.
hydraulic reservoir.
STEP 206
STEP 213
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.

BD06F211
STEP 216
Tag and disconnect the hoses from the thermal Check the level of the hydraulic oil in the reservoir
valve. Install a plug in the hose and a cap on the and add as required. Tighten the filler 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
Problem 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 Load Travel Stabilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING THE MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TESTING THE PILOT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TESTING THE LOAD TRAVEL STABILIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
 8002-3

SPECIFICATIONS
Pump Output ..........................................................................................................150 L/min at 2200 rpm at 207 bar
(40 gpm at 2200 rpm at 3000 psi)
Main relief valve pressure settings .........................................................................248 to 255 bar (3596 to 3700 psi)
Differential pressure .......................................................................................................22 to 25 bar (320 to 360 psi)
Pilot pressure..................................................................................................................29 to 40 bar (420 to 580 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (TC and Z Bar)........................................................................................290 bar (4206 psi)
Bucket A and B port (Z Bar) .......................................................................................................290 bar (4206 psi)
Bucket A port (TC) .....................................................................................................................183 bar (2654 psi)
Bucket B port (TC) .....................................................................................................................290 bar (4206 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Accumulator pressure..................................................................................................................... See Section 7002
8002-4

SPECIAL TOOLS

633L95 B877168V
380001741 PRESSURE FITTING KIT 380001740 FLOWMETER FITTING KIT

632L95 B877895M
380001742 PRESSURE FITTING KIT 380001726 HAND PUMP

B785789M B877558M
380001731 FLOWMETER 380001739 PRESSURE FITTING KIT
 8002-5

TROUBLESHOOTING PROCEDURE

Visually check the machine for oil leakage and

damaged or missing parts. Repair or replace
any damaged or missing parts.

Check the oil level in the hydraulic reservoir. Fill the hydraulic reservoir with the hydraulic
No oil specified in Section 1002.
Is the oil level correct?.

Yes

Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.

Problem in all Circuits

Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.

See page 7. Test and adjust pump

differential pressure then proceed to Page 7
See Section 8003 and check for and do the flowmeter tests of the hydraulic
No
contaminated oil. Is the oil contaminated? p u m p . S e e p a g e 12 and t e s t t h e p i l o t
pressure.

Yes

See Section 8003 and clean or replace the

oil.

Problem in all Loader Circuits

See Page 10 and check the pressure setting
Adjust the main relief valve. See page 10 in
of the main relief valve in the loader control No this section.
valve. Is the pressure setting correct?

Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.
8002-6

Problem in a Single Loader Circuit

Start and run the engine at full throttle. The loader control valve is damaged. See
Operate the control for the bad circuit. Does No Section 8005 and repair the loader control
the cylinder move in both directions? valve

Yes

Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?

Yes

See Page 13. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of control valve and check for worn or
No
the circuit again. Does the circuit work damaged parts.
correctly?

Yes

The problem is repaired.

Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?

Yes

See Page 7. Do the Primary Pump Output

Test.

Problem in the Load Travel Stabilization

Lift arms rapidly and continuously sink See the Load Travel Stabilization Test
towards the ground. No Procedure page 14 in this section.

Yes

Check the manual bleed valve for the load

travel stabilization accumulator to be sure
that it is closed.
 8002-7

TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE

NOTE: The Pump Differential Pressure must be set before attempting any other tests.

Pressure Check STEP 3

STEP 1
Make sure that the temperature of the hydraulic oil is
at least 52°C to 60°C (125°F to 140°F). The following
is the procedure for heating the hydraulic oil.
A. Apply the parking brake.
B. Start the engine.
C. To measure the oil temperature with the
instrument cluster: 1
● Press the up or down arrow key.
● Stop at the info screen with the temperatures BD00M030
that need to be monitored are on.
1. ARTICULATION LOCK
D. Run engine at full throttle. Install the articulation lock (1).
E. Hold the bucket control lever in the
ROLLBACK position while raising and STEP 4
lowering the lift arms from ground level to full
height.
F. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to
134°F).

STEP 2

1
BD00M041

1. COVER PLATE

1 Remove the cover plate to gain access to the loader

control valve.

BD03A092

1. SAFETY LINK
Raise the loader arms and install the safety link (1).
8002-8
STEP 5 STEP 9
Subtract the reading of the test port (1) from the
reading of the test port (3).

STEP 10
The difference between the two readings should be
22 to 25 bar (320 to 360 psi).
2
STEP 11
If this reading is more or less than that specified, it
1
will be necessary to adjust the pump.

Adjusting the Main Hydraulic

BD00N020 Pump
STEP 12

BD00N017
W110R581
1. TEST PORT (LOAD SENSE)
2. TEST PORT (PILOT PRESSURE)
The delta pressure adjusting screw is the farthest
3. TEST PORT (PUMP PRESSURE) from the pump. Turn the screw clockwise to increase
the differential pressure. Turning the screw
counterclockwise will decrease the differential
Connect two 69 bar (1000 psi) test gauges to the test
pressure.
ports (1) and (3) located on the loader control valve.
NOTE: One turn of the adjustment screw will change the
STEP 6 pressure approximately 16 bar (230 psi).
Start the engine and run at low idle.

STEP 7
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (3).

STEP 8
The pressure on test port (1) should read
approximately 29 bar (420 psi). The pressure on test
port (3) should read approximately 51 bar (740 psi).
NOTE: These readings may vary from one machine to
another. The important value is the difference between the
readings of gauges 1 and 3.
 8002-9

12
NOTE

11
8

4 9

10

1 2
3

BC06C158

1. CAP 1-7/16-12 ORFS 7. FILTER INLET MANIFOLD

2. LOADER CONTROL VALVE 8. INLINE NEEDLE VALVE
3. FLOWMETER INLET HOSE 9. UNION
4. LOADER CONTROL VALVE INLET HOSE 1-7/16-12 ORFS 10. “T” FITTING
5. 380001731 FLOWMETER 11. LOAD SENSE HOSE 9/16 X 18 ORFS
6. FLOWMETER OUTLET HOSE 12. CAP 9/16 X 18 ORFS

NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.
8002-10

TESTING AND ADJUSTING THE MAIN RELIEF VALVE

NOTE: The Pump Differential Pressure must be set before attempting any other tests. Refer to page 7 of this section.

Pressure Check STEP 3

STEP 1

1
BD00M041

Remove the cover plate to gain access to the loader

BD00M030
control valve.
1. ARTICULATION LOCK
STEP 4
Install the articulation lock (1).

STEP 2

2
1
BD00N017

1. LOADER CONTROL VALVE

2. TEST PORT
BD03A092

1. SAFETY LINK
Stop the engine and install a 345 bar (5000 psi)
pressure gauge to the test port (2) on the front of the
Raise the loader arms and install the safety link (1).
loader control valve (1).
 8002-11
STEP 5 Adjustment
Make sure that the temperature of the hydraulic oil is
at least 52°C to 60°C (125°F to 140°F). The following
is the procedure for heating the hydraulic oil. STEP 10
A. Apply the parking brake.
B. Start the engine.
C. To measure the oil temperature with the
instrument cluster:
Press the up or down arrow key.
Stop at the info screen with the temperatures
that need to be monitored are on.
D. Run engine at full throttle.
E. Hold the bucket control lever in the
ROLLBACK position while raising and
lowering the lift arms from ground level to full
height.
F. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to
134°F).

STEP 6 2
Start the engine and remove the safety link (refer to
step 2) and lower the loader arms to the ground.
1
STEP 7 BS01A046
Operate the machine at full throttle. Tilt the bucket to 1. LOADER CONTROL VALVE
a full rollback position and hold while observing the 2. RELIEF VALVE ADJUSTMENT
pressure gauge.
With the engine running and the loader on the
ground, loosen the jam nut and turn the adjustment
STEP 8 screw (2) clockwise for higher pressure or
The pressure should read between 248 and 255 bar counterclockwise for lower pressure.
(3596 to 3700 psi).
NOTE: 1/4 turn of the adjusting screw changes the
STEP 9 pressure setting approximately 35 bar (500 psi).
If the pressure is not within the specifications, it will
be necessary to adjust the main relief valve.
STEP 11
Repeat the Pressure Check Procedure.

STEP 12
If the pressure is not within the specifications, repeat
steps 10 and 11 until pressure is within the required
range.

STEP 13
Stop the engine before removing the pressure
gauge.
8002-12

TESTING THE PILOT PRESSURE

STEP 1 STEP 3

BD00M030
BD00N020
1. ARTICULATION LOCK
Stop the engine and connect a 69 bar (1000 psi) test
Install the articulation lock (1). gauge to the pilot pressure test port located on the
loader control valve.
STEP 2 NOTE: This can be accessed through the articulated joint
Make sure that the temperature of the hydraulic oil is area, use articulation joint lock before connecting gauge in
at least 52°C to 60°C (125°F to 140°F). The following this manner.
is the procedure for heating the hydraulic oil.
A. Apply the parking brake. STEP 4
B. Start the engine. Start and run the engine at low idle, roll the bucket
back against the stops and hold.
C. To measure the oil temperature with the
instrument cluster:
STEP 5
Press the up or down arrow key. A pressure reading of 29 to 40 bar (420 to 580 psi)
Stop at the info screen with the temperatures should be obtained.
that need to be monitored are on.
STEP 6
D. Run engine at full throttle.
If pressure is not as specified, replace the pressure
E. Hold the bucket control lever in the reducing valve, refer to section 8005.
ROLLBACK position while raising and
lowering the lift arms from ground level to full STEP 7
height.
If pressure is correct, raise lift arms to the top and
F. Continue this procedure until the temperature turn off the engine. Turn the ignition switch to the
of the hydraulic oil is 54° to 57°C (129° to “RUN” position and disengage the controller lockout
134°F). switch.

STEP 8
Wait for the buzzer to stop then repeatedly put the
loader control lever into “FLOAT” position and back
to neutral.

STEP 9
The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
NOTE: If 10 full actuations cannot be made, an internal
hydraulic leak exists.
 8002-13

TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Pressure Check STEP 3

Connect the hand pump to the disconnected line that
STEP 1 goes to the loader control valve.
Circuit relief valves are located as shown below.
STEP 4
6 Make sure that the hand pump is full of hydraulic oil
5 1 5 and that the temperature of the oil is approximately
1
21°C (70°F).

STEP 5
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
4 4 be sure of the reading.

STEP 6
Compare the reading to the specifications on Page 3.

STEP 7
If the pressure is not correct, adjust the circuit relief
valve.

3 Adjustment
3 1
1 STEP 1
2 Loosen the lock nut. Turn the adjustment screw
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
BS01A046

1. CIRCUIT RELIEF VALVE STEP 2

2. MAIN RELIEF VALVE Check the pressure again. Repeat the adjustment as
3. BUCKET SPOOL
necessary.
4. LIFT SPOOL
5. AUXILIARY SPOOL
6. LOADER CONTROL VALVE
Remove the cover at the front of the machine.

STEP 2
Lower the bucket to the floor. Shut off the engine.
Find an easy place to disconnect the line for the
circuit to be tested.
8002-14

TESTING THE LOAD TRAVEL STABILIZATION

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 load travel stabilization
STEP 2 accumulator.

STEP 7
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
their stops, place the pilot control lever in the neutral
position.

STEP 8
1 Set the load travel stabilization rocker switch to the
“Always On” position. The lift arms should rise 15 to
30 cm (6 to 12 inches) with an empty bucket.
NOTE: Test results will be for a machine with a empty
BD00M030
factory bucket and no attachments.
1. ARTICULATION LOCK
STEP 9
Install the articulation lock (1), start the machine,
If there is little or no lift arm raise, the test may have
activate the parking brake.
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
STEP 3
NOTE: If test was done too slowly, repeat in the allotted
With the pilot controller in neutral, set the load travel
time.
stabilization rocker switch on the right side console to
the “Always On” position and observe the switch
lamp, the lamp should illuminate. STEP 10
If test was completed in the allotted time and the lift
STEP 4 arms still do not rise, test the nitrogen charge in the
accumulator.
Set the load travel stabilization rocker switch to the
“Off” position and observe the switch lamp, the lamp
should go out.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not illuminate
see section 4002 and troubleshoot the electrical system for
the load travel stabilization.

STEP 5
Raise the lift arms to the top of their travel and dump
the bucket.
NOTE: Keep rocker switch in the “Off” position during
steps 5, 6, 7.
 8002-15

HYDRAULIC COMPONENT LOCATIONS

6 20
14 3
15
13 2
1 4
9 11
5 10
16
12
4

18
7
8 19

17

BC00N140
1. LOAD TRAVEL STABILIZATION VALVE (OPTIONAL) 11. STEERING PRESSURE DIAGNOSTIC COUPLER
2. LOAD TRAVEL STABILIZATION ACCUMULATOR 12. BRAKE ACCUMULATORS
3. ACCUMULATOR BLEEDER VALVE 13. BRAKE AND ACCUMULATOR CHARGING VALVE
4. LIFT CYLINDERS 14. BRAKE WARNING PRESSURE SWITCH
5. BUCKET CYLINDER (TILT CYLINDER) 15. BRAKE LIGHT PRESSURE SWITCH
6. STEERING CONTROL VALVE 16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
7. STEERING CYLINDERS 17. REAR BRAKE LINE
8. AUXILIARY STEERING PUMP AND MOTOR 18. FRONT BRAKE LINE
19. PARKING BRAKE
9. AUXILIARY STEERING PRIORITY VALVE 20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC
COUPLERS
10. AUXILIARY STEERING PRESSURE SWITCH

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic schematic for
reference.
8002-16

HYDRAULIC COMPONENT LOCATIONS

39
42 23 31
41 22 40
35 38
25 37
36
26 34
30 33
29
25
21
32

27
28

24

BC00N140

21. FAN DRIVE MOTOR 32. PILOT PRESSURE ACCUMULATOR

22. FAN REVERSING VALVE (OPTIONAL) 33. PILOT PRESSURE DIAGNOSTIC COUPLER
23. FAN VALVE (STANDARD) 34. FLOAT SWITCH
24. BRAKE HYDRAULIC PUMP 35. CONTROLLER
25. COUPLER LOCKING VALVE 36. LOADER CONTROL VALVE
26. COUPLER LOCKING CYLINDERS 37. PUMP PRESSURE DIAGNOSTIC COUPLER
27. IMPLEMENT HYDRAULIC PUMP 38. LOAD SENSING DIAGNOSTIC COUPLER
28. HYDRAULIC OIL FILTER 39. BRAKE PRESSURE SWITCH (2)
29. HYDRAULIC OIL RESERVOIR 40. AUXILIARY STEERING LOAD SENSE SOLENOID VALVE (OPTIONAL)
30. HYDRAULIC RESERVOIR BREATHER 41. PARKING BRAKE ACCUMULATOR
31. HYDRAULIC OIL COOLER 42. PARKING BRAKE ACCUMULATOR DIAGNOSTIC COUPLER
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic schematic for
reference.
 Section
8003

8003
CLEANING THE HYDRAULIC SYSTEM
8003-2

TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
 8003-3

SPECIAL TOOLS

806128

380001733, fitting kit.

806127

380001727, filter unit, portable.

TR98H032

380001728, vacuum pump.

8003-4

GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All 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
testing in a laboratory. Examples of the D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.
 8003-5

CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
19. Decrease the engine speed to low idle.
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
22. Stop the engine.
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.
8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
oil as required. See Section 1002 for
specifications.
 8003-7

FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.

39-4
17. Start the engine and run the engine at low idle.
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. oil as required. See Section 1002 for
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.

7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.

8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.

9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have another
person hold a container under the hydraulic lines while you
do step 13.
8003-8
NOTES
 Section
8004

8004
HYDRAULIC PUMP
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 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 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 marks made during
disassembly.

STEP 17

BC06F567

Check the bearing surface.

STEP 20

BC06F565

Check for wear on the splines, seal areas for

grooves, bearing areas for scaring, and key set.

STEP 18

BC06F568

Check that the retaining plate is free of grooves and

that there is no sign of wear.

STEP 21

BC06F566

Check the surface that the pistons contact for

grooves and scaring.

BC06F569

Check the sliding surface for scratches or metal

deposits, check the tightness of the cup on the
piston.
NOTE: If a piston needs to be replaced, all of the
pistons must be replaced.
8004-10
STEP 22 STEP 24

BC06F572
BC06F570

Check the cylinder bores and splines for damage. Check cylinder surface for grooves, wear, embedded
particles. Check flow plate for scratches or wear.
STEP 23
STEP 25

BC06F571
BC06F573
Check ball for grooves and wear.
Check mounting surface for the flow plate for
damage.
 8004-11

Assembly STEP 27

STEP 26

BC06F574 BC06F575

Install the plug in the housing and tighten to 127 Nm Put the shaft and bearing in the housing.
(93.5 pound-feet). Install shim and press in the
bearing race. STEP 28

BC06F576

Press in a new race into the end cover.

8004-12
STEP 29 STEP 31

BC06F579

Install the seal and retaining ring.

STEP 32

BC06F577

Install the end cover, 4 bolts and hand tighten.

STEP 30

BC06F578

A bearing pre load of 0.05 mm (0.002 inch) must be

obtained, add remove shims from bearing as
required.

BC06F580

Put new bearings in the housing. Install the reaction

spring.
 8004-13
STEP 33 STEP 34

BC06F582

Install the piston into the housing with flat surface

out. Lubricate the O-ring and install the plug, tighten
the plug to 90 Nm (66 pound-feet).

STEP 35

BC06F581

Install the swash plate into the housing, work the

swash plate from side to side to seat it in the
bearings and spring. Install the piston rod.

BC06F583

Use grease to hold the pressure pins into position,

install the spacer, spring and snap ring.
8004-14
STEP 36 STEP 39

BC06F584

Use a suitable compressor, compress the spring and

install the snap ring.

STEP 37

BC06F585 BC06F587

Place the ball onto the pressure pins, install the Hold the pistons in the rotating housing using an
pistons into the retaining plate. O-ring, install the rotating group into the housing,
remove the O-ring.
STEP 38

BC06F586

Lubricate the piston and retaining plate with clean oil,

install the piston into the rotating housing.
 8004-15
STEP 40 STEP 41

BC06F588

Use the shim that was required for the bearing pre
load in step 30. Install the shim and bearing onto the
shaft.

BC06F589

Install a new O-ring on the end cover, place the flow

plate onto the rotating group with aligning notch up.
Place the end cover onto the housing, make sure that
the aligning pin in the end cover aligns with the slot in
the flow plate.
8004-16
STEP 42 STEP 43

BC06F591

Use new O-rings, install and tighten the control valve.

BC06F590

Instal and tighten the four bolts to 165 Nm

(121.5 pound-feet).
 Section
8005

LOADER CONTROL VALVE

8005
8005-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Circuit Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
 8005-3

SPECIFICATIONS
Special Torques
End plate mounting bolts.......................................................................... 20 to 25 Nm (177 to 221 pound-inches)
Pressure relief, flow limit, and pilot pressure reducing valves.................. 20 to 25 Nm (177 to 221 pound-inches)
Allen head plugs..................................................................................................................60 Nm (44 pound-feet)
Steering Priority Spool Cap .................................................................................................60 Nm (44 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............................................................................................................60 Nm (44 pound-feet)
Combination anticavitation and circuit relief ........................................................................90 Nm (66 pound-feet)
Cone and plug ............................................................................................................. 10 Nm (88.5 pound-inches)
Main relief valve pressure settings .........................................................................248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port ................................................................................................................290 bar (4206 psi)
Bucket A and B port ..................................................................................................................290 bar (4206 psi)
8005-4

10 7

6 5
11

12
5A

1
7

13
8
9

BC06D160

1. HOUSING 5. LOAD CHECK VALVE 7. ANTICAVITATION AND CIRCUIT RELIEF 10. O-RINGS
2. PLATE 5A. REGENERATION CHECK VALVE 8. LS (MAIN) RELIEF VALVE 11. LS BLEED ORIFICE
3. BOLT 6. REGENERATION RELIEF VALVE 9. PILOT PRESSURE REDUCING VALVE 12. STEERING RELIEF VALVE
4. WASHER 13. LS SHUTTLE CHECK VALVE
2 SPOOL VALVE HOUSING CONFIGURATION
 8005-5

21 24
14 10
22
17
15
25
17

18 26

25 24
19
23
16 20 17

27
17

28

29 18
17
19
10

23

16

14

15
BC06D161

14. CAP SCREW 18. SPRING RETAINER 22. ADJUSTING NUT 26. STEERING PRIORITY SPOOL
15. THROTTLE CHECK VALVE 19. SPRING RETAINER 23. ADJUSTING ROD 27. COMPENSATION SPOOL
16. COVER 20. SPOOL 24. PLUG 28. PLUG
17. SPRING 21. JAM NUT 25. ORIFICE 29. RING
2 SPOOL VALVE SPOOL CONFIGURATION
8005-6

5 31
10

10
30 27
17
24

31

BC06D162

2. PLATE 17. SPRING

3. BOLT 24. PLUG
4. WASHER 27. COMPENSATION SPOOL
5. LOAD CHECK VALVE 30. HOUSING
10. O-RING 31. ANTICAVITATION AND CIRCUIT RELIEF
3 SPOOL MOUNTING CONFIGURATION
 8005-7

15 21
22

16

23
10 10
18
17
18 14

20

16 18
15 17
10
10
23
21

22 14

BS03C037

10. O-RING 18. SPRING RETAINER

14. CAP SCREW 20. SPOOL
15. THROTTLE CHECK VALVE 21. JAM NUT
16. COVER 22. ADJUSTING NUT
17. SPRING 23. ADJUSTING ROD
3 SPOOL VALVE SPOOL CONFIGURATION
8005-8

LOADER CONTROL VALVE

Disassembly STEP 11
Remove the pilot pressure reducing valve (6).
STEP 1
Remove valve from machine, see section 8001. STEP 12
Remove bolts (3) and washers (4), remove plate (2)
STEP 2 from housing (1).
Remove bolts (14), covers (16), and springs (17).
STEP 13
STEP 3 2
Remove cap (24), spring (17), and plug (28).

STEP 4
Use wooden dowel or brass drift and push spools (20
2
and 26) from housing (1).
1
IMPORTANT: Do not force spools from housing, if spool
1
binds work back and forth until spool comes out freely.
NOTE: Repeat steps 2 and 4 for 3 spool valve
configuration.
BS03C026
STEP 5 1. O-RINGS 2. THRUST RINGS
Remove anticavitation valves (7 and 27). Remove and discard O-rings and thrust rings from
NOTE: Repeat step 5 for 3 spool anticavitation valves flow limit valve (11).
(31).
STEP 14
STEP 6
2
Remove cone (13).

STEP 7
Remove pressure relief valve (8 and 12).
1
STEP 8 1
Remove flow limit valve (9).

STEP 9
Remove check valves (5).
BS03C025

1. O-RINGS 2. THRUST RINGS

STEP 10
Remove flow limiting valve (11). Remove and discard O-rings and thrust rings from
pilot pressure reducing valve (9).
 8005-9

1
1

2
BS03C029

1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (8 and 12).
8005-10
STEP 15

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 (7 and 31).
 8005-11

Inspection 4. Check the parts of the pressure relief valve,

anticavitation valves, and the anticavitation and
1. Discard all O-rings, thrust rings, and spool seals. circuit relief valves. Use new parts as necessary.
2. Clean all parts in cleaning solvent. 5. Inspect the other parts of the control valve. If any
3. Check the spools and the spool bores for of the parts are damaged, install new parts.
damage and wear.

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 (7 and 31). Torque relief valve (A) into
anticavitation valve to 140 Nm (103 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.
8005-12
STEP 2

1
1

2
BS03C029

1. O-RINGS 2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (8 and 12).

STEP 3 STEP 4
2 2

1 2
1 1
1

BS03C025 BS03C026

1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RINGS

Install new O-rings and thrust rings on flow limiting Install new O-rings and thrust rings on flow limit valve
valve (9). (11).
 8005-13
STEP 5 STEP 12
Install and torque regeneration check valve (14) to Install and torque check valves (5) to 40 Nm
100 Nm (73.7 pound-feet). (29.5 pound-feet).

STEP 6 STEP 13
Install new O-rings on housing (1). Install plate (2), Install and torque cone and plug (13) to 10 Nm
bolts (3) and washers (4), onto housing (1). Torque (88.5 pound-inches).
bolts to 20 to 25 Nm (177 to 221 pound-inches).
STEP 14
STEP 7 Install and torque plug (28) to 60 Nm (44 pound-feet).
Install and torque pilot pressure reducing valve (6) to
90 Nm (66 pound-feet).
STEP 15
Lubricate spools with hydraulic oil and push spools
STEP 8
(20 and 26) into housing (1).
Install and torque anticavitation valves (7) to 90 Nm
(66 pound-feet). IMPORTANT: Do not force spools into housing.

NOTE: Repeat step for 3 spool anticavitation valves (31).

STEP 16
Install spring retainers (18), springs (17), covers (16),
STEP 9
and bolts (14). Torque bolts to 6 Nm
Install anticavitation valves (27), spring (17), and cap (53 pound-inches).
(24) and torque cap to 60 Nm (44 pound-feet).
NOTE: Repeat steps 15 and 16 for 3 spool valve
STEP 10 configuration.
Install and torque flow limit valve (9 and 11) to 20 to
25 Nm (177 to 221 pound-inches). STEP 17
Install spring (17) and cap (24) and torque cap to
STEP 11 60 Nm (44 pound-feet).
Install and torque pressure relief valves (8 and 12) to NOTE: Prior to installation in the machine, circuit reliefs
20 to 25 Nm (177 to 221 pound-inches). can be tested.

STEP 18
Install valve in machine, see section 8001.

STEP 19
Check loader limit pressure, see section 8002.
8005-14

CIRCUIT RELIEF

Pressure Test Adjustment

STEP 1 STEP 1
Connect the hand pump to the port for anticavitation Loosen the lock nut. Turn the adjustment screw
and circuit relief valves (7). clockwise to increase the pressure or
counterclockwise to decrease the pressure.
STEP 2
Make sure that the hand pump is full of hydraulic oil STEP 2
and that the temperature of the oil is approximately Check the pressure again. Repeat the adjustment as
21°C (70°F). necessary.

STEP 3
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.

STEP 4
Compare the reading to the specifications on Page 3.

STEP 5
If the pressure is not correct, adjust the circuit relief
valve.
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........................................................................................................................................380001732
8006-4

LIFT CYLINDER

Disassembly Inspection
1. Clean exterior of cylinder. If hoses were removed 1. Clean all parts in cleaning solvent. Use only lint
with cylinder, remove hoses from cylinder. free cloths for cleaning and drying.
2. Fasten tube (1) in an acceptable repair stand or 2. Check to be sure that piston rod (13) is straight. If
other holding equipment. Do not damage tube 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, 380001732, to loosen
and remove bolt (14) that fastens piston (15) to 7. Inspect gland end of tube (1) for sharp edges
piston 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
(100 to 400 pound-feet).
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

Disassembly Inspection
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 new
3. Loosen and remove the cap screws (2) and 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 11
gland (3).
7. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (4). Make 10
sure that the piston rod (4) is clean.
8. Lubricate the bore of the gland (3) and the piston
rod (4) with clean oil.
9. Push the gland (3) onto the piston rod (4). If
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (4). 4
10. Put a support below and near the end of the
GS98J804
piston rod (4). Use a shop cloth between the
support and the piston rod (4) to prevent damage PISTON AND PISTON ROD HOLE ALIGNMENT
to the piston rod (4). 17. Install the pin (11) in the piston (7) and the piston
rod (4).
18. Install the retaining ring (10) in the pin (11).
8006-10
19. Install a new wear ring (5) in the wide groove on 27. Tighten the cap screws (2) 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 be 1
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
1. Use an acceptable driver to press new bushings
(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.
3. Use an acceptable driver to press new bushings
(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
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
 8007-3

COUPLER SOLENOID VALVE

Removal
Park the machine on a level surface and lower the 8 6 7 5 4
bucket to the ground. Stop the engine and apply the
parking brake.
3
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. 13 1

2
11 3

10
W130R0062
COUPLER SOLENOID VALVE PARTS ILLUSTRATION

1. VALVE SOLENOID 8. NUT M6

2. BRACKET COUPLER 9. ELECTRICAL CONNECTOR
SOLENOID
3. CONNECTOR 10. HOSE COUPLER PRESS.
4. WASHER 11X24X2 MM 11. ELBOW 10 MM ORFSXM14
BD01F143-01
5. NUT 12. HOSE Z-BAR COUPLER
Put the articulation lock in the LOCKED position. 6. WASHER 6.6X18X1.6 MM 13. HOSE COUPLER TANK
7. BOLT M6X50

Tag and disconnect the hoses (10-12-13) from the

coupler solenoid valve. Install a plug in each hose
12 and cap all fittings.
Loosen and remove the nuts, washers and bolts
(6-7-8) from bracket (2).
Remove the coupler solenoid valve from the
machine.
9 Remove and discard all O-rings from the fittings.

W110R582
Installation
Disconnect the electrical connector (7) from the Place the coupler solenoid valve into position on the
coupler solenoid valve. machine.
Lubricate and install new O-rings in the fittings.
Install the bolts, washers and nuts. Tighten the nuts.
Connect the hoses to the coupler solenoid valve,
remove and discard tags. Reconnect the electrical
connector.
Check the level of the hydraulic oil in the reservoir.
Start the engine and run the engine at low idle for two
minutes.
Stop the engine and check for hydraulic oil leakage
at the coupler solenoid valve.
Check the level of the hydraulic oil in the reservoir
and add as required.
8007-4

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
these conditions are seen.
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).
 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
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
 8013-3

SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 7
Ride Control Accumulator Fluid Capacity............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure...........................................................248.4 bar (3600 psi)

ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap.................................................................................13.6 Nm (10 pound-feet)
Gas Charging Valve ............................................................................................88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)

SPECIAL TOOLS

94L95 B786441M
380001737 NITROGEN ACCUMULATOR CHARGING KIT 380001738 GLAND WRENCH
8013-4

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

C E

D B A
94L95
380001737 NITROGEN CHARGING KIT

1. Use the 380001737 Nitrogen Charging Kit to 7. Turn the T-handle inward on valve F to engage
discharge the accumulator, refer to the the pin in the valve stem.
illustration above. The tool must be disconnected
8. Open valve D and check the charge pressure on
from the nitrogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open
3. Adjust the regulator A to the minimum pressure valve B. The accumulator charge will bleed down
setting by turning the knob counterclockwise. through the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
5. Remove the guard and valve assembly cap from
the accumulator. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the
accumulator.
 8013-5

4 2 1 4 3

W230R026

1. CYLINDER 3. GAS VALVE 5. FLUID CONNECTION

2. PISTON 4. END CAP
RIDE CONTROL ACCUMULATOR
8013-6

CHARGING THE ACCUMULATOR WITH NITROGEN

6 5
4 3

GS98N801

1. VALVE C 4. VALVE B
2. TO NITROGEN TANK 5. VALVE D
3. VALVE A 6. TO ACCUMULATOR
NITROGEN CHARGING KIT 380001737

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A

WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406

WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407

IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.

IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.
 8013-7
1. Close the shutoff valve A by turning it all the way 11. Open the shutoff valve A on the nitrogen supply
to the left (counterclockwise), refer to the tank. While observing the pressure on the gauge,
illustration on page 6. slightly open the needle valve on the
accumulator charge hose. By regulating the
2. Open valve B by turning it out all the way to the
needle valve, fill the accumulator to pressure
left (counterclockwise).
according to temperature chart below. Close the
3. Close valve C by turning it all the way to the right needle valve. Close the shutoff valve A on the
(clockwise). nitrogen supply tank.
4. Close the gauge valve D by turning it all the way TEMPERATURE CHARGE PRESSURE
to the right (clockwise). 10° C 50° F 1636 KPA 237 PSI
13° C 55° F 1655 KPA 240 PSI
5. Connect the charging hose to the nitrogen supply
16° C 60° F 1674 KPA 243 PSI
tank.
18° C 65° F 1687 KPA 245 PSI
6. SLOWLY turn valve A clockwise while watching 21° C 70° F 1706 KPA 248 PSI
the high pressure gauge. Stop turning valve A 24° C 75° F 1726 KPA 250 PSI
when the needle on the gauge reaches 31 bar 27° C 80° F 1745 KPA 253 PSI
(450 psi). 29° C 85° F 1758 KPA 255 PSI
32° C 90° F 1777 KPA 258 PSI
NOTE: If the needle goes over the needed pressure,
35° C 95° F 1796 KPA 261 PSI
quickly open and close valve D and check the pressure
38° C 100° F 1815 KPA 263 PSI
setting again.
The charging kit is now ready to be installed on the TEMPERATURE/CHARGE PRESSURE RIDE CONTROL
accumulator. ACCUMULATOR
12. Close valve B by turning to the right (clockwise).
7. Remove the valve cap from the pressure valve
After a few minutes, check the accumulator for
on the accumulator.
leakage.
8. Back off the needle valve on the accumulator
13. Back off the needle valve on the accumulator
end of the charging hose by turning it
end of the charging hose by turning it
counterclockwise to the maximum amount. This
counterclockwise the maximum amount. This will
prevents nitrogen from escaping from the
p r e v e n t n i t r o g e n f r o m e s c a p i n g fr o m th e
accumulator when the charging hose is attached
accumulator as the hose is removed. Remove
to the accumulator gas charging valve.
the charging hose from the accumulator
9. Install the charging hose fitting onto the pressure valve.
accumulator pressure valve.
14. Install the valve cap onto the pressure valve on
10. Tighten the needle valve by turning it clockwise. the accumulator.
Slowly open the gauge valve D and observe the
15. Remove the charging hose from the nitrogen
reading on the gauge. This reading is the
supply tank.
nitrogen pressure level inside the accumulator.
8013-8
NOTES
 Section
8014

8014
RIDE CONTROL VALVE
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

Section Title Section Number

Air Conditioning Troubleshooting and System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9002

Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Roll Over Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010
Rear View Camera Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020
 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 form a
Liquid refrigerant getting into the eyes can cause
combustible gas.
serious injury. 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 380001325 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, 380001326

A22090
ELECTRONIC LEAK DETECTOR 380001327
 9002-5

OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
contains five major components: compressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. evaporator meters refrigerant flow based on
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and 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
condenser then removes the heat from the cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
the condenser to the receiver-drier. The consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A.C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.

3
5
4

208L95

1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER
9002-6

TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?

Problem: No Cooling
Mechanical - See Mechanical Compressor
No Check Page 8
Compressor Runs
Electrical - See Blower and Compressor
Clutch Check Page 9

Yes

Internal System Problem

See Pressure Testing, Page 13
 9002-7

Problem: Problem:
Not Enough Cooling Erratic Cooling

MECHANICAL

See Mechanical Compressor Check Page 8.

HEATER
Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.

INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.
Problem:
System Makes Noise

ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL

See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.
REFRIGERANT

See Cab Temperature Check Page 10.

ELECTRICAL

See Compressor Clutch Check Page 9.

INTERNAL SYSTEM PROBLEM

See Pressure Testing, Page 13. INTERNAL SYSTEM PROBLEM

See Pressure Testing, Page 13.

9002-8

SYSTEM CHECKS

Mechanical Compressor Check

1. Too much belt wear - replace a worn belt,
Compressor and Fan Belts because a worn belt will cause too much
slippage.

1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
Compressor Mounting Brackets 2. Bracket has cracks or breaks - replace the
bracket.

1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Remove the compressor for
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
Compressor Clutch between the front plate and pulley
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor
rotation should be smooth and not require
much effort.

1. The compressor pulley and the

compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Pulley and Belt Alignment Use a straight edge to check pulley
alignment. Adjust the compressor
mounting bracket if needed.
 9002-9

Blower and Compressor Clutch Check

NOTE: Check supply voltage with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch
1. If there is electrical system voltage to the
clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.

1. See Section 4002 and check the high and

Low and High Pressure Switches low pressure switches.

Blower Fuse (10 amp) 1. Check for damaged blower fuse.

1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.

1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor 2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.

1. With key in ON position, turn switch to

maximum cold. Compressor clutch must
engage.
NOTE: Blower must be operating, since
electrical power to temperature control switch
is received from blower switch.
Temperature Control Switch 2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
switch terminals. If continuity is not
present when switch is on maximum cold,
replace switch.
9002-10

Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers louvers must be closed.
2. Check blower; blower must be running.

ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning 1. Feel the air conditioning hoses. The high pressure hoses
(small line) must be warmer than the low pressure hose
(large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.

1. Put a thermometer in the air duct behind the seat and

run the compressor for five minutes to make
temperature stable. Refer to page 12.
2. Duct temperature must be below 25° C (72° F) if the
system is operating at maximum efficiency.
Duct Temperature NOTE: Ambient temperature must be 27 to 43° C (80 to
110° F).
3. If temperature is above 25° C (72° F), system is low on
refrigerant, there is a restriction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.

1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
Temperature Sensing Probe Check 4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control switch
should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.
 9002-11

Visual and Leak Check

1. Make sure that all hose connections are
tight.
Compressor Hoses 2. Check hoses for bends or cracks. Replace
all hoses that have damage.

1. Shut off the engine.

WARNING: When refrigerant comes in
contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector 380001327 to
inspect all connections. Use instructions
from manufacturer of leak finding tool.
Leak Finding Check
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion valve
for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.

1. Make sure the condenser is clean and the

seals are in place. Make sure condenser
Condenser fans run when temperature control switch
is ON.
9002-12

Evaporator/Heater Core Check

Make sure heater valve is closed

Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fins that have bends or
damage must be made straight.
3. Inspect the evaporator/heater core for
restrictions. If the core is dry, use
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
water drains freely from the
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.

1. See Section 9004 for access to the

evaporator/heater core.
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
evaporator/heater core.

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
Connect the manifold gauge set into the air
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
evacuation effectiveness. A vacuum reading
indicates a system malfunction. For this reason, it is
necessary to use a compound gauge that will
indicate both pressure and vacuum.
9002-14

PRESSURE-TEMPERATURE CHART

AMBIENT NORMAL LOW AIR LOUVER (BEHIND

NORMAL HIGH
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.

°F (°C) psi (bar) psi (bar) °F (°C)

80 (27) 9 to 12 145 to 165 55 (14)

(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)

The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction
pressure. The table shown represents readings taken 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
WA RNING: Do not steam clean any air when working with liquid refrigerant. Liquid
conditioning system parts while the system is refrigerant in your eyes could cause
charged. The heat will cause the refrigerant blindness. SM105A
to rise to a pressure that could cause the
system to explode. SM104A
STEP 5
Make sure the charging station manifold gauge
STEP 2 valves are in the closed position.
Connect the hoses from the test gauges to the
service ports by turning the knurled knobs on the STEP 6
depressors. Start the engine and run at 1500 RPM maximum
speed. Operate the air conditioner system at
STEP 3 maximum cooling setting and blower speed for 15
Connect the hose from the low pressure gauge to the minutes with the cab door open. Observe the test
port on the suction hose. gauges and check the chart on page 13 against the
gauge readings.
9002-16

PROBLEM: NO COOLING

VERY LOW VERY LOW

476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.

2. Evacuate and reclaim remaining

refrigerant from system. See Section
9003.

3. Repair system leaks as needed. Follow

the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off 4. Check level of oil in compressor - possible
Yes
rapidly after start-up. (A/C warning light for compressor to have an oil loss.
in cab should illuminate).
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.

6. Charge system with new refrigerant. See

Section 9003.

7. Continue performance test for other

possible problems.
 9002-17

HIGH HIGH

476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

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
system. See Section 9003.
4. Charge system with new refrigerant. See
Section 9003.

Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.

2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
reclaim and recharge refrigerant until gauge
pressure is normal. See Section 9003.

4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
caused by oil or reduced heat transfer.
condenser) is very hot.
A. Remove refrigerant from the system. See
B. Discharge air from evaporator warm.
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.

5. Continue the performance test for other possible

problems.
9002-18

Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at See Section 9004 and replace the expansion
compressor. valve.
C. Much condensation on evaporator
outlet.

Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
Refrigerant Contamination
table represent the boiling point for HFC-134a.
C. Pressure readings below range given in chart indicate
contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.

HFC-134a Stable Saturation Pressure/ Temperature Chart

Temperature qF (q C) Pressure PSIG (Bar)

50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)
 9002-19

PROBLEM: NOT ENOUGH COOLING

NORMAL TO
SLIGHTLY HIGH NORMAL

476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

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.
7. Charge system with new refrigerant. See
Section 9003.
9002-20

LOW LO W

476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

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
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

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
system. See Section 9003.
4. Charge system with new refrigerant. See
Section 9003.
9002-24

PROBLEM: INTERMITTENT COOLING

NORMAL NORMAL

476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

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
system. See Section 9003.
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

4. Charge system with new refrigerant. See

Section 9003.
 9002-25

PROBLEM: NOISE IN SYSTEM

NORMAL
HIGH
TO HIGH

476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

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
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
STATION 380001326
9003-4

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
conditioning systems. Refrigerant HFC-134a does
the air conditioner system before reclaiming
not contain 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 form a
Liquid refrigerant getting into the eyes can cause
combustible gas.
serious injury. 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.
 9003-5

AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refrigerant passes through an oil STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.

STEP 1

A22114

Open the high and low valves.

STEP 4

BD03A213

Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.

STEP 2

A22107

Make certain the refrigerant tank gas and liquid

valves are open.

BD03B001

With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the port on the discharge hose. Turn in valve
depressor.
9003-6
STEP 5 STEP 7

A22112 A22110

Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.

STEP 6

A22111

Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.

STEP 9

A22108

Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.

BD03A213

Remove the hoses from the service ports and install

the caps.
 9003-7

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or Air and moisture are removed from the system by a
more of the following conditions occurs before you vacuum pump. A vacuum pump is the only
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 start. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
leak-free system will leach refrigerant from
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114

Fully open the low and high pressure valves.

STEP 17
STEP 15

A22113

Press the charge key to begin refrigerant charging.

A22107
“Automatic” and “Charge” will appear on the display.
Open the red (vapor) and blue (liquid) valves on the The display shows the programmed amount and
tank. counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.
 9003-9
STEP 18 STEP 21

A22114 BD03B001

Completely close the high and low pressure manifold Stop the engine, close any open valves and carefully
valves. remove the manifold gauge hoses.
ATTENTION: Check the 380001326 equipment manual
before performing Step 19 to avoid damaging the recovery STEP 22
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
indicator lamp will illuminate when the relay is BD03B213

actuated by a low or high pressure and the Install the caps on the service ports on the suction
compressor clutch will disengage. To restart the and discharge hoses.
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
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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

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 form a
Liquid refrigerant getting into the eyes can cause
combustible gas.
serious injury. 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.
9004-4

SPECIAL TOOLS

A22094
REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION 380001326
 9004-5

COMPRESSOR

Removal STEP 4

STEP 1
Place the master disconnect switch in the OFF
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
port on the compressor. Immediately install
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
Park the machine on a level surface and lower the
bucket to the floor.

STEP 18
If changing any air conditioning components,
discharge the air conditioning system according to
the instructions in Section 9003.

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 t h e i n s i d e f i l t er a re a f e e l t he

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. Disconnect the electrical connector for the

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 Remove the switch panel from the console.
Disconnect the electrical connectors and remove
Remove the fans from the lower PPE, disconnect the
switches as required.
electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.
9004-14

Installation STEP 53

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
Replace switches and connect the electrical 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

1. TRANSMISSION FILTER
control.
2. AIR CONDITIONING HOSES
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
Fill engine coolant system with a solution of 50%
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
Park the machine on a level surface and lower the
bucket to the ground.

STEP 81
Place the master disconnect switch in the OFF
position.

STEP 82
Discharge the air conditioning system according to
the instructions in Section 9003.
BS03A107

STEP 83 Fasten identification tags on the hoses and

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 88 Installation
STEP 91
Put the condenser in position on the bracket.

STEP 92

BD06G211

Fasten identification tags on the hoses and

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
Place the master disconnect switch in the ON
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 compartment,
always support or lower the equipment
(backhoe, blade, boom, bucket, etc.) to the
ground and stop the engine.
CSM105

5. Position the return to travel target (5) opposite

the proximity switch (3) and tighten it to the target
mounting plate (1).
9006-6

2
A

B
1

BS01C082

1. HEIGHT CONTROL TARGET 2. RETURN TO TRAVEL TARGET 3. TARGET MOUNTING PLATE

APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT

621F Z-Bar 54 mm (2.1 inches) 380 mm (15.0 inches) 48 mm (1.9 inches) 3302 mm (130 inches)

621F XT 51 mm (2.0 inches) 403 mm (15.9 inches) 43 mm (1.7 inches) 3302 mm (130.0 inches)

621F XR 78 mm (3.07 inches) 459 mm (18.07 inches) 54 mm (2.1 inches) 3302 mm (130.0 inches)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

8. Refer to the table and the illustration on this 13. Place the detent switch in the ON position, and
page. Position the height control target (1) on the set the return to travel/float detent switch to the
target mounting plate (3) using the table above. return to travel position.
NOTE: The higher the height control target (1) is 14. Place the loader control lever in the raise position
positioned in its slot in the target mounting plate (3), and verify that the electromagnet holds it in that
the lower the lift arms will stop as they are raised. position until the height control target (2) passes
in front of the proximity switch (3). Refer to the
9. Tighten the height control target (1).
illustration on page 5.
10. Position the return to travel target (2) using the
15. With the lift arms still raised, place the loader
table above.
control lever in the lower position and verify that
NOTE: The higher the return to travel target (2) is the electromagnet holds it in that position until
positioned in its slot in the target mounting plate (3), the return to travel target (5) passes in front of
the lower the lift arms will stop as they are lowered. the proximity switch (3). Refer to the illustration
on page 5.
11. Check to make sure the proximity switch (3) and
all of the mounting bolts are tight. Refer to the 16. Repeat steps 8 through 15 until the desired
illustration on page 5. heights are reached.
12. Start the engine. 17. Lower the bucket to the ground and stop the
engine.
 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
bucket cylinder (8) in place. 20. Disconnect the electrical connector (1), remove
the lock nut from the proximity switch (2) and
14. If the machine is equipped with auxiliary remove the proximity switch (2) from 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
loader frame (2). Install caps on the hoses and 21. Repeat Steps 17 and 18 for the other pivot pin (9
plugs in the tube fittings. or 10).

15. If the machine is equipped with front lamps, 22. Raise the loader frame (2) out of the front frame.
loosen and remove the cap screws and lock Carefully move the machine out of the loader
washers that fasten the lamp brackets to the front frame (2).
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
19 17 15
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
25. Start the engine and run the engine at low idle.
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 y o u r f i n g e r s t o
lamps to the front frame. Tighten the cap screws. check the alignment of the cylinder rod.
11. If the machine is equipped with auxiliary Personal injury can be the result.
48-88
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses. Connect the 27. Remove the driver and install the pivot pin (3).
hoses to the tubes.
28. Install the bolt (12), washer (13), and spacer(14)
12. Connect the chain hoist to the bucket cylinder (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 y o u r f i n g e r s t o 32. Tighten the filler plug in the reservoir.
check the alignment of the cylinder rod.
33. If the machine is equipped with auxiliary
Personal injury can be the result.
48-88
hydraulics, start the engine and run the engine at
low idle.
15. Install the pivot pin (7) in the bell crank (11) and
34. Slowly extend and retract the clam cylinders four
the piston rod eye of the bucket cylinder (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
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
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

ROLLOVER PROTECTIVE STRUCTURE (ROPS)

CAB STRUCTURAL FRAME (CSF)
After an accident, fire or rollover, the following MUST
be performed before returning the machine to field or
Attention
job site operation:
● The ROPS or CSF structure MUST be replaced.
The Rollover Protective Structure (ROPS) or Cab ● The ROPS or CSF mounting or suspension,
Structural Frame (CSF) is a special safety operator seat and suspension, seat belts and
component of your machine. mounting components and wiring within the
DO NOT attach any device to the ROPS or CSF for operator’s protective system MUST be carefully
pulling purposes. inspected for damage.
● All damaged parts MUST be replaced.
The ROPS or CSF is a certified structural support
and any damage, fire, corrosion or modification will DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
weaken the structure and reduce your protection. If REPAIR THE ROPS OR CAB STRUCTURAL
this occurs, the ROPS or CSF MUST be replaced so FRAME.
that it will provide the same protection as a new
ROPS or CSF.

MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following: WARNING: Do not install attachments that will
make the total weight of the machine more than
1. Check the torque on the CSF cab or ROPS the weight shown in the maximum gross vehicle
canopy mounting bolts; torque should be 773 to weight section of the ROPS serial number plate.
854 Nm (570 to 630 lb-ft). If necessary, tighten 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 not
torque on operators seat mounting bolts; torque authorized, such as welding, drilling or cutting will
should be 73 to 87 Nm (54 to 64 lb-ft). If make the ROPS weaker and decrease your
necessary, tighten the bolts to the correct torque. protection. Replace the ROPS if it becomes
Replace parts that are worn or damaged. damaged in any way. DO NOT TRY TO MAKE
REPAIRS TO THE ROPS. 47-25
WARNING: Grade 8 hardware is used to 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
Park machine on a level surface and lower bucket to
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 control valve. Plug hoses and cap steering control
windshield washer nozzle hoses from supply hoses. valve fittings to prevent entry of foreign matter into
hydraulic system.
STEP 9
STEP 12
2 3

BD06G205
1. TRANSMISSION FILTER
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.

W110R585

Disconnect throttle connector and the air duct.

9007-6
STEP 14 STEP 19

BD06F209
W110R586
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

STEP 16 gain 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
hydraulic reservoir, turn on the pump.

STEP 17
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.

STEP 18
Push the hoses out of the bottom of the cab with the
rubber gromment.

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

Installation STEP 32

STEP 26
Check rubber mounts (3 an 4) for deterioration, tears,
deformation, or other damage; replace rubber
mounts as necessary.

STEP 27

BD06G188

Position floor mat.

STEP 33

BD01D388

Position cab over rear chassis then put wood blocks

under brake valve. Slowly lower cab onto rear
chassis making sure that brake valve is positioned so
that brake pedal enters into cab. Remove wood
blocks as cab is lowered onto brake valve.

STEP 28
Install washers, bolts, and nuts to secure cab to rear BD06G192
chassis. Tighten bolts to a torque of 773 to 854 Nm
Remove plugs from hoses and caps from fittings.
(570 to 630 pound feet)
Connect hoses to steering control valve following
tags installed during removal. Remove and discard
STEP 29 tags.
Disconnect lifting equipment from cab.
STEP 34
STEP 30
Remove lifting eyes.

STEP 31

W110R585

Connect throttle connector and mount air duct.

BD06G185

Align mounting holes in brake valve with associated

holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
9007-10
STEP 35 STEP 37

BD06G186 BD06G194

Install the ducts on the machine. If machine is equipped with windshield washers,
connect front and rear windshield washer nozzle
STEP 36 hoses following tags installed during removal.
Remove and discard tags.

STEP 38

2 3

1
BD06G189

At RH rear, bottom of cab, connect ground strap to

rear chassis.
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES

If machine is equipped with a heater, remove plugs

from hoses and caps from fittings, connect heater
hoses (3), if machine is equipped with air
conditioning, remove plugs from hoses and caps
from fittings, connect air conditioning hoses (2),
charge the air conditioning system, see section 9003.

STEP 39
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
shown on pages 11, 12, and 13.
 9007-11

1 2 3 4

10 5
9 7 6
8

1 9
2 8
10 7
3 6
4 5

BS07D284

1. ORANGE BLACK 5. ORANGE WHITE 8. GREEN BLACK

2. YELLOW BLACK 6. YELLOW WHITE 9. RED BLACK
3. RED WHITE 7. PILOT PRESSURE HOSE 10. PILOT TANK HOSEL
4. GREEN WHITE
JOYSTICK AND 2 LEVER HOSE COLOR CODING
9007-12

2
2
3
8
6

3
7 5
4
7

6 1

8
5

5 3
5 3
7
7 6
6 2
2 4
4 1
1 8
8

BS07D283

1. YELLOW WHITE 1. YELLOW WHITE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK 3. RED BLACK
4. PILOT TANK HOSE 4. PILOT TANK HOSE
5. ORANGE BLACK 5. ORANGE BLACK
6. YELLOW BLACK 6. YELLOW BLACK
7. GREEN BLACK 7. GREEN BLACK
8. RED WHITE 8. RED WHITE
JOYSTICK AND 1 LEVER HOSE COLOR CODING 3 LEVER HOSE COLOR CODING
 9007-13

6 2

5 3

4
4 2
5 6

3 1

BS07D285

1. PILOT PRESSURE HOSE

2. RED BLACK
3. PILOT TANK HOSE
4. ORANGE BLACK
5. YELLOW BLACK
6. GREEN BLACK
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

W110R586
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, turn to
first notch, then wait until all pressure is released. Scalding
can result from fast removal of radiator cap.

STEP 50
BD01F184
Put articulation lock in OPERATING position.
If machine is equipped with a heater and coolant was
drained, check that coolant drain cap is tight.

STEP 47
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. 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 primed surface
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the
front glass apply extra adhesive in corners, refer to
Figure 3.

SILICONE SEALANT APPLICATION - FRONT WINDOWS

1. Clean the edges of the front center and front side 6. Fill the joint with the clear silicone sealant
windows. Use glass cleaning primer. (114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
2. Apply masking tape to the inside edge of each
glass sections. The sealant must extend at least
glass section next to the gap.
1.5 mm (1/16 inch) above the outside surface of
3. Apply the polyester tape on top of the masking the glass section for the length of the gap. Be
tape across the inside side gap. Do not push the sure the sealant fills against the adhesive at 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 forming tool
template.
9010-4
9. Remove all the silicone from the forming tool
1 2 immediately after use.
10. Remove the outside tape from the glass
sections.
11. Remove the extra silicone sealant from the inside
joint by carefully sliding the forming tool down the
length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.
3 13. Remove the inside joint masking tape.

4 14. If two or more glass sections are being replaced,

498L93
use the procedure on the second joint.
1. FRONT RH SIDE GLASS 3. SILICONE BEFORE 15. Apply the gray silicone sealant above the front
SMOOTHING center, front side or rear windows for additional
2. FRONT CENTER GLASS 4. SILICONE AFTER leak protection.
SMOOTHING
FIGURE 1. SILICONE APPLICATION 16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
NOTE: Make the forming tool from 10 mm (3/8 inch)
each front side window replaced, refer to Figure
plexiglass, or wood. Sand all radius and edges
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 completing the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
9010-6
NOTES
 Section
9020

REAR VIEW CAMERA INSTALLATION AND REMOVAL

9020
9020-2

TABLE OF CONTENTS
Rear view camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation - Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation - Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
 9020-3

REAR VIEW CAMERA

Installation - Camera STEP 5

STEP 1

CAMERA TO EXTENSION CABLE

Route the camera cable down through the grill

SAFETY LOCK
screen hole and connect to the extension cable.
Park machine on a level surface and lower bucket to
ground. Put articulation lock in LOCKED position.
STEP 6
STEP 2

EXTENSION CABLE ROUTING 1

Route the extension cable on the left side of the hood

RAISE HOOD
and tie wrap to the existing harness.
Raise the engine hood and turn the master switch to
the off position.
STEP 7
STEP 3
Drill the camera bracket mounting holes in the screen
per Camera mounting - Illustration 1. (3 holes, 6.6
mm in screen if necessary)

STEP 4
Assemble and mount the camera brackets as shown
in Camera mounting - Ilustration 1. Route the camera
harness through the screen.

EXTENSION CABLE ROUTING 2

Route cable down left side and under fan to the right
side of the Wheel Loader. Pull cable and tie wrap
through firewall to the bottom of the fuse box.
9020-4
STEP 8 STEP 11

EXTENSION CABLE TO FUSE BOX CAMERA TO MONITOR CONNECTORS

Pull cable up through existing hole into the fuse box. In the fuse box connect the extension cable from the
camera to the CA1 cable from the monitor. Tie wrap
STEP 9 to secure cable.

STEP 12

MONITOR MOUNTING

Attach the mounting bar to Cab right post per Monitor

mounting - Illustration 2. Install the display arm and POWER TO SYSTEM

monitor as shown and tighten all nuts. Connect the remaining monitor connector to the
“MON” connector in the fuse box. Tie wrap to secure
cable.
STEP 10 STEP 13
Install the 5A fuse to F19 in the ECA fuse panel.
Always install the correct fuse size.

For additional information see the camera manual

included with the camera kit.

JUNCTION BOX UNDER SEAT

Install the access plate and route the cable with the
engine harness. The monitor cable will run through
the grommet on the access plate and up to the
monitor per Plate access mounting - Illustration 3.
 9020-5

Installation - Monitor
Camera mounting - Illustration 1

84336466(1)

Monitor mounting - Illustration 2

84336466(2)
9020-6
Plate access mounting - Illustration 3

84336466(3)

Parts List - Illustration 4

84336466(4)
 9020-7

Removal STEP 4

STEP 1

CAMERA ON GRILL BOTTOMVIEW

Remove the mounting bolts holding the bracket to

SAFETY LOCK
the grill screen, and remove the camera.
Park machine on a level surface and lower bucket to
ground. Put articulation lock in LOCKED position.

STEP 2 STEP 5

RAISE HOOD MONITOR MOUNTING BACKSIDE

Raise the engine hood and turn the master switch to Unplug the monitor cable and loosen the handle on
the off position. display arm. Remove monitor.

STEP 3

CAMERA TO EXTENSION CABLE

Disconnect camera from the extension cable.

9020-8
NOTES
 ECA ECB ECC ECD
PIN NAME LOCATION PIN NAME LOCATION PIN NAME LOCATION PIN NAME LOCATION
CONNECTOR LIST CONNECTOR LIST CONNECTOR LIST CONNECTOR LIST
INDEX OF FUNCTIONS A1
A2
A1
A2
8,1G
13,1D
B1
B3
30_K1
30_K2
4,3D
4,4E
B1
B3
30_K1
30_K2
11,7G
11,6G
B1
B3
30_K1
30_K2
11,4G
11,4F
NAME DESCRIPTION CNH SHT, ZONE NAME DESCRIPTION CNH SHT, ZONE NAME DESCRIPTION CNH SHT, ZONE NAME DESCRIPTION CNH SHT, ZONE
A3 A3 9,7F B5 30_K3 4,4D B7 30_K4 10,7E B5 30_K3 10,2F
DIAGRAM SYMBOL DESCRIPTIONS A4 A4 11,10H B7 30_K4 10,11D B9 30_K5 4,5C B7 30_K4 10,8G PART NUMBER PART NUMBER PART NUMBER PART NUMBER
FUNCTION SHT A5 A5 10,1H B9 30_K5 9,3F B2 85_K1 11,7F B9 30_K5 12,8G 115 GRID_HTR_PWR 8602660 4,12C DM DIODE OR 245485C1 11,8G GND_S1 GROUND_A 1964718C1 10,6C PHF HYD_OIL_FILT_RES_SW 1964703C1 9,9E
AIR SEAT 12 A6 A6 9,3G B2 85_K1 4,3D B4 85_K2 11,6F B2 85_K1 11,4F 193 STARTER_RELAY 386010A1 4,12D DNOX2 (ONLY TIER4) NOX CONTROLLER 87713291 5,9E GND_S2 GROUND_A 1964718C1 10,5C PHF9 HYD_FLTR_RES_SW 371614A1 9,8E
SPLICE SYMBOL A7 A7 10,11F B4 85_K2 4,4E B8 85_K4 10,7E B4 85_K2 11,4E 194 STARTER_SIGNAL 1964720C1 4,10F DS DOOR SWITCH 245482C1 7,10G GND_SSCHAS SSM_GROUND_CABLE AMER_CABLE_20102 11,12C PO1 POWER_OUTLET 12176446 12,2G
CAN COMMUNICATION 12 SPLICE NAME A8 A8 6,11F B6 85_K3 4,4C B10 85_K5 4,6B B6 85_K3 10,2F 195 STR_REL_PWR 1964721C1 4,12D DTLTS (ONLY TIER4) DEF_TANK_LEVEL_TEMP_SENSOR84062580 5,5C GND_SSMOD SEC STR CHASIS GND 1964712C1 11,10B PO2 POWER_OUTLET 12176446 12,2G
A9 A9 4,7H B8 85_K4 10,11C D1 86_K1 11,7G B8 85_K4 10,8G
COLD START 4 WIRE NAME A10 A10 5,11G B10 85_K5 9,3E D3 86_K2 11,6G B10 85_K5 12,9F 108F DIAGNOSTIC_CONNECTOR 291663A1 8,3E DTS DOWNSTREAM TEMP SENS 87709793 5,8C GND_TRANS GROUND_TRANS 1964718C1 9,9C PRB1 RED_BRAKE_SW 245483C1 9,9D
C1 C1 12,10G D1 86_K1 4,3D D7 86_K4 10,7E D1 86_K1 11,4G 140M DIODE_MODULE 245488C1 11,3D D_OR DIODE OR 245485C1 7,4H GND_WIF GRND WIF RING TERM 1964706C1 9,5B PRB2 RED_BRAKE_SW 245483C1 9,9C
ENGINE CONTROL 5 WIRE COLOR C2 C2 11,4G D3 86_K2 4,4E D9 86_K5 4,6C D3 86_K2 11,4F 197F MAIN_CAB_FNR 225350C1 8,4F ECA_L1 B+ POWER RING_TERM_6MM 4,3G HD HOOD_SWITCH 245485C1 11,7D PRBF ROLLBACK_PRES_SW 245483C1 10,8C
WIRE SIZE (mm^2) C3 C3 11,2F D5 86_K3 4,4D C2 87A_K1 11,7F D5 86_K3 10,2F 197M FNR-MAIN_CAB 225351C1 8,4F EDC7 ENGINE CONTROLLER 87632418 4,9C, 5,9F HDM HOOD_LIFT_MOTOR 225316C1 11,6D PRH AC HIGH PRESS SW 245482C1 12,11G
HOOD LIFT 11 C4 C4 6,1H D7 86_K4 10,11D C4 87A_K2 11,6F D7 86_K4 10,8G
MALE CONEECTOR C5 C5 12,2E D9 86_K5 9,3F C8 87A_K4 10,7E D9 86_K5 12,9G
202M ROLLBACK_JUMPER 245482C1 10,8C EM RTD_HEIGHT_CONT_RTT 225351C1 10,4E HD_9 HOOD TO ENG 225319C1 6,5C PRL AC LOW PRESS SW 245482C1 12,11F
HVAC 12 FEMALE CONNECTOR C6 C6 12,6H C2 87A_K1 4,3D C10 87A_K5 4,5B C2 87A_K1 11,4F 209F BACK-UP_ALRM_DISA_JMP 245481C1 6,1D ENG2 ENG BULKHD 2 87703998 4,7F, 5,11F, 6,7C, 11,8F HD_E HOOD-TRANS 245484C1 6,4C PRMB_L1 B+ POWER RING_TERM_6MM 4,4G
C7 C7 11,11G C4 87A_K2 4,4E D2 87_K1 11,7F C4 87A_K2 11,4E 209M BACK-UP_ALRM_DISA_JMP 245480C1 6,1D ENG_B CAB BTTOM 225411C1 5,9E, 9,1C, 12,12F HD_N HOOD TO ENG 225319C1 6,5B PRMB_L2 B+ POWER 1964710C1 4,3G
IGNITION SWITCH 4 C8 C8 12,4H C6 87A_K3 4,4C D4 87_K2 11,6F C6 87A_K3 10,2F 20M TRANS_KICK-DOWN 225316C1 8,5F ENG_D DISC_HARNESS 245483C1 4,9E HN1 HORN_PWR 282459A1 10,7D PRM_A PWR RLY MOD A PRM_A
SPL_G1 C9 C9 7,12C C8 87A_K4 10,11C D8 87_K4 10,7E C8 87A_K4 10,8G
INSTRUMENT CLUSTER 9 21C_C W-1.0
0_GA Bk-2.0
A A
B B L1 L1_1 8,2G C10 87A_K5 9,3E D10 87_K5 4,5B C10 87A_K5 12,8F
215F ALTERNATOR_RESISTOR 199436A1 4,6E ENG_H ENGINE TO HOOD 225320C1 6,5C HN2 HORN_GRND 282459A1 10,7D PRM_A1 PRM OUTPUT 409084A1 4,5G
L1 L1_2 13,1D D2 87_K1 4,3D A1 A1 7,10E 216F ALTERNATOR_RESISTOR 199436A1 4,6E ESS ENG_SPEED_SENS 291718A1 8,11D HOT HYD_OIL_TEMP_SEND 194788A1 9,7D PRM_A2 PRM SIGNAL 256340A1 4,5G
93M 93F D2 87_K1 11,4F
HOOD LIFT 11 CONNECTOR REFERENCE DESIGNATOR L1 L1_3 9,7F D4 87_K2 4,4E A2 A2 7,7E D4 87_K2 11,4E 21M TRANS_KICK-DOWN 225316C1 13,11E EVGT_3 EVGT_FUSE 225155C1 5,4E HTS HMDTY AND AMB TEMP 87709809 5,6G PRM_B1 PRM SIGNAL 256340A1 4,3G
L1 L1_4 11,11H D6 87_K3 4,4C A3 A3 6,11F HVAC1 HVAC1 239451A1 12,10F
LIGHTING 1 (combos...) 6 L1 L1_5 10,2H D8 87_K4 10,11C A4 A4 6,9H
D6
D8
87_K3
87_K4
10,2F
10,8G
242F CHAS_GRD-SEC_STRG_MTR AMER_CABLE_20157 11,12D EVGT_4 EVGT 225306C1 5,5D PRM_C1 PRM SIGNAL 256340A1 4,2G
244F STARTER-SEC_STRG_MTR AMER_CABLE_20102 11,11E E_HD TRANS-HOOD 245485C1 6,4C HVAC2 HVAC2 87552622 12,11F PRM_D PWR RLY MOD D PRM_D
L1 L1_6 9,3G D10 87_K5 9,3E A5 A5 4,1F
LIGHTING 2 (work lights) 7 L1 L1_7 10,12F A1 A1 12,3G A6 A6 10,6H
D10 87_K5 12,8F 245F SEC_STR_FLYBACK 1964704C1 11,12E FFH FUEL_FLTR_HTR 182069A1 4,8G ISS INT_SPEED_SENS 291718A1 8,11D PRM_D1 PRM OUTPUT 409084A1 4,9H
AA2 A1 6,5F
L1 L1_8 6,12F A2 A2 12,3G A7 A7 11,7H 64F FLASHER_CONNECTOR 245481C1 6,7G FLSHR FLASHER_MODULE 225389C1 6,7G JMP1 JSS LOAD SENSE 245482C1 13,7B PRM_D2 PRM SIGNAL 256340A1 4,9G
MACHINE CONTROLS 10 CONNECTOR INTERFACE L1 L1_9 4,8H A3 A3 6,10F A8 A8 9,10F
AA1 A2 6,5F
64M FLASHER_CONNECTOR 245480C1 6,7G FM FILT_MAINT_SW 371614A1 8,11E JMP2 JSS LOAD SENSE 198456A1 13,6C PSS SEC STR PRES SWITCH 245485C1 11,9C
AA4 A3 4,2C
RADIO/POWER CONVERTER 12 (ONE HARNESS CONNECTS TO ANOTHER HARNESS) L1 L1_10 5,12G A4 A4 6,10E A9 A9 12,8E AA3 A4 4,2C AB+ ALTERNATOR_B+ 397579A1 4,11H FNR_RLY RELAY K2 245731C1 13,7D JSS_197F MAIN_CAB_FNR 225350C1 13,11E PVRES JSS JOYSTICK 1792058 13,12E
L2 L2_1 12,11G A5 A5 6,10D A10 A10 8,2G
INDICATES WIRES CROSSING (NOT CONNECTED) AA6 A5 4,7D AB_5 ALTERNATOR B+ 225067C1 4,11G FSS FAN_SPEED_SENS 87747172 9,11D JSS_197M FNR-MAIN_CAB 225351C1 13,7F PW_B CAB POWER 87581779 4,11G
POWER DISTRIBUTION 4 L2 L2_2 11,4G A6 A6 6,10E L1_1 L1_1 7,10E AA5 A6 4,7D ACT AC_COMP_CLUTCH 8602417 12,7F FWD_DIODE DIODE ASSY 245485C1 13,9E JSS_ARM JSS ARMREST TO CAB 225400C1 13,6F PW_E CAB POWER 87706435 4,11G
L2 L2_3 11,2F A7 A7 6,9G L1_2 L1_2 7,7E AA8 A7 5,12F
TRANSMISSION CONTROL 8 L2 L2_4 6,2H A8 A8 6,9F L1_3 L1_3 6,11F AA7 A8 5,12G
AD ALTERNATOR D+ 1964710C1 4,11H FWM FRONT-WIPER_MOTOR 245715C1 11,5D JSS_CAB JSS CAB 225389C1 12,11B, 13,3D PXF RTD 245485C1 10,2D
L2 L2_5 12,3E A9 A9 12,5F L1_4 L1_4 6,10H AA10 A9 6,2F ALT_5 ALTERNATOR D+ 8602487 4,11H FWMG WIPER GROUND 245480C1 11,5D JSS_CNT JSS CONTROLLER 967242_TYCO 13,2C PXH HGT_CNTRL-RTT 245484C1 10,3C
SCR EXHAUST TREATMENT 6 L2 L2_6 12,7H A10 A10 12,3F L1_5 L1_5 4,1F AA9 A10 6,2G ARM_FNR FNR-MAIN_CAB 280453A1 13,9D FWW FRONT_WASHER 3227856R1 11,2D JSS_FRM JSS FRAME TO CAB 256352A1 13,7D PXM RTD 245484C1 10,2D
18G_C Or-1.0 A A L2 L2_7 11,11G AA1 B1 12,2G L1_6 L1_6 10,7H A2 AA1 6,5F ARM_POS ARM POSITION 225259C1 13,9G GH GRID_HEATER 87354284 4,10B JSS_LS JSS LOAD SENSE 245483C1 13,8B PXT RTD 245484C1 10,2D
SECONDARY STEERING 11 0_J Bk-1.0 C C
INDICATES PARTIAL CONNECTOR L2 L2_8 12,5H AA2 B2 12,2G L1_7 L1_7 11,8H A1 AA2 6,5F
L2 L2_9 7,12D AA3 B3 6,9F L1_8 L1_8 9,10F B1 STARTER PWR STUD 386008A1 4,10F GHC GRID_HEATER_REL 3227856R1 4,12C JSS_LS2 JSS LOAD SENSE 198456A1 13,7C P_A1 B+ POWER 1964722C1 4,3F
128F 128M A4 AA3 4,2C
WIPER/WASHER SYSTEM 11 (NOT ALL ENTRY PORTS SHOWN) AA4 B4 6,9E L1_9 L1_9 12,9E B2 STARTER_POWER 382256A1 4,11F GHF1 GRID HTR FUSE 8602094 4,11C JSS_PIL_DUMP JSS PILOT DUMP 225316C1 13,11C P_A2 B+ POWER 1964722C1 4,6F
A3 AA4 4,2C
AA5 B5 6,9D L1_10 L1_10 8,2G B3 STARTER-BATTERY AMER_CABLE_20156 4,11F GHF3 GRID_HTR_FUSE 8602094 4,11C JSS_PIL_PR JSS PILOT PRESSURE 245483C1 13,7B P_A3 B+ POWER 1964722C1 4,3F
JOYSTICK STEERING 13 AA6 B6 6,9E
A6 AA5 4,7D
A5 AA6 4,7D B4 STARTER_POWER AMER_CABLE_20103 4,11F GHF4 GRID_HTR 8602660 4,12C JSS_RLY RELAY K2 245731C1 13,3G P_C1 B+ PWR FRM PRMD 8602094 4,10F
AA7 B7 6,8G
sht6, TECM A8 AA7 5,12G B5 STARTER PWR STUD 387078A1 4,10F GH_1 GRID_HTR 87354284 4,10B JSS_VALVE JSS HYD VALVE 239451A1 13,11C P_C2 B+ PWR FRM PRMD 8602094 4,10F
AA8 B8 6,8F
A7 AA8 5,12G B6 STARTER POWER 382255A1 4,11F GND_CAB1 GROUND_A 1964718C1 7,4C K5 K5 P_C3 B+ PWR FRM PRMD 8602094 4,9F
AA9 B9 12,4F
COLOR ABBREVIATIONS AA10 B10 12,2F
A10 AA9 6,2G
B7 STARTER-BATTERY 20102 4,11F GND_CAB2 GROUND_A 1964718C1 11,6C KD_DIODE DIODE ASSY 245485C1 13,8E P_C4 B+ PWR FRM PRMD 1964722C1 4,10F
A9 AA10 6,2F
B8 STARTER_POWER 20102 4,11F GND_CAB3 GROUND_C 1964718C1 12,4C KWCO WIPER CUTOUT 245731C1 11,5F P_C6 B+ PWR FRM PRMD 8602094 4,9F
ABBREVIATION COLOR INDICATES THAT THE WIRE CONNECTS TO CONNECTOR BPP PEDAL POSITION 87710588 8,4D GND_CAB4 GROUND_C 1964718C1 12,3C L1_ECC ECC BATT PWR 1964721C1 7,9F R1 RESISTOR RESISTOR_FORGO 13,5C
Bk BLACK TECM (TRANSMISSION ELECTRONIC CONTROL MODULE) 62 AIC_1 ENG ENGINE-CAB1 ENG2 ENG BULKHD 2 FRONT SW_PD SWITCH PAD 70 BT1 BATTERY_STARTER AMER_CABLE_10041 4,12G GND_CAB5 GROUND_C 1964718C1 12,1C LBEGRD LIGHT BEACON GRND 631801C1 7,3C RAD RADIO_POWER 292495A1 12,3F
PIN LOCATION PIN LOCATION PIN LOCATION PIN LOCATION
DU DARK BLUE ON SHEET 6. TECM CAN BE LOCATED ON SHEET 6 USING 1 9,7G 1 6,10C
PIN LOCATION BT2 BATTERY_NEG_STUD AMER_CABLE_10044 4,12G GND_CAB6 STRT, FFH, WAT_SEP_HTR 1964718C1 4,3C LBEPWR LIGHT BEACON PWR 631801C1 7,3C RAD_J1 RADIO_POWER 292497A1 12,3E
1 9,11F A 5,11F 1 6,9D
G GREEN ZONE (GRID) LOCATIONS GIVEN IN TABLES ON SHEET2. 2 9,12G B 4,7F 2 6,10C 3 10,11D
BT3 STARTER-BATTERY AMER_CABLE_10120 4,12F GND_CAB3D GROUND_A 1964718C1 8,3C LDM1 DOME_LIGHT_B+ PACK_2965401 7,2C RAD_J2 SPEAKER 292501A1 12,3E
3 12,12E 2 12,8F
K PINK C 5,11F 3 6,10C 4 9,8G
BT4 BATTERY_NEG_STUD AMER_CABLE_10042 4,12F GND_CAB_SPL CAB GRND SPLICE 87324393 12,6C LDM2 DOME_LIGHT_AUTO PACK_2965401 7,2C RAD_J3 RADIO_JUMPER 411311A1 12,3F
4 12,12E 3 4,7C 4 10,8E BTM_C CAB BOTTOM BULKHD 87703931 6,5H, 8,4C, 9,2C GND_CAB_SPL2 SPL BACK LGHT GD 87324393 4,2B, 6,3F LDM3 DOME_LIGHT_GND PACK_2965401 7,2C RECT ENG_COOL_TEMP 194788A1 9,10E
LG LIGHT GREEN 4 4,7D D 4,7F 5 9,12G
6 9,6D E 4,7F 5 6,10C BTM_E CAB BTTOM 225408C1 5,9E, 9,1C, 12,12F GND_CB GROUND, ON COOLING BOX 1964718C1 6,2B LLF LIGHTS_LH 225351C1 6,12C RFL FUEL_SENDER 1964703C1 9,11E
LU LIGHT BLUE 7 7,2G 5 9,11F 7 12,11E
INDICATES INTERNALLY GROUNDED COMPONENT F 5,11F 6 6,10C
8 12,10E BU1 BACKUP_ALARM_GRND 1964702C1 6,2D GND_ENG1 STRT, FFH, WAT_SEP_HTR 1964718C1 4,11B LLFW LH_FRONT_WK_LT 225316C1 7,3D RFLG FUEL_SEND_GRND 1964703C1 9,11D
N BROWN 9 9,8G 6 4,7D 7 6,10C
11 9,11G G 4,7F 9 9,10G BU2 BACKUP_ALARM 1964702C1 6,2D GND_ENG2 DEDICATED WIF, EDC 1964718C1 5,7G LLR LH_REAR_COMB_LT 239451A1 6,4E RFL_23 FUEL_LEVEL_SEND 256340A1 9,11D
Or ORANGE 7 9,12F H 5,11F 8 10,4D
12 9,6D 8 10,12C 9 10,3D 10 9,6G BUZ AIC_BUZZER 222136A1 9,5F GND_ENG3 SPLC_PK, WSHR MTR 1964718C1 11,5C LLRW LH_REAR_WK_LT 225316C1 7,1F ROOF ROOF TO CAB CONNECTION 388708A1 7,11G, 7,4F, 11,2C, 12,4F
P PURPLE OR VIOLET 13 9,6G J 6,7C CABE2 CAB TO ENG2 BULKHD 87703918 4,7F, 5,11F, 6,7C, 11,7F GND_ENG4 REAR LIGHTING 1964718C1 6,4D LLR_9 LH_REAR_COMB_LT 225351C1 6,6D RSPK RIGHT_SPEAKER 195552A1 12,4E
9 4,8D 10 6,10C TRANS TRANSMISSION-CAB
14 9,4G K 6,7C
R RED 10 5,6F 11 10,3D PIN LOCATION CAB_ARM CAB TO ARMREST 225402C1 13,6F GND_ENG6 DEDICATED 1964718C1 9,6C LLR_E LH_REAR_COMB_LT 225351C1 6,6D RTHP THROTTLE_PEDAL 225351C1 5,9E
19 10,12F L 6,7C
S GREY REF DES NAMING CONVENTION 20 10,2E 11 4,7C M 6,7C
12 10,3D 1 9,8F CAB_ARM_FRM CAB TO ARM TO FRM 225388C1 13,3E, 13,3D GND_ENG7 GRND TRANS_CLNT 1964718C1 9,11C LPL LIC_PLATE_LIGHT 245482C1 6,2C RVS_DIODE DIODE ASSY 245485C1 13,9E
13 10,8E 2 8,9F
T TAN S.... ROCKER SWITCHES 21 13,2E 12 5,6F N 6,7C 14 6,10C 3 11,10F
CAB_B CAB BTM BULKHEAD 87703902 6,5H, 8,4D, 9,2C GND_FC GROUND_A 1964718C1 10,4C LRF LIGHTS_RH 225351C1 6,11C RWM REAR_WIPER_MTR 245715C1 11,3C

L.... LIGHTS 22 4,1D 13 5,6G P 6,7C 15 6,10C 4 11,10F CAB_FNR MAIN_CAB_FNR 280451A1 13,9D GND_GH1 STRT, FFH, WAT_SEP_HTR 8602094 4,9B LRFO FRONT_WK_LT_OPT 225316C1 7,2E RWMG REAR_WIPER_MTR_GD 245480C1 11,3C
U BLUE 23 10,12D 14 5,6G R 6,7D 5 8,9E CAB_FRM CAB TO JSS FRAME 256354A1 13,7C GND_GL GROUND, REAR GRILL 1964716C1 6,2B LRFR FRONT_WK_LT_OPT 225316C1 7,2E RWW REAR_WASHER 3227856R1 11,2D
P.... PRESSURE SENSORS/SWITCHES 16 6,10C
W WHITE 25 9,10G S 6,7D 6 11,10F
15 4,8E 17 10,8E CAB_PW CAB POWER 87315254 4,8E GND_JSS GROUND_A 1964706C1 13,9B LRFS FRONT_WK_LT_OPT 225315C1 7,3E SAJ FNR_SWITCH 382391A1 13,10D
Y YELLOW
Y.... SOLENOIDS 26 10,12F
16 9,11F T 11,8F 18 10,8E
7 8,9D
CAB_RF CAB TO ROOF CONNECTION 388710A1 7,11G, 7,5F, 11,2C, 12,5F GND_PDST GROUND_A 1964706C1 9,4C LRFW RH_FRONT_WK_LT 225316C1 7,3E SBE BEACON_SW 382391A1 7,9D
8 8,9D
R.... RESISTANCE MEASURE 17 9,5C U 11,8F 9 8,9D CAB_T CAB-TRANSMISSION 380839A1 8,9D, 8,3F, 9,8F, 11,10F GND_PDST1 GROUND_A 1964706C1 9,4C LRR RH_REAR_COMB_LT 239451A1 6,3E SBU BACK-UP_ALRM_DIS_SW 382391A1 6,2E
71 AIC_2 V 11,7F
ABOVE LETTER FOLLOWED BY THE FIRST LETTER PIN LOCATION
18 5,6F
W 11,7F
10 8,9E CBPW CAB POWER 277431A1 4,8E GND_PDST2 GROUND_A 1964706C1 9,3C LRRW RH_REAR_WK_LT 225316C1 7,1G SC SEAT_COMP_MOTOR 245482C1 12,6G
11 8,9D
OF THE FIRST TWO WORDS OF THE SYMBOL LABEL. 2 7,12G 19 9,5C X 11,7F 12 8,9D
CL CIGAR_LIGHTER 3227856R1 12,5G LRR_9 RH_REAR_COMB_LT 225351C1 6,5D SDA DIFF LOCK SWITCH 382391A1 8,8G
LARGE CONNECTOR LIST; See also next page for pin locations. 4 9,9G 20 9,5C CNV 24V TO 12V PWR CONVERTER 225351C1 12,2H LRR_E RH_REAR_COMB_LT 225351C1 6,5D SDC DECLUTCH_SWITCH 382391A1 8,2C
SPL_.... SPLICE 13 8,9D
NAME DESCRIPTION CNH SHT, ZONE 5 9,4G 21 4,8E 14 8,2F DC1 DISCONECT-BATTERY AMER_CABLE_20102 4,11E LSPK LEFT_SPEAKER 195552A1 12,4E SDM DIFF LOCK SWITCH 371614A1 8,9G
PART NUMBER 6 9,5G 22 10,12C 15 8,3F DC2 DISCON-BLCK_GRND AMER_CABLE_20102 4,11E MH HEATED MIRROR 225295C1 12,2D SDR DRIVING LIGHTS SW 382391A1 6,11G
AIC_1 ADV INSTR CLUSTER 1 87419488 4,1D, 7,2G, 9,12G, 9,11G, 9,10G, 9,8G, 9,7G, 9,6G, 9,6D, 9,4G, 10,12F, ... 7 10,11F 23 10,12C 16 8,9E
17 8,9E DC3 FUEL_SOL_DISCONNECT 446658 4,11E MHS TRANS_ENABLE_SW 382391A1 12,4C SFC FAN_CONTROL_SW 382391A1 10,11E
AIC_2 ADV INSTR CLUSTER 2 87410948 4,2E, 6,6F, 7,12G, 9,11G, 9,10G, 9,9G, 9,6G, 9,5G, 9,5D, 9,4G, 10,11F, ...
8 10,11F 24 11,3D
9 6,6F 18 8,9E DC4 FUEL_SOL_DISCONNECT 446658 4,12E MH_C HEATED MIRROR 225294C1 12,2D SFL RETURN_TO_TRAVEL_SW 382391A1 10,4G
CAB_E CAB-ENGINE 291661A1 4,7E, 4,7C, 5,6F, 9,11F, 9,5C, 10,12C, 11,3D, 12,11G, 12,8F
10 6,6F 25 11,3D 19 8,9E DEFDM DOSER METERING VLV 87709793 5,8D MH_L MIRROR_HTR 225316C1 12,2C SFNR FNR_SWITCH 382391A1 8,6F
CAB_F CAB-FRNT_CHAS 319184A1 6,9C, 10,8E, 10,3D 11 11,9G 26 4,8E 20 8,9E
DIA DIAGNOSTIC 87736919 12,7D MH_R MIRROR_HTR 225316C1 12,2D SFWW FRONT WIPER/WASHER 87345132 11,2G
27 4,7C 21 8,9E
CAN_MOD_2 JSS CAN MOD 87635073 13,11G, 13,10G, 13,9G, 13,8G, 13,7G 12 12,8G DIA_2 DIAGNOSTIC 87736919 5,5G MON CAMERA/MONITOR 280451A1 7,10C SHC HEIGHT CONTROL SW 382391A1 10,4F
22 8,9E
ECA ELECT CNTR A 87315248 4,7H, 5,11G, 6,11F, 6,1H, 7,12C, 8,1G, 9,7F, 9,3G, 10,11F, 10,1H, 11,11G, ... 14 9,10G 28 9,12F 23 9,8F DISC DISCONNECT-ENGINE 245482C1 4,9E NOXS NOX SENSOR 84190317 5,6E SHZ HAZARD_SWITCH 382391A1 6,3G
ECB ELECT CNTR B 87312843 4,4E, 4,4D, 4,3D, 6,9F, 6,9E, 6,9D, 6,8G, 6,8F, 9,3F, 10,11D, 12,4F, 12,2G, ... 15 9,5D 29 12,11G 24 8,2F
16 10,10F NTRL_DIODE DIODE ASSY 245485C1 13,9E SJS JOYSTICK_CONTROL_SW 382391A1 13,1E
ECC ELECT CNTR C 87315249 4,6C, 4,1F, 6,11F, 6,9H, 7,10E, 7,7E, 8,2G, 9,10F, 10,7E, 10,6H, 11,7H, ... 30 12,11G 25 8,3F
17 4,2E 26 11,10F OSS OUT_SPEED_SENS 291719A1 8,10E SPB PARKING_BRAKE_SWITCH 382391A1 9,6E
ECD ELEC CNTR D 87312843 4,7D, 4,2C, 5,12F, 6,5F, 6,2F, 10,8G, 10,2F, 11,4G, 11,4F, 12,9G 31 12,8F
18 10,1E 27 8,9F PAF AIR_FILT_RES_SW 291718A1 9,12C SPC PILOT_CONTROL_SWITCH 382391A1 10,3D
ENG ENGINE-CAB1 374973A1 4,8E, 4,7D, 5,6G, 9,12F, 9,5C, 10,12C, 11,3D, 12,11G, 12,8F
20 9,9G 28 8,9E PBD DEC_PRESS_SW 245482C1 8,2F SPE PIN_ENGAGE_SW 382391A1 10,9F
FRONT FRNT_CHAS-CAB 319149A1 6,10C, 10,8E, 10,3D 21 9,6G 29 8,9E
PBL BRAKE_LT_PRES_SW 222136A1 6,4H SPK SPEAKER 292494A1 12,3E
SW_PD SWITCH PAD 87635073 6,9D, 9,12G, 9,10G, 9,8G, 9,6G, 10,11D, 12,11E, 12,10E 22 9,5D 30 9,8F
24 9,11G 31 8,9E PBW BRK_WARN_PR_SW 371614A1 9,3D SPL2 ULTRASONIC SPLICE_FARGO 12,3D

INDEX / WIRE INFORMATION 1 CONNECTOR LIST 2

sht7,L1_ECC sht11,SPL_19S sht6,ECC sht10,ECC
CONNECTOR LIST CONNECTOR LIST CONNECTOR LIST UNSWITCHED POWER
sht6,ECA sht5,ECA sht8,ECA
IGN POWER
NAME DESCRIPTION CNH SHT, ZONE NAME DESCRIPTION CNH SHT, ZONE ACC POWER sht12,ECA
NAME DESCRIPTION CNH SHT, ZONE
PART NUMBER PART NUMBER PART NUMBER ILLUM POWER 10 AMP
SPL3 ULTRASONIC SPLICE_FARGO 12,3D SPL_EDC4 ULTRASONIC SPLICE_FARGO 5,8G SPL_WRK1 ULTRASONIC SPLICE_FARGO 7,2E J10 BUSS-ECA

J11 BUSS-ECA
14 LG-1.0 J9 BUSS-ECA A B
SPL_1 ULTRASONIC SPLICE_FARGO 12,3D SPL_ENG ULTRASONIC SPLICE_FARGO 11,5C SPL_WRK2 ULTRASONIC SPLICE_FARGO 7,2E

J1 BUSS-ECA
L1_9 A9
AD
SPL_2 ULTRASONIC SPLICE_FARGO 11,10G SPL_FAN ULTRASONIC SPLICE_FARGO 10,12C SPL_WRKF ULTRASONIC SPLICE_FARGO 7,4E
3 PRM_D IN REAR EDC7 FUEL SHUTDOWN sht12,TEL 19S1 Or-3.0

J6_ECC BUSS-'
SPL_3 ULTRASONIC SPLICE_FARGO 11,1C SPL_FLSHR_PWR ULTRASONIC SPLICE_FARGO 6,6H SPL_WRKR ULTRASONIC SPLICE_FARGO 7,3G 18 PWR REL MOD PRM_D1 ECA-F9
SPL_TEL 18U_F Or-0.8
D+ A A 18J_F Or-3.0 sht5,SPL_EDC2 18U_A Or-5.0
SPL_12V ULTRASONIC SPLICE_FARGO 12,4G SPL_FNR ULTRASONIC SPLICE_FARGO 8,5F SRC RIDE_CONTROL_SW 382391A1 10,9G SPL_HTR
R B+ 1_BA R-13.0 30 C 1_GA R-3.0 PRMB_L1 ECA_L1
SPL_13M ULTRASONIC SPLICE_FARGO 4,9E SPL_FW ULTRASONIC SPLICE_FARGO 11,3G SRC_1 RELAY 225316C1 4,12D
AB+ PRMB_L2
SPL_19S ULTRASONIC SPLICE_FARGO 11,9G SPL_H1 ULTRASONIC SPLICE_FARGO 8,11E SRHSTLK RH STALK SWITCH 87318288 6,12E -
85 B 31B Or-0.8 PRM_A PRM_B PRM_C
SRP WORK LIGHTS SW 382391A1 4,7B ALTERNATOR sht12,SPL_CNV
86 A

18U_C Or-3.0
SPL_H2 ULTRASONIC SPLICE_FARGO 8,10D 28F W-0.8

1_GB R-2.0
SPL_1N ULTRASONIC SPLICE_FARGO 4,8F PRM_A1
28V 65A PWR REL MOD PWR REL MOD PWR REL MOD
SPL_35A ULTRASONIC SPLICE_FARGO 6,3D SPL_HB ULTRASONIC SPLICE_FARGO 6,10E SRTD DETENT_SWITCH 382391A1 10,4E PRM_D2 A A
SPL_42C ULTRASONIC SPLICE_FARGO 7,6F SPL_HC ULTRASONIC SPLICE_FARGO 11,3F SRWP REAR_WIPER_SW 382391A1 11,2D sht5,SPL_EDC4 30 C 19L Or-3.0
SPL_A1 ULTRASONIC SPLICE_FARGO 10,8D SPL_HOOD ULTRASONIC SPLICE_FARGO 11,7H SSD SEC_STR_DIODE 245485C1 11,11F sht5,EDC7 FUEL FILTER 21
A A HEATER
SPL_HOOD_GRND HOOD GRND 6PCK 87324391 11,5E SSM SEC STR MOD 225389C1 11,9D FL FLTR HTRENGINE ECM 85 B 85 B 85 B 0_EB Bk-0.8
SPL_A2 ULTRASONIC SPLICE_FARGO 10,3C B B 1.9 ±0.3 86 A 12ACC_C W-0.8
14 86 A 15 86 A

1_GC R-2.0
F1 FUSE F2 FUSE

J5_ECC BUSS-'
SPL_A3 ULTRASONIC SPLICE_FARGO 10,3D SPL_HRN ULTRASONIC SPLICE_FARGO 10,8F SSS SS MAG SWITCH 1964704C1 11,12E AT 20°C
BT1 1 1 40A30 A 13 PRM_A2

18U_E Or-3.0
SS_TR SS_MOD-TRANS 245489C1 11,10E 1_NG R-8.0 FFH PRM_B1 PRM_C1
SPL_A4 ULTRASONIC SPLICE_FARGO_CYL 9,3D SPL_HTR ULTRASONIC SPLICE_FARGO 4,8H

0_EC Bk-0.8
POS 1_NB R-62 PW_B PW_E

13K_C Or-1.0
SPL_A1A ULTRASONIC SPLICE_FARGO 6,5C SPL_J1 ULTRASONIC SPLICE_FARGO 6,3D STA TRANS_AUTO_SW 382391A1 8,2E 0_BX Bk-2.0 sht4,GND_ENG1

12ACC_B W-0.8
0_EU Bk-0.8
STE TRANS_ENABLE_SW 382391A1 8,5G

1_C R-8.0
SPL_AC ULTRASONIC SPLICE_FARGO 12,10G SPL_J2_N ULTRASONIC SPLICE_FARGO 6,4D
NEG WSH PWR CNVRTRDCU PWR ACC POWERSEC STRG IGN POWERSPARE
SPL_ACC ULTRASONIC SPLICE_FARGO 4,3F SPL_JSS_1 ULTRASONIC SPLICE_FARGO 13,2E STTR_GRN GRID_HTR_FUSE 8602094 4,10E
1_ND R-62 B B
WATER SEPARATOR
HEATER
20 F1 FUSEF2 FUSE F1 FUSEF2 FUSE F1 FUSEF2 FUSE
SPL_ACP ULTRASONIC SPLICE_FARGO 12,12G SPL_JSS_2 ULTRASONIC SPLICE_FARGO 13,2D SWL WORK LIGHTS SW 382391A1 7,7F BT2 sht11,244F 20 A20A 40A20A 40A

18U_C Or-3.0
1_NC R-19.0 A A 1.9 ±0.3
SPL_ACS ULTRASONIC SPLICE_FARGO 12,12G SPL_JSS_3 ULTRASONIC SPLICE_FARGO 13,2D S_KEY IGNITION_SWITCH 225253C1 4,1E LEFT BATTERY P_C1 P_C2 P_C4 P_C3 P_C6
AT 20°C
SPL_AJ ULTRASONIC SPLICE_FARGO 13,10D SPL_JSS_4 ULTRASONIC SPLICE_FARGO 13,4E TCOT TCO_SENDER 291718A1 8,11E ONLY TIER4

0_BW Bk-2.0
SPL_ALT ULTRASONIC SPLICE_FARGO 4,7E SPL_JSS_5 ULTRASONIC SPLICE_FARGO 13,5D TECM TRANS 411398A1 8,8E, 8,8C, 8,5C 5 B4 B3 B2 B1 194
1 sht5,DNOX2
TEL TELEMATICS 388708A1 12,8C BT3
SPL_AP ULTRASONIC SPLICE_FARGO 9,6G SPL_JSS_6 ULTRASONIC SPLICE_FARGO 13,5F BS
18U_D Or-2.0 B B

1_BB R-8.0

1_E R-19.0
TERM_CAN_2 CAN BULK HEAD 225295C1 5,6F POS 1_NA R-62

1CB R-19.0
SPL_B1 SPLICE_FARGO 6,5D SPL_JSS_7 ULTRASONIC SPLICE_FARGO 13,4F
P_A2 P_A1 P_A3
SPL_B8 ULTRASONIC SPLICE_FARGO 6,6D SPL_JSS_9 ULTRASONIC SPLICE_FARGO 13,5D THV TANK HEATER CONTROL VALVE 84192117 5,7D 9 M
sht4,GND_ENG1 sht5,DNOX2 E E
SPL_BCK_LGT SPLICE BACK LGHT PWR 87324393 7,5H SPL_JSS_10 ULTRASONIC SPLICE_FARGO 13,7F TRANS TRANSMISSION-CAB 380838A1 8,9E, 8,3F, 9,8F, 11,10F NEG 0_NC Bk-62 18U_B Or-2.0 0_EB Bk-0.8
SPL_BCK_LGT2 SPL_BACK LGT PWR 87324393 10,7F SPL_JSS_11 ULTRASONIC SPLICE_FARGO 13,5D TRC TRANS_CONTROL 371566A1 8,10F SPL_SD3
BT4 SPL_1N 1_NJ R-3.0 G G 1_NL R-3.0 0_EC Bk-0.8
TRLY TIMER RELAY 245731C1 12,4D AIC_2
SPL_BCK_LT_GD SPL BACK LGHT GD 87324393 7,6D SPL_JSS_13 ULTRASONIC SPLICE_FARGO 13,10F RIGHT BATTERY M 1_NH R-8.0 1_NK R-3.0 D D 1_NM R-3.0 SPL_ACC
TR_SS SEC_STR_MOD_OPT 245488C1 11,9E CRANKING 10 AMP
SPL_JSS_14 ULTRASONIC SPLICE_FARGO 13,6C 12ACC_C W-0.8

0_NB Bk-62
SPL_BCK_LT_GD2 SPL_BACK LGT GRND 87324393 10,3B
MOTOR sht5,EVGT_3 ENG2 CABE2 ```
SPL_BLWR ULTRASONIC SPLICE_FARGO 12,9F SPL_JSS_15 ULTRASONIC SPLICE_FARGO 13,10F TS1 TRANSMISSION_SHIFTER 245486C1 8,9C 1_T R-1.0 A B
STTR_GRN
SPL_BUZ ULTRASONIC SPLICE_FARGO 9,6F SPL_JSS_16 ULTRASONIC SPLICE_FARGO 13,8C TS2 TRANSMISSION_SHIFTER 245487C1 8,9C PSTN HIGH L1_5 A5
13C Or-1.0 1CB R-19.0 1 1 1CB_A R-19.0 1CB_A R-19.0 KEY SW PWR
SPL_C3 ULTRASONIC SPLICE_FARGO 11,10C SPL_JSS_17 ULTRASONIC SPLICE_FARGO 13,10C TSS TURB_SPEED_SENS 291718A1 8,11D DC1 17

12ACC W-0.8
DC4 DC3 DC2 CBPW CAB_PW SPL_NEU ECC-F5
sht5,WIF sht8,TECM 25T_C LU-0.8
SPL_CAN ULTRASONIC SPLICE_FARGO 12,11E SPL_JSS_18 ULTRASONIC SPLICE_FARGO 13,4E TURBO ENG DASH_TURBO 87694583 5,3D 25T LU-0.8 21K_B W-0.8 <

13K_C Or-1.0
75

21K_A W-0.8
UBJ (ONLY TIER4) DEF LEVEL TEMP 84062580 5,6C 1DM R-1.0
SPL_CAN_DH ULTRASONIC SPLICE_FARGO 5,8G SPL_JSS_20 ULTRASONIC SPLICE_FARGO 13,4C
8 2 RESISTOR sht8,TS1 25T_B LU-0.8

13M Or-1.0
SPL_CAN_DIAG ULTRASONIC SPLICE_FARGO 12,9D SPL_JSS_21 ULTRASONIC SPLICE_FARGO 13,8F UBJM (ONLY TIER4) DEF LEVEL TEMP 371616A1 5,6C SPL_13M 86 30
13M_C Or-1.0 ECB
SPL_CAN_DIAG_L ULTRASONIC SPLICE_FARGO 12,9D SPL_L1 SPLICE_FARGO 6,6D UTS (ONLY TIER4) UPSTREAM TEMP SENSE 87709793 5,7C S_KEY
14_AC LG-0.8
SPL_CAN_DL ULTRASONIC SPLICE_FARGO 5,8G SPL_LB ULTRASONIC SPLICE_FARGO 6,10E WIF WATER_IN_FUEL_SNSR 8602416 5,6H 5 `
sht12,TEL NEUTRAL START 1
SPL_CAN_GH ULTRASONIC SPLICE_FARGO 5,5G SPL_LT ULTRASONIC SPLICE_FARGO 7,8E WSH WATER_SEP_HTR 182069A1 4,8F sht11,SPL_2 SPL_SD2 BAT
215F 216F K2 13K Or-1.0 3
SPL_ALT SPL_CRK
11
IGN
SPL_CAN_GL ULTRASONIC SPLICE_FARGO 5,5G SPL_NEU ULTRASONIC SPLICE_FARGO 4,4E YDL DIFF LOCK SOLENOID 225316C1 8,12G MASTER DISCONNECT SWITCH 26

SPL_CAN_HT ULTRASONIC SPLICE_FARGO 5,6F SPL_P9 SPLICE_FARGO 6,4C YDL_1 DIFF LOCK SOLENOID 225315C1 8,12G
13M Or-1.0 B B 13M_B Or-1.0 14 LG-1.0 26
21
14_AB LG-0.8 14_A LG-0.8 19R_D Or-0.8 < 21K W-0.8 2 ST

13C Or-1.0 A A 13C_A Or-1.0 13C_A Or-1.0 21 13C_B Or-1.0 12ACC W-0.8 4 ACC

SPL_CAN_HV ULTRASONIC SPLICE_FARGO 5,7F SPL_PBS ULTRASONIC SPLICE_FARGO 9,2G YDL_2 DIFF LOCK SOLENOID 225316C1 8,11G DISC ENG_D 6 `
85 87A87

13K_B W-0.8
15
SPL_CAN_JS_H1 ULTRASONIC SPLICE_FARGO 12,10C SPL_PED_BL SPL BACK LGT PWR 6 PCK 87324391 10,10D YFN FAN_PWM_SOL 256340A1 10,11C < 21D W-1.0 15
9
21D_A W-0.8 < IGNITION
SPL_CAN_JS_H2 ULTRASONIC SPLICE_FARGO 12,10C SPL_PED_BL_GD SPL BACK LGT GD 6PCK 87324391 10,9B YFR FAN_REV_SOL_OPT 225316C1 10,11C
193 9
10 SWITCH
SPL_CAN_JS_L1 ULTRASONIC SPLICE_FARGO 12,10C SPL_PIN SPL_BACK LGT PWR 87324391 10,10E YLS TC_LOCKUP_VALVE 371614A1 8,2F 1 30
1_BB R-8.0 1_E R-19.0 ENG
CAB_E
ECD
30
F5/F6 0_EA Bk-0.8 0_EW Bk-0.8

<
87 195 SPL_CR
SPL_CAN_JS_L2 ULTRASONIC SPLICE_FARGO 12,10C SPL_PINE ULTRASONIC SPLICE_FARGO 10,8F YLV HEATED VALVE OPT 225316C1 10,11B 1_Z R-8.0
AA5
21C_B W-0.8 < < 21C W-0.8 AIC_1
21D_A W-0.8 >

13M_A Or-0.8
SPL_CAN_L ULTRASONIC SPLICE_FARGO 12,10E SPL_PK1 SPLICE 3-4WAY 87324462 7,2H, 12,8D YLV2 HEATED VALVE OPT 225315C1 10,11B 87 A6
sht5,GND_ENG2 86 30
YLV3 HEATED VALVE OPT 225316C1 10,10B RELAY 85 AA6 ECB

21C_A W-0.8
SPL_CAN_LT ULTRASONIC SPLICE_FARGO 5,7F SPL_PK3 SPLICE 3-4WAY 87324462 6,7F, 11,3G 86 SHUTDOWN
28G W-1.0 gxl 21H W-0.8
SPL_CAN_LV ULTRASONIC SPLICE_FARGO 5,7F SPL_POS ULTRASONIC SPLICE_FARGO 6,5C YPB PARK_BRK_SOL 225316C1 9,3D 1 < 21G W-0.8
85 86 A5 LOW

0_BAT Bk-1.0
SPL_CAN_TEL ULTRASONIC SPLICE_FARGO 12,9C SPL_POS_L ULTRASONIC SPLICE_FARGO 6,7E YPE PIN ENGAGE JUMPER 245482C1 10,9D 2 EDC7 ENGINE CONTROLLER IGN PWR LATCH
22
SPL_POS_NA ULTRASONIC SPLICE_FARGO 6,3B YPE1 PIN ENGAGE JUMPER YPE2 10,9D SRC_1 12 GRID_HEATER_SOURCE 12 CRANK CONTROL K1 13K_A W-0.8
SPL_CAN_TEL2
SPL_CAN_TRANS
ULTRASONIC
ULTRASONIC
SPLICE_FARGO
SPLICE_FARGO
12,9C
12,10E SPL_POS_R ULTRASONIC SPLICE_FARGO 6,8D YPE2 PIN_ENGAGE_OPT 245482C1 10,9D ENG
RELAY 4 21F W-0.8 << 158
17 CRANK_CONTROL_LOW 17 21H_A W-0.8 txl 0_EY Bk-0.8

<
SPL_CAN_TRANS_L ULTRASONIC SPLICE_FARGO 12,9E SPL_PR ULTRASONIC SPLICE_FARGO 6,10F YPP PILOT_PRES_SOL 245482C1 10,2F 0_GB Bk-1.0

0_EZ W-0.8
6 85 87A87
SPL_CNV ULTRASONIC SPLICE_FARGO 12,3H SPL_PTM ULTRASONIC SPLICE_FARGO_CYL 9,3E YRC RIDE_CONTROL_OPT 291718A1 10,8C 32 KEY_SW_CRANK RQST LSD
REQUEST FROM VEHICLE TO START
32 21E_A W-0.8 txl >> < 6
4 4
0_DF Bk-0.8 < 86 30
ECD F3/F4
SPL_CR ULTRASONIC SPLICE_FARGO 4,4D SPL_RAD ULTRASONIC SPLICE_FARGO 12,4F YRC_J RIDE CNTRL_JUMPER 291717A1 10,8C 3
21H W-0.8 ECB 30
37 CRANK_CONTROL_RLY HIGH 37 3
YRC_J2 RIDE_CONTROL_OPT 291718A1 10,7C 21G_A W-0.8 txl 21G W-0.8 AA3

SPL_CRK ULTRASONIC SPLICE_FARGO 4,2E SPL_RD ULTRASONIC SPLICE_FARGO 9,10D OK TO CRANK SIGNAL FROM EDC
GHF4 0_ET Bk-0.8
SPL_D1 ULTRASONIC SPLICE_FARGO 10,4E SPL_REV SPLICE_FARGO 6,4D YSS SEC_STRG_SOL 225316C1 11,9D 16 1_Y R-19.0
GH FUSE GHF1 40 KEY_SWITCH_FUSED_PWR 40 13M_A Or-0.8 txl
27 27 sht12,TEL
CRANK REQUEST SPL_SD1
87 A4
85 AA4
SPL_D11 ULTRASONIC SPLICE_FARGO 8,9C SPL_ROOF SPLICE ROOF GROUND 87324391 7,5E ``S4_S S4_S 14,4D 30 >> 11 11
>> 21J W-0.8 K3
6
0_EV Bk-0.8
SPL_D12 ULTRASONIC SPLICE_FARGO 8,6E SPL_RTT ULTRASONIC SPLICE_FARGO 10,4G 87 115 GHF3 150A 75 GRID_HEATER SUPPLY B+ 75 21F_A W-0.8 <<

<<
1_BE R-19.0 86 A3
SPL_D15 ULTRASONIC SPLICE_FARGO 8,4H SPL_RWW ULTRASONIC SPLICE_FARGO 11,1E
GRID EDC7 CAB_E >>
HEATER IGN PWR
SPL_D16 ULTRASONIC SPLICE_FARGO 8,3F SPL_SD1 ULTRASONIC SPLICE_FARGO 4,2C RELAY 86
sht5,SPL_EDC3
86 30
85 87A87
CNTRL 159
SPL_D17 ULTRASONIC SPLICE_FARGO 8,4D SPL_SD2 ULTRASONIC SPLICE_FARGO 4,2E 1 28G W-1.0 TO
85 ECC

0_KA Bk-0.8
21E_B W-0.8
2 0_BV Bk-0.8 0_BV Bk-0.8 txl GROUND
SPL_D19 ULTRASONIC SPLICE_FARGO 8,4E SPL_SD3 ULTRASONIC SPLICE_FARGO 4,5F PL23 DIFFERENT CONNECTOR
GHC 1
SPL_D24 ULTRASONIC SPLICE_FARGO 10,2G SPL_SEC ULTRASONIC SPLICE_FARGO 11,11C
SPL_D25 ULTRASONIC SPLICE_FARGO 10,3F SPL_SS ULTRASONIC SPLICE_FARGO 11,9D
2 START LOCKOUT 21E W-0.8 >> RIGHT
GRID HEATER PL23/26 150 AMPS 3 K5 CONSOLE H 0_EQ Bk-0.8
SPL_D26 ULTRASONIC SPLICE_FARGO 10,8F SPL_SW_PD ULTRASONIC SPLICE_FARGO 9,10F
ON ENG BLOCK
NEAR STARTER 17 110 A ±8% 4 sht7,SPL_BCK_LT_GD 160 G 0_DE Bk-0.8
SPL_TEL ULTRASONIC SPLICE_FARGO 4,6H at 22V 5 0_B32 Bk-0.8 F 0_BBC Bk-0.8
SPL_D8_C1 ULTRASONIC SPLICE_FARGO 6,2D GND_CAB6
GH_1 ON ENG BLOCK 6 E
SPL_DC ULTRASONIC SPLICE_FARGO 8,2C SPL_TRNS_PWR TRANS_PWR 87324393 8,1D 85 87A87
0_GB Bk-1.0 A B 0_ES Bk-19 Indicator 7

0_EQ Bk-0.8
NEAR GRID HTR D
SPL_DCUG ULTRASONIC SPLICE_FARGO 5,8D SPL_WHS ULTRASONIC SPLICE_FARGO 11,4E 0_BX Bk-2.0 Light 8 0_J Bk-0.8 C 0_K Bk-0.8 sht7,MON
GND_ENG1 GH
SPL_DLY3 ULTRASONIC SPLICE_FARGO 9,10F SPL_WK ULTRASONIC SPLICE_FARGO 7,4E 0_BW Bk-2.0
GND_GH1
9 >> B
SPL_DR ULTRASOIC SPLICE_FARGO 6,10F SPL_WL ULTRASONIC SPLICE_FARGO 7,6F 10 67B Or-0.8 A 0_J Bk-0.8
SRP GND_CAB_SPL2
SPL_EDC1 ULTRASONIC SPLICE_FARGO 5,8G SPL_WL1 ULTRASONIC SPLICE_FARGO 7,5F sht4,FFH sht4,WSH sht13,SPL_JSS_1
CHASSIS GROUND
SPL_EDC2 ULTRASONIC SPLICE_FARGO 5,8H SPL_WLS ULTRASONIC SPLICE_FARGO 11,3D DEDICATED GRND
SPL_EDC3 ULTRASONIC SPLICE_FARGO 5,8G SPL_WR ULTRASONIC SPLICE_FARGO 7,3F

CONNECTOR LIST 3 COLD START POWER DISTRIBUTION IGNITION SWITCH 4

ELECTRICAL SCHEMATIC SIDE 1
621F TIER 3 WHEEL LOADER
Additional copies of this schematic can be ordered through Technical Publications Distribution System.
 UNSWITCHED POWER sht7,ECC sht6,ECC sht6,ECC sht4,ECC UNSWITCHED POWER
IGN POWER sht4,ECA sht10,ECA IGN POWER
ACC POWER sht12,ECA sht11,ECA
ACC POWER sht7,SPL_BCK_LGT
ILLUM POWER ILLUM POWER sht10,SPL_PED_BL
sht4,ECA 0_EH Bk-0.8 sht6,GND_CAB_SPL2
WIF WATER_IN_FUEL_SNSR CAB_B
ONLY TIER4 sht4,PRM_D1
23B_E Or-1.0 gxl
sht4,SPL_13M
35W W-0.8 txl 1 1 WATER_INDICATOR 22 J5_ECC BUSS-'
10 AMP
SPL_FLSHR_PWR G G J14 BUSS-ECA
5 AMP

24 18J_F Or-3.0 gxl

0_BP Bk-1.0 gxl
13M_C Or-1.0 gxl 0D_C Bk-0.8 gxl
2
3
2WATER_SEP_SENS_GRND sht12,GND_CAB_SPL
J4_ECC BUSS-' A
L1_4
B
A4
1_DV R-2.0 H
J
H
J 44 T-1.0 2 2
BRAKE LIGHT
PRESSURE SWITCH
J15 BUSS-ECA A
L2_4
B
C4
3 UNSWITCHED PWR

J9 BUSS-ECA
J8 BUSS-ECA
J10 BUSS-ECA sxl EDC7 ENGINE CONTROLLER BRAKE LTS/FLSHR BACK-UP
2 EDC7_FUSED_POWER_3 2 18J_C Or-1.0 gxl
SPL_EDC2
ECC-F4
1_DR R-1.0 K K 1_AA R-1.0 1 1 N.O. CLOSES AT
90 sht10,SPL_PED_BL_GD ECA-F14
5 AMP
3 EDC7_FUSED_POWER_4 3 18J_B Or-1.0 gxl
ON ENG BLOCK
NEAR STARTER
WIF
DIA_2 92 1
FLSHR FLASHER_MODULE
FLASHER_MODULE_PWR 1 1_DU R-1.0 BTM_C PBL
60 PSIG (414KPA)

5 EDC7_GROUND_3 5 sht12,SPL_PK1 A DIA_2 DIAGNOSTIC

0_BE Bk-1.0 gxl 2 FLASHER_OPP_SIDE_CNTRL 2 45N_A N-0.8 1 1 1_KA R-1.0
A B 6 EDC7_GROUND_4 6 0_BF Bk-1.0 gxl SPL_EDC1 18K_B Or-0.8 gxl B A GROUND
3 6
sht4,ENG B DIAG_FUSED_PWR 3 FLASHER_MODULE_GRND 64F 64M
L1_10 A10 8 EDC7_FUSED_POWER_1 8 18J_D Or-1.0 gxl 0_BAC Bk-2.0 sxl C 77 0_B19 Bk-0.8 sht7,SPL_BCK_LT_GD 4 0_EG Bk-0.8 1_DW R-1.0 7 7 0_B24 Bk-0.8
GND_ENG2 ONLY TIER4 C CAN_HIGH 4 FLASHER_MODULE_GRND

19H Or-1.0
DNOX CNTRLR 9 EDC7_FUSED_POWER_2 9 18J_E Or-1.0 gxl D 8 8 sht7,SPL_BCK_LGT 8
162 49_P S-0.8 5 8 49_D S-0.8
5 NONE
ECA-F10 10 EDC7_GROUND_1 10 0_BD Bk-1.0 gxl SPL_EDC4 0_BAT Bk-1.0 sxl HUMIDITY AND AMBIENT E D CAN_LOW
55 19Z_B Or-1.0 6 sht6,GND_CAB_SPL2 CONNECT FOR NA OPERATION, OPP SIDE STEADY ON. 1
6 NONE
F E DIAG_ISO_K_LINE

CAN_LX G-0.8 gxl

11 EDC7_GROUND_2 11 0_BC Bk-1.0 gxl 31B Or-0.8 gxl TEMPERATURE SENSOR DISCONNECT FOR EUROPEAN OPERATION, OPP SIDE OFF.
161 10 7 45R_E N-0.8 5

CAN_HO Y-0.8 gxl

HTS F 7 RIGHT_TURN_SIGNAL

J4_ECC BUSS-'
sht12,GND_CAB_SPL 13 SWITCHED_B+_OUTPUT_LSD 13 31 Or-0.8 gxl sht4,PRM_D2 G 9 8 LEFT_TURN_SIGNAL 8 45L_D N-0.8 4
18T Or-0.8 gxl

26 HUMIDITY AND TEMP 26 23K_B Y-0.8 txl 2 H G 66 41T_C K-1.0 sht7,D_OR 9 45A_A N-0.8 sht6,SRHSTLK 9
9 LEFT_TURN_SWITCH_POWER
4 J H

J3_ECC BUSS-'
ECD F7/F8 27 HUMIDITY AND TEMP 27 23K_C Y-0.8 txl 11 10 45B_A N-0.8 sht6,SRHSTLK 10
3 J 10 RIGHT_TURN_SWITCH_POWER
30 28 HUMIDITY AND TEMP GND 28 SPL_EDC3 23K_E LU-0.8 txl 4 11 HAZARD_SWITCH_POWER 11 45H N-0.8 3 3
AA7
23B_A Or-0.8 gxl 29 DIGITAL_GROUND 29 21F_B W-0.8 txl 21F_A W-0.8 GXL sht4,ENG 23K_A K-0.8 txl 1 33 ECD
41T K-1.0 12 FLASHER_OPP_SIDE_CNTRL 12 45N_B N-0.8 2 2 F9/F10
87 A8
23B_B N-0.8 gxl
34
EDC7
CAN_L 34 CAN_LJ G-0.8 TXL/TWIST
SPL_CAN_DL CAN1_L G-0.8
CAN_L G-0.8 TXL/TWIST
ENG
13
CAN_LL G-0.8 gxl
SPL_CAN_GL
CAN_LA G-0.8 TXL/TWIST sht12,SPL_CAN_JS_L1
22 19Z_A Or-1.0 5 AMP FLSHR
ECD
93 HAZARD
SHZ
30
85 AA8 SPL_CAN_DH 13 SPL_CAN_GH SDR F1/F2 AA9
23B_E Or-1.0 gxl

35 CAN_H 35
14 DRIVING LIGHTS AIC_2 AIC_2 ` sht8,TECM
23B_C Bk-0.8 gxl CAN_HK Y-0.8 TXL/TWIST CAN_H Y-0.8 TXL/TWIST 14
18
CAN_HM Y-0.8 gxl 41T_B K-1.0 A B 18F_C Or-1.0 30
EDC7 sht12,SPL_CAN_JS_H1 87 A10
23B_D Or-0.8 gxl CAN1_H Y-0.8 18 23J_B W-0.8 GXL CAN_HA Y-0.8 TXL/TWIST
95 A7 B7 AA1

44_A T-0.8
86 A7 sht4,PRM_D2 12
POSITION LFT ``` ``` 85 AA10
36 FUEL_FILTER_HTR_RELAY 36 28F W-0.8 txl 12 TIER 2 ONLY SPL_PR 35C Y-0.8
10 15 AMP ECB-F7 SPL_PK3 87 A2
NOX SENSOR 42 WATER_IN_FUEL_SENSOR 42 35W W-0.8 txl 10 TIER 2 PL23 ONLY SPL_DR 85 AA2 19A_P Or-1.0
48 LOW_IDLE_SWITCH 48 24L W-0.8 txl HIGH HIGH GND_CAB_SPL2 86 A9 sht8,SPL_TRNS_PWR
' CAB_E A B 19Z Or-1.0 5 AMP 9 10
51 EVGT_RELAY 51 13A Or-0.8 CAN_L2 G-0.8 38H W-0.8 txl L1_3 A3 BACK-UP ALARM
ONLY TIER4
EDC7 CAN_L3 G-0.8 SPL_CAN_LV SPL_CAN_LT
TERM_CAN_2 DRIVING LTS 41T_A K-1.0 A B 45L_E N-0.8
86 A1 sht6,FLSHR J RELAY
78
52 CAN2_L 52 CAN_LS G-0.8 TXL/TWIST SPL_CAN_HV CAN_LZ G-0.8 SPL_CAN_HT CAN_LV G-0.8 gxl A A 120 ECC-F3 BRAKE LIGHTS sht6,FLSHR K

21F_C W-0.8 txl

A8 B8 SPL_PK3 0_EH Bk-0.8
CABE2 53 CAN2_H 53 CAN_HS Y-0.8 TXL/TWIST CAN_HZ Y-0.8 CAN_HV Y-0.8 gxl B B POSITION RT 45R_C N-0.8 0_EG Bk-0.8 L
RELAY
ACFH
ENG2 ACFH
EDC7 CAN_H3 Y-0.8 C C
84058092
ECB-F8 91 0_EF Bk-0.8 M
35A_A Y-0.8

18G Or-1.0
68 SENSOR_SUPPLY HTS 68 23K_A K-0.8 txl CAN_H2 Y-0.8 TERMINATOR
77 THROTTLE_SUPPLY 77 24S W-0.8 txl ON ENG BLOCK 44A_A T-0.8
5 AMP
78 THROTTLE_GROUND 78 24R W-0.8 txl NEAR STARTER CASE North America
5 AMP
79 THROTTLE_SIGNAL 79 24B W-0.8 txl CAN_HW Y-0.8 41H_B Or-0.8 A B 18B_A Or-2.0 44_A T-0.8

CAN_HU Y-0.8
89 ISO-K_INTERFACE 89 20G_A W-0.8 txl sht12,ENG CAN_LW G-0.8 A B NH World Wide
A3 B3

CAN_LU G-0.8
LFT HIGH BEAM CASE Euro L.H. REAR COMBO LT R.H. REAR COMBO LT sht7,SPL_BCK_LT_GD
EDC7 31A Or-0.8 L1_8 A8
TURN SIGNALS ECB-F3
ECA-F8 101 L.H. REAR COMBO LIGHT 100 R.H. REAR COMBO LIGHT 101 STOP/TURN
100 STOP/TURN 0_B21 Bk-0.8
163
VIOLET 6 6 6 TAIL TAIL
IDLE VALIDATION SWITCH (IVS) 24L_A W-0.8 txl 6 NOXS 5 AMP
CLOSES @ 0.775V ±0.1V YELLOW 1 1 1 SBU
21F_D W-0.8 txl 1 SPL_HB STOPTURNTAILREVERSE STOPTURNTAILREVERSE
THROTTLE POSITION POTENTIOMETER
RED 5 5 24S_A W-0.8 txl 5 5 4 NOX SENSOR 41H_C Or-0.8 A B 18C_A Or-0.8 ```` ````
10
5V REFERENCE GREEN 3 3 3 3 7

18F_C Or-1.0
24B_A W-0.8 txl 3 TURN 49A 49a 19B Or-0.8 A4 B4 0_B21 Bk-0.8 7
0.35V ±0.1V LOW IDLE BLACK 4 4 24R_A W-0.8 txl 4 4 5 SIGNAL LEFT
L L 45A_A N-0.8 sht6,FLSHR RT HIGH BEAM 49_L S-0.8 8 8
23 4.0V ±0.1V WOT
2 2 BTM_E ENG_B 23D_D Bk-0.8 txl 2 RIGHT R R 45B_A N-0.8 sht6,FLSHR ECB-F4 9
1 56 56 41J Or-1.0 6
THROTTLE PEDAL RTHP DRIVING 5 AMP
LIGHTS 56A 56a 41H_A Or-1.0 SPL_LB 5
23A_A N-0.8 txl 13A Or-0.8 56B 56b 41L_A Or-1.0 41L_B Or-0.8 A B 18D_A Or-0.8 35R_C Y-0.8 1 1
18T_A Or-1.0 gxl sht4,P_C6 EVGT_3 PL23 56D 56d 19Z_C Or-1.0 A6 B6 4
23B_F Or-1.0 sxl
ONLY TIER4 A 1 ONLY
LIGHT/
HORN 31B 31b 64C Or-0.8 sht10,ECC LFT LOW BEAM BADC BADC
3 3
1_T R-1.0 sht12,GND_CAB_SPL ECB-F6 LLR3214 LRR3214
0_BAU Bk-1.0 B 2 10A 31 31 0_EP Bk-0.8 35A_B Y-0.8 2 2
(C1)
DNOX2
79
HORN SRHSTLK
THV 5 AMP SPL_POS_L BACK-UP ALARM DISABLE SWITCH
DNOX2 NOX CONTROLLER SPL_POS_R SPL_35A

45L_BN N-1.0

45R_BN N-1.0
TURN SIGNAL
169 TURBO 162345 162345

0_BR_N Bk-1.0
1
1 BATTERY+VIA_MAIN_RELAY 38D Or-0.8 txl 2 TANK HEATER 30 D 1_B R-1.0
94 41L_C Or-0.8 A B 18E_A Or-0.8 ON ENG BLOCK 35A_D Y-0.8

44A_FN T-1.0
TURBO ENG DASH_TURBO HI/LOW BEAM LLR_E 154326 LRR_E 154326
2 1

44A_GN T-1.0
2 BATTERY+VIA_MAIN_RELAY 1 CONTROL VALVE 87 A5 B5 NEAR STARTER

0_BT_N Bk-1.0
A 1 CAN LO

18G_CN Or-1.0
& HORN SPL_D8_C1
3 BATTERY_PLUS 3 18U_D Or-2.0 gxl sht4,ENG2 87a E 2 RT LOW BEAM 35A_E Y-0.8 1 A
2
164

18G_F Or-0.8
4 BATTERY_PLUS 4 18U_B Or-2.0 gxl sht4,ENG2 85 C 13A Or-0.8 3 ECB-F5
3

0_BR Bk-1.0
209F 209M

35A_M Y-0.8
5 CAN_1_H 5 86 B 4

18G_G Or-0.8
31A Or-0.8 4

38C LU-0.8 txl

18F_A Or-0.8
6 5 SW_PD
6 CAN_1_L EVGT_4 5 GRND L.H. FRONT COMBO LIGHT R.H. FRONT COMBO LIGHT DISCONNECT WHEN BACK UP ALARM

18F_B Or-1.0
45L_A N-1.0

35A_L K-1.0
7 CAN_2_H 7 CAN_HQ Y-0.8 gxl EVGT 13B Or-1.0 6 DISABLE SW IS INSTALLED (ON TUV
6 BATT ``` GND_ENG4

44A_E T-1.0
8 CAN_2_L 8 7 ROAD APPROVED MACHINES ONLY)
CAN_LK G-0.8 gxl RELAY 7 CAN HI HIGHPOSITIONLOWTURN HIGHPOSITIONLOWTURN SPL_J2_N

45R_B N-0.8
9 8 BEAMBEAM BEAMBEAM
35A_F Y-0.8

45L_B N-0.8
9 OPEN
168

18F_E Or-0.8
DEFDM 8 HIGH sht7,MON
10 OPEN 10 9
9 OIL LEVEL 1 BU1
11 DEF_DOSING_MODULE 11 38A LU-0.8 gxl 2 DOSER METERING 10
10 OIL LEVEL ENG2
SPL_J1
12 DEF_DOSING_MODULE_SUPPLY 12 38 R-0.8 gxl 1 VALVE 11 0_JB Bk-1.0
11 CLOG GRND CABE2
13 OPEN 13 12 41H_D Or-0.8 SPL_B8 0_BT Bk-1.0
SPL_DCUG 12 CLOG SIG
14 BATTERY_MINUS 14 0_LB Bk-2.0 gxl 0_BBF Bk-3.0 sxl sht9,GND_ENG7 S S 44A_D T-1.0 44A_F T-1.0 35A_HN Y-1.0

0_BAG Bk-1.0
15
15 BATTERY_MINUS 0_LC Bk-2.0 gxl R R 35A_H Y-1.0 BU2 103

0_JA Bk-1.0
DTLTS
16 OPEN 16 P P 45R_A N-1.0 0_JC Bk-1.0
ONLY TIER4 17 CATALYST_UPSTREAM_TEMP_SENSOR_GRND 17 2 2 2 FRONT CAB_F 18G_F Or-0.8 N N 18G_H Or-1.0 BACKUP ALARM
18 DEF_TANK_LEVEL_SIGNAL 18 38B Y-0.8 gxl
0E_A Bk-0.8 gxl 0_T Bk-0.8 gxl
38B Y-0.8 gxl 1 1
0_TA LU-0.8 gxl
38B_A Y-0.8 gxl 1 165 364251 364251
18F_A Or-0.8 M M SPL_A1A

38H W-0.8 txl

19 3 3 3 1 1 L L 35A_J K-1.0 35A_K K-1.0 FOR 521E EURO HOOD
19 DEF_TANK_LEVEL_TEMP_SENSOR_GRND
20 OPEN 20
0_T Bk-0.8 gxl 38G Y-0.8 gxl
UBJ UBJM
38G_A Y-0.8 gxl
96 315246 LLF
9795 315246LRF
7 7 SPL_POS 18G_J Or-1.0 C C HARNESS, REF DES AND
21 DEF LEVEL 45R N-1.0 3 3 45R_D N-0.8 18G_D Or-1.0 A A 18G_E Or-0.8 WIRE NAMES ARE ONLY
21 OPEN
22 HOSE_HEATING_1 (DO NOT CONNECT) 22 ONLY TIER4 167 AND TANK TEMP 18E Or-1.0 15 15 18E_A Or-0.8 35A_F Y-0.8 K K 35A_G Y-1.0 B B DIFFERENT
23 DEF_TANK_HEATING 23 38C LU-0.8 txl 18G_A Or-1.0 5 5 18G_G Or-0.8 J J E_HD HD_E
24 DTS ONLY TIER4 18C Or-1.0 16 16 18C_A Or-0.8 LPL
24
25
SWITCHED_BATTERY+
CATALYST_DOWNSTREAM_TEMP_SENSOR_GRND 25 0_U Bk-0.8 sxl 2 DOWNSTREAM TEMP 166 45L N-1.0 2 2 45L_C N-0.8 A A LICENSE
CATALYST_DOWNSTREAM_TEMP_SENSOR_SIGNAL
26 26 38E Y-0.8 gxl 1 SENSOR
UTS
UPSTREAM TEMP ONLY TIER4 18D Or-1.0 14 14 18D_A Or-0.8 0_BAG_N Bk-1.0 18G_EN Or-1.0 B B PLATE
27 2 LIGHT

35A_C Y-0.8
27 OPEN 0E_A Bk-0.8 gxl SENSOR 18F Or-1.0 10 10 18F_E Or-0.8 1 1 0_JA_N Bk-1.0
28 1 18B Or-2.0 6 6 18B_A Or-2.0 35A_R Y-1.0 8 8 `
28CATALYST_UPSTREAM_TEMP_SENSOR_SIGNAL
29 DEF_TANK_TEMP_SIGNAL 29
38F Y-0.8 gxl
38G Y-0.8 gxl 44A_DN T-1.0 2 2 44A_EN T-1.0 ON COOLING 102
30 OPEN 30 45L_AN N-1.0 3 3 45L_BN N-1.0 BOX ON REAR

0_AJ Bk-1.0
31 ISO-K_INTERFACE 31 38H W-0.8 txl 45R_AN N-1.0 4 4 45R_BN N-1.0 SPL_POS_NA GRILL
32 18G_HN Or-1.0 5 5 18G_JN Or-1.0

0_AH Bk-1.0
32 HOSE_HEATING_3 GND_CB GND_GL
33 FILTER_OUTLET_HEATING 33 18F_AN Or-1.0 6 6 18F_BN Or-1.0
34 HOSE_HEATING_4 34 35A_GN Y-1.0 7 7 35A_HN Y-1.0
ENG_H HD_N
35 HOSE_HEATING_2 35 35A_C Y-0.8 0_G Bk-2.0
sht10,SPL_A1 sht10,SPL_A1
CHASSIS GROUND
DEDICATED GRND
CHASSIS GROUND
DEDICATED GRND

ENGINE CONTROL 5 LIGHTING 1 BACKUP ALARM 6

UNSWITCHED POWER sht12,ECC
UNSWITCHED POWER sht4,P_A1 sht6,ECC sht4,ECA_L1 sht13,ECA
IGN POWER
IGN POWER ACC POWER
sht12,ECA ACC POWER ILLUM POWER sht7,SPL_BCK_LGT
ILLUM POWER sht12,HVAC1 sht8,STA sht8,SDC sht6,SDR sht6,SBU sht8,STE sht11,SRWP
sht7,SPL_BCK_LT_GD
SPL_PK1

J1 BUSS-ECA
sht10,SPL_BCK_LT_GD2 0_DAP Bk-0.8

J2 BUSS-ECA
AIC_1 SPL_D15
49 DU-1.0 9 19A_F Or-0.8 sht8,SPL_TRNS_PWR
AIC_2 STE

J10_ECC BUSS-`
77 0_B31 Bk-0.8
D_OR ``` 88 49_Z S-0.8 10 10 19A_E Or-0.8
SPL_BCK_LGT
DOOR A 172 5 7 7 0_DAP Bk-0.8
A B HIGH 6 8 8 49_H S-0.8
sht10,SPL_BCK_LGT2
HIGH 7 34C_A LU-1.0 34C_A LU-1.0 10 1 19A_D Or-0.8
B C 7.5 AMP
2
49_C S-0.8 C DIODE 34A_D Or-1.0 34A_D Or-1.0 4 54 6
49_H S-0.8 D OR 8981 1 5 J1 BUSS-ECA A B
49_L S-0.8 E 49 DU-1.0 33 34B LU-0.8 4 L1_1 A1
1 1 1 1 DIFF LOCK DIFF LOCK 22 9 9 TRANS ECM
49A S-0.8 F
G
41T_C K-1.0 sht6,SPL_PR
2 2
34A_E Or-1.0
34C_D LU-1.0 2 2 SOLENOID 173 SWITCH
34A_A Or-0.8
SDA 3 3
32J_C Y-0.8
26E_A LU-0.8 ECA-F1
49_P S-0.8 3 2 DIFF LOCK SWITCH sht9,SPL_PBS
sht10,SPL_BCK_LGT2 2 2 19A_D Or-0.8 7.5 AMP
49_R S-0.8
49S S-0.8
H
J
YDL YDL_1 YDL_2
171 A B

32J_C Y-0.8
TRANSMISSION ENABLE SWITCH
49_E S-0.8 K 43_A DU-0.8 3 2 JOYSTICK ONLY L1_10 A10
PIN 1 AND 2 CONNECTIONS 57 TRANS ECM
1_C R-8.0

CAB_RF L
DOOR 81
49_B S-0.8
49_A S-0.8 M C C 43_B DU-0.8 TRC TRANS_CONTROL
CLUTCH # FORWARD REVERSE NEUTRAL
1 2 3 4 1 2 3 1 2 3 4
ARE UNIQUE FOR PL23
12
SDM
55 TRANS
KICK-DOWN
ECC-F10
R R 1 TRANS_SOL_VALVE_Y1
SINGLE AXIS CONTROLLER ONLY
43S_A W-0.8 43S_B W-0.8 B B SWITCH 0_B14 Bk-0.8 K4 * 1 1 2 SWITCH
P P 19U_F Or-0.8 A A CLOSES WITH 42C_D DU-1.0
LRRW
2 TRANS_SOL_VALVE_Y2 KR * * * 2 ` 59

34A_B Or-0.8
SPL_WRKR
DOOR OPEN 42R_C DU-2.0 S S 42R_F DU-2.0 SPL_WR 42R_G DU-1.0 1 A 3 TRANS_SOL_VALVE_Y3 K1 * * * 3 KICK SFNR 56 SPL_D16

34D LU-0.8
ROOF DS BRAKE DECLUTCH
77 0_B14 Bk-0.8 0_DY Bk-1.0 B B 0_MH Bk-1.0 0_MF Bk-1.0 2 B 4 TRANS_SOL_VALVE_Y4 K3 * * * * * 4 DOWN 1 2
7
49_B S-0.8

7 32J_A Y-0.8 20M 12 24 24 19A_A Or-1.0 A A PRESSURE SWITCH

8 8 49_A S-0.8 SPL_42C 5 TRANS_SOL_VALVE_Y5 KV * * * 5 R PINK 8 B B
8 19A_G Or-0.8 14 14 25G LU-1.0 N.C. OPENS AT
55 H H RH REAR 6 TRANS_SOL_VALVE_Y6 K2 * * * 6 BROWN
L1_ECC 10
42_B R-1.0
SPL_WL1
42C_A DU-2.0 42C_F DU-2.0
88 WORK LIGHT 7 OUTPUT_SW_PWR_VPS1 7
5
6
5
4
5
4
19A_V Or-0.8
19A_U Or-0.8 25Y_C LU-0.8
5
6
5
6
32J_E Y-0.8
25Y_B LU-0.8
CAB_T TRANS PBD
BY TREDAL
350PSIG (2414KPA)
8 VALVE_BODY_TEMP_SIG 8 N SPL_FNR
9 0_B13 Bk-1.0 0_DZ Bk-2.0 A A 0_MV Bk-2.0 LLRW 1 9 19A_B Or-0.8 1 1 19A_C Or-0.8

25K LU-0.8
25K_9 LU-0.8
25L_9 LU-0.8
66 42R_C DU-2.0 9 VALVE_BODY_TEMP_RET 9 sht9,SPL_PBS YELLOW 2 6 2 2
6 26F_A LU-0.8 26F_B LU-0.8

25L LU-0.8
J19 BUSS-ECA

11 19U_D Or-0.8 D D 19U_C Or-0.8 42R_H DU-1.0 1 A 10 NONE 10

4 1 4 4 1 1 LOCKUP

25M LU-0.8
1 26R_A LU-0.8 26R_B LU-0.8 15 15 25R_B LU-1.0
4 0_ME Bk-1.0 2 B 11 NONE 11 F PURPLE 3 3 3 2 2 SOLENOID
10 26N_B LU-0.8 25 25

19A_T Or-0.8
25N LU-0.8

32J_D Y-0.8
B+

25G_A LU-0.8
12 NONE 24T_B LU-1.0

19T_C Or-0.8
12
33 42C_C DU-2.0 46_C K-1.0 E E 46_D K-1.0 3 3 26N_A LU-0.8

25P LU-0.8
SPL_WL 13 NONE 13 YLS
174
sht8,SPL_D19 197M 197F CAB_T TRANS
L1 LOCATED ON 22 42_A R-2.0 0_DR Bk-1.0 F F LH REAR 2 2 26J LU-0.8
87

25J LU-0.8
WORK LIGHT 14 NONE 14 TRANS CAB_T F-N-R SWITCH
ELECTRICAL CENTER C. SWL 0_DS Bk-1.0G G

25S LU-0.8
WORK LIGHTS 15 NONE 15 F-N-R SWITCH
0_DD Bk-2.0

ECC_L1 BUSS-` 2 2 34A_C W-0.8

80

36T P-0.8
CAB_RF ROOF 16 NONE 16 (OPTION)
86 27 27 34C LU-0.8 SPL_D12 25S_C LU-0.8

25T_A W-0.8
TRC
25S_B LU-0.8
J3_ECC BUSS-'
20 AMP
SPL_WRKF
LRFW LRFS
SPL_WRK1
LRFR *MODULATED AND CURRENT CONTROLLED 46 16 16 25K_A LU-0.8
36R_C P-0.8 25L_A LU-0.8 TECM TECM TECM TECM
J2_ECC BUSS-' A B 42 R-2.0 SPL_WK 42C_G DU-1.0 1 1 42R_A DU-1.0 42R_B DU-1.0 1 A 17 17 TECM TRANS
25M_A LU-0.8 11 DIFF LOCK SOL 0_DP Bk-0.8 sht8,GND_CAB3D
18 18 1 DIAG_TECM_GRND 1
0_MN Bk-1.0

0_MJ Bk-1.0 11
L1_2 A2 2 2 0_ML Bk-1.0 2 B

25R_A LU-0.8
WORK LIGHTS 25N_A LU-0.8 56 TRANS_SOL_VALVE_Y1 0_DQ Bk-0.8 sht8,GND_CAB3D
19 19 56 2 DIAG_TECM_GRND 2
ECC-F2 20 20 25P_A LU-0.8 10 10 TRANS_SOL_VALVE_Y2 5 TRANS_ENABLE_LIGHT 5 32J_D Y-0.8
RH FRONT
7.5 AMP
SPL_LT WORK LIGHT 47 FILTER
21 21 25J_A LU-0.8 32 32
55
TRANS_SOL_VALVE_Y3
TRANS_SOL_VALVE_Y4
6 NONE 6
sht6,ECD
sht10,ECD

A B A 1 32F Y-1.0 22 22 25S_A LU-0.8 55 7 BCK-UP_ALRM_PULL-DWN 7 35C Y-0.8 STA

19U_B Or-1.0 19U_D Or-0.8 sht7,SPL_BCK_LT_GD
LRFO MAINTENANCE B 2 36R_B P-1.0 5 5 36T_A P-0.8 9 9 TRANS_SOL_VALVE_Y5 8 PWR_VPS2 8 58H_A W-0.8 58H_C W-0.8 10
L1_1 A1 F sht8,CAB_T
BEACON/DOME LIGHT E 0_MK Bk-1.0 SPL_WRK2 42R_K DU-1.0 1 A
SWITCH 510 FM 45 31 31 32F_A Y-0.8 51 51
39
TRANS_SOL_VALVE_Y6
VALVE_BODY_TEMP_SEND
12
13
OUTPUT_SW_PWR_VPS1
OUTPUT_SW_PWR_VPS1
12 DIAGNOSTIC
CONNECTOR
0_B17 Bk-0.8 7 7
8 8
ECC-F1 D 0_MN Bk-1.0 0_MG Bk-1.0 0_MP Bk-1.0 2 B
39 13 SPL_D19
sht7,SPL_BCK_LGT
sht11,RWMG TORQUE CONV SPL_H1 OUTPUT A 1 0_HE Bk-1.0 28 28 0_DN Bk-0.8 17 17 XMSN_FILTER_MAINT_SW 14 NONE 14 3 9
19U_G Or-0.8 C
B
0_MA Bk-1.0
0_MB Bk-0.8 FRONT WORK OUTPUT TEMP
A 2 36R_D P-1.0 SPEED B 2 4 4 OUTPUT_SPEED_SENSOR_GRND 15 DIAGNOSTIC_SIGNAL 15 34A_C W-0.8 5 49S S-0.8 6 58
2
0_MC Bk-1.0 OPTION - H/O WORK LIGHT (LH & RH)) LIGHT (OPTION) SENDER
B 1 SENSOR C 3 25D LU-1.0 10 10 25D_A LU-0.8 62 62 OUTPUT_SPEED_SIGNAL 16 NONE 16 37D_A P-0.8
61 5
19U_H Or-1.0

A 19A Or-1.0 19A_M Or-0.8 46 TEMP/FILTER_RETURN 37E P-0.8 6 4

18 DIAGNOSTIC_SIGNAL
48 OSS
TCOT 29 29 46 18
10 3521 49 49 TCO_TEMP_SENDER 20 FNR_FORWARD_SIGNAL 20 26F_B LU-0.8 4 1
SPL_ROOF SPL_D17
7 7 AT 20°C 36R_A P-1.0 12 12 36R_E P-0.8 19 ENGINE_SPEED_SIGNAL 23 FUSED_BATT_PWR 19T_A Or-0.8 1 25H LU-0.8 3 3
0_B15 Bk-0.8 19 23

25Y_B LU-0.8
8 8 49_B S-0.8 36G P-1.0 13 13 36G_A P-0.8 3 3 SPEED_SENSOR_GRND 24 PEDAL_SENSOR_GRND 24 19A_Q Or-0.8 2 2
LLFW ENGINE 42 INTERMEDIATE_SPEED sht12,SPL_CAN_TRANS 108F
A 1 25A LU-0.8 7 7 25A_A LU-0.8 25 CAN_H CAN_HD Y-0.8
49
9 42 25 TRANSMISSION/AUTO SWITCH
42C_H DU-1.0 1 A SPEED B 2 0_HF BK-0.8 0_DM Bk-0.8 41 TURBINE_SPEED_SIGNAL CAN_LD G-0.8 sht12,SPL_CAN_TRANS_L
6 11 11 41 26 CAN_L 26
46_C K-1.0 0_MU Bk-1.0 2 B SENSOR ESS 9 9 25B_A LU-0.8 21 21 LOCKUP_SWITCH 27 CAN_L 27
5
4 INTERMEDIATE SPL_H2 8 8 25C_A LU-0.8 28 NONE 28
SPL_TRNS_PWR
1 LH FRONT A 2 0_HG BK-0.8 0_HD Bk-1.0 29 TRANS_AUTO_SIGNAL 29 25H LU-0.8
SPEED
3 3
0_B13 Bk-1.0 A
WORK LIGHT 85 50 SENSOR B 1 25B LU-0.8 30 FNR_REVERSE_SIGNAL 30 26R_B LU-0.8
26E_A LU-0.8 sht8,SPL_D15
19A_N Or-1.0
19A_F Or-0.8
A
B
2 2 19U_H Or-1.0 ISS 31 TRANS_ENABLE_SIGNAL 31
SBE 0_B14 Bk-0.8 B TURBINE 22A DU-0.8 33 NONE 33 19A_Q Or-0.8 C
ROTATING BEACON SWITCH 0_B15 Bk-0.8 0_B15 Bk-0.8 C A 2 0_HH BK-0.8 34 NONE 34 19A_T Or-0.8 D
SPEED
(OPTION) 0_B6 Bk-1.0 51 B 1 25C LU-0.8 34B LU-0.8 19A_W Or-0.8 E
L2_9

D 35 DIFF_LOCK_SW 35
84 SENSOR sht4,SPL_NEU
A

0_B17 Bk-0.8 E TSS 36 NONE 36 19A_C Or-0.8 F

sht10,SPL_BCK_LT_GD2 TECM
19F TECM 22B K-0.8 22E K-0.8 2 sht6,ECD 19A_P Or-1.0 G
37 PEDAL_SENSOR+5V B B
2+

0_B18 Bk-0.8 F 37
52
ECA-F19

3
CAMERA

68 FUSED_BATT_PWR 38 PEDAL_POS_SIGNAL 22C Y-0.8 C 22F Y-0.8 19A_R Or-0.8 H

3

0_B19 Bk-0.8 G 68 38 C
5 AMP

FORWARD REVERSE NEUTRAL TS2 BRAKE

H 25T_C LU-0.8 67 67 NEUTRAL_SIGNAL 40 NONE 40 22D LU-0.8 A 22G LU-0.8
A 1 1-
19A_K Or-0.8 J
TS2 TRANSMISSION_SHIFTER 1 2 3 4 1 2 3 4 1 2 3 4 BLACK A A 5 PEDAL
25G_C LU-0.8 66 DECLUTCH_SWITCH 26N_B LU-0.8 255E K-0.8 19A_M Or-0.8 K
5+

0_B21 Bk-0.8 J 19U_C Or-0.8 A NONE * * * * * * * * * * * *

66 44 FNR_NEUTRAL_SIGNAL 44 E E
GREEN B B 4 POSITION
25W LU-0.8 65 3RD_AND_4TH_GEAR_SIGNAL 19A_K Or-0.8 401B Y-0.8 L
4

K 0_MB Bk-0.8 43_B DU-0.8 B 3RD_AND_4TH_GEAR_SIGNAL * * * * * * BLUE

65 45 CAB_SWITCHED_PWR 45 F F
C C 25Z LU-0.8 SPL_D11 64 64 REVERSE_SIGNAL 47 NONE 47 D 016B DU-0.8
D 6 6-
M
L 46_D K-1.0 C 1ST_AND_4TH_GEAR_SIGNAL * * * * * *
C9

D D 25Y LU-0.8 63 1ST_AND_4TH_GEAR_SIGNAL CAB_B BTM_CWITH 5 SPD

B

M 0_MC Bk-1.0 D TRANS_KICKDOWN_SIGNAL

63 48 NONE 48 BPP SDC
MON sht7,SPL_BCK_LGT 19A_H Or-0.8
MON CAMERA/MONITOR LDM3 LDM2 LDM1
61 61 NONE 50 LOCK UP SOLENOID 50 25R_A LU-0.8
TS1 TRANSMISSION_SHIFTER RED A A sht7,SPL_BCK_LT_GD
66A Or-0.8 1 1 ACC B+ SPL_BCK_LT_GD 19A_H Or-0.8 43 43 FORWARD_SIGNAL 52 NONE 52 10
A TRANS_CONTROL_PWR * * * * * * * * * * * * YELLOW B B 7
25F LU-0.8 25Y_A LU-0.8 22 22 TRANS_KICKDOWN_SIG 53 PWR_VPSL 58H_B W-0.8 0_B18 Bk-0.8 7
2

53
3

0_K Bk-0.8 2 2 GRND B FORWARD_SIGNAL * * * * PINK

170 C C 25R LU-0.8 54 NONE 49_R S-0.8 8
MANUAL

0_DAV Bk-0.8
54
AUTO

sht4,GND_CAB_SPL2 35A_M Y-0.8 3 3 REVERSE C REVERSE_SIGNAL * * * * GREY D sht4,SPL_NEU sht10,ECD

D 25T_B LU-0.8 57 RIDE_CNTRL_RELAY_SINK 57 58L Bk-0.8 25G_A LU-0.8 9
4 4 TRIGGER 2 D NEUTRAL_SIGNAL * * * * RIGHT
sht6,SPL_35A 5 5 TRIGGER 3
RIGHT
LBEGRD LBEPWR TRANS. SHIFTER TS1 5381 58 NONE 58
CONSOLE 6
LIGHT
DOME

CONSOLE 59 DIFF_LOCK_MANUAL
0_B32 Bk-0.8

6 TRIGGER 4 1 1
59 SPL_DC 5
6 *INDICATES HIGH (24V) 25G_B LU-0.8 1
60 NONE
0_DAP Bk-0.8

60
GND_CAB3D 1
A
B

0_DS Bk-1.0
GND_CAB1 0_DQ Bk-0.8 4
60
83 34D LU-0.8 0_DP Bk-0.8 3 3
(OPTION)
BEACON
ROTATING

0_DR Bk-1.0 19T_B Or-0.8 19T_B Or-0.8 19A_R Or-0.8 2 2

22A DU-0.8
M

DECLUTCH/LOCKUP SWITCH
19A_M Or-0.8
0_B23 Bk-0.8

25G_C LU-0.8

87 sht8,TECM sht8,TECM

sht8,STA sht6, sht8,STE sht4,SRP

sht8,SDC SDR sht6,SBU sht11,SRWP CHASSIS GROUND
CHASSIS GROUND DEDICATED GRND
DEDICATED GRND

LIGHTING 2 7 TRANSMISSION CONTROLS 8

ELECTRICAL SCHEMATIC SIDE 2
621F TIER 3 WHEEL LOADER
Additional copies of this schematic can be ordered through Technical Publications Distribution System.
 sht12,ECC UNSWITCHED POWER sht11,ECA sht13,ECA sht10,ECA sht10,ECA sht4,ECC sht11,ECC
IGN POWER UNSWITCHED POWER
sht9,ECA sht6,ECA sht11,ECA sht9,ECA
ACC POWER IGN POWER
ILLUM POWER ACC POWER
sht10,SPL_PED_BL
ILLUM POWER
7 7 0_B2 Bk-0.8
7 7 0_B20 Bk-0.8 sht10,SPL_BCK_LT_GD2 8 8 49_K S-0.8 sht10,SPL_BCK_LT_GD2

J6_ECC BUSS-'

J7_ECC BUSS-'
J7 BUSS-ECA
J6 BUSS-ECA
8 8 49_G S-0.8 5 5 55B W-0.8

J7 BUSS-ECA

J8 BUSS-ECA
sht10,SPL_BCK_LT_GD2
5 5 58C W-0.8
25 4 4 0_29 Bk-0.8 7.5 AMP
SW_PD AIC_1 AIC_1 AIC_2 SW_PD AIC_1 AIC_2 AIC_2 AIC_2 SW_PD AIC_1 AIC_1 AIC_2 SW_PD AIC_1 AIC_2 AIC_2 AIC_1 35 4 4
9
58T W-0.8
sht8,SPL_D19
7.5 AMP
6
10
6 54B_C W-0.8
J6 BUSS-ECA
J5 BUSS-ECA A B
6 6 58H_C W-0.8 A B 19U Or-0.8 1 1 55A_B W-0.8 L1_5 A5
AIR FLTR FUEL RADIATOR FAN SPD SW_PAD +24V FOR BATTERY BATTERY BRAKE HYD FLTR HYDRAULIC KEY SW B+ KEY SW B+ SW_PAD POWER PARK BRAKE BRAKE PARK BRAKE 1 1 L1_6 A6 9 PILOT/RIDE CNTRL/EM DETENTS
86 30 SPL_RTT
10 HORN 3 3 55A_C W-0.8 ECA-F5
LOW ANALOG FAN_CTRL SPD POS POS B+ PWR B+ LOW LOW ANALOG IGN IGN GND HIGH HIGH LOW LOW ECD
3 3 ECC-F6 2

J3 BUSS-ECA
2 53P_B W-0.8
5 2 11 24 9 25 14 20 4 4 9 1 21 10 13 6 5 14
2 2 SFL
5 AMP RETURN TO TRAVEL
RIDE CONTROL
A B RIDE CONTROL SW
SRC
36 K4 FLOAT SWITCH sht12,TEL

19S_D Or-0.8
19D_A Or-1.0

31H_A Y-0.8
33R Y-0.8
19C_D Or-1.0
36F_A P-0.8

17P_A Or-0.8
(OPTION)

19S_F Or-0.8
19S_E Or-0.8
31F_A Y-0.8

36C_A P-0.8

19C_D Or-1.0
J4 BUSS-ECA
L1_6 A6 SPL_D24 19C_E Or-0.8

17P_B Or-0.8
J9_ECC BUSS-'
PARK BRAKE sht10,SPL_BCK_LT_GD2

35B W-0.8
36H_A P-0.8
77 0_B3 Bk-0.8 19C_A Or-1.0

0_B28 Bk-0.8
ECA-F6

19S_C Or-0.8
85 87A 87 88 49_M S-0.8 19C_F Or-0.8
34A_A Or-0.8 sht8,SDA sht8,TECM 9

19C_B Or-1.0
58_F W-0.8

19C_C Or-0.8
SPL_AP 58L Bk-0.8 10
SPL_PBS 26 66 54A W-0.8
460_A Y-0.8

19D_B Or-0.8 M 49_S S-0.8 5

BUZ
SPL_SW_PD SPL_DLY3 L 4

19E_A Or-0.8
7.5 AMP SPL_D26
SPL_BUZ 1 1 58_E W-0.8 K 49_G S-0.8 1
19S_B Or-0.8 0_B27 Bk-0.8 2 2 34A_B Or-0.8 sht8,SDM sht11,140M sht8,SDA 86 30
A B 19P Or-0.8 58_D W-0.8 J 49_Z S-0.8 33 ECD
19D_C Or-1.0 L1_7 A7 H 49_T S-0.8 sht11,SFWW 22 53P_D W-0.8 PILOT PRESSURE AVAILABLE
sht13,JSS_CAB 7.5 AMP WHEN RELAY CLOSES(PILOT CTRL SW OPEN)
PIN ENG/FAN RVSR sht10,SFC
31F_A Y-0.8 17P_C Or-0.8
63 G 49_Q S-0.8 SHC

58_C W-0.8
0_B26 Bk-0.8

19A_L Or-0.8
AIC
A B ECA-F7 (OPTION) 10 10 49_F S-0.8 F 49_F S-0.8
HEIGHT CONTROL
29 PILOT PRESS CONTROL

31H_A Y-0.8
36H_A P-0.8
sht12,TEL 10 AMP BUZZER SWITCH

33U Y-0.8
L1_3 A3 3 E 49_K S-0.8 K3

33R Y-0.8
A B 19S_B Or-0.8 AIC PWR
8 D 49_M S-0.8

52C W-0.8
ECA-F3 86 30 AIC_1 AIC_1 AIC_2 AIC_2 AIC_2

19U Or-0.8
0_L Bk-1.0 L1_8 A8 ECB 7 C 49_J S-0.8 10
CAB_E AIC PWR sht11,GND_CAB2 sht12,MH sht10,SPL_BCK_LT_GD2
7281516 6 B 49Y_A S-0.8 7 7 0_B4 Bk-0.8 85 87A 87
ECC-F8 HEAT VALVE ```` ```` ``` COUPLER sht7,SPL_BCK_LGT
7281516 CAB_T 12330 5 SPL_PINE A 49_E S-0.8 8 8 49_J S-0.8
ENG sht10,SPL_PED_BL_GD PARKING BRAKE
TRANS 12330 111 57_B W-0.8 9 SPL_D25 53P_C W-1.0
K5 HIGH OUT HIGH MANUAL HIGH AUTO HIGH HIGH 99 0_B5 Bk-0.8 SPL_HRN
SPL_BCK_LGT2
6 53P_A W-0.8 A A PILOT
33
36H P-1.0 9 64 19 26 7 8 16
4 19U_A Or-0.8 31 5 0_DU Bk-0.8 B B PRESSURE
36F P-1.0

SOLENOID

58_C W-0.8
7 7 0_B29 Bk-0.8 222 sht10,SPL_BCK_LT_GD2

57_A W-0.8
sht10,SPL_PED_BL 4
YPP

53P_F W-0.8
8 8 49_V S-0.8 sht12,GND_CAB_SPL 29.9 AT 20°C, JOYSTICK

52M W-0.8
85 87A87 SPE 19U_E Or-0.8 1
460 Y-1.0 5 PIN ENGAGE SWITCH 27.4 AT 20°C, SINGLE AXIS

52AU W-0.8
33 53A W-0.8
33R_A Y-1.0 6 (OPTION) 86 30
ECC 22 53P_E W-0.8
36C P-1.0 10 32 SRTD
AIC_1 AIC_2

52P_B W-0.8
37 RETURN TO DIG

53C_A W-0.8
4 57_C W-0.8

56 W-0.8
SWITCH
31F Y-1.0

1 ``` ``
RADIATOR
A A 3 3 7 7 0_B7 Bk-0.8 sht10,SPL_BCK_LT_GD2
19P_A Or-0.8 HORN
K4
98
COOLANT TEMP. SPL_PIN CAB_F
0_BK Bk-1.0

B B 31H9 Y-1.0 2 2 19A_L Or-0.8 sht10,SPL_BCK_LGT2 4181713 SOL LOW SW HIGH

8 8 49_Q S-0.8 RETURN 3 3 53A W-0.8
SENDER SPB 4181713 20 18
36J P-1.0

RECT PARKING BRAKE SWITCH 5 5 19P_C Or-0.8 A TO DIG 4 4 53B_B W-0.8

31H Y-1.0

3521 sht12,TEL FRONT

HYDRAULIC FILTER
68
36F P-1.0

` SPL_PTM 4 4 B HEIGHT 2 2 54A W-0.8

AT 20°C 2 2 85 87A 87
27 SPL_D1

57 W-1.0
RESTRICTION SWITCH ON PEDESTAL 67A Or-0.8 sht6,SRHSTLK CONTROL
1 1 N.O. CLOSES AT 74 10 19P_C Or-0.8 C 5 5 54B_B W-0.8
10 sht10,SPL_PED_BL_GD

64 Or-1.0
6 6 D RETURN 1 1 55A_A W-0.8

58_B W-1.0
PHF9 40PSIG (276KPA) 1 1 19P_D Or-0.8 E 64C Or-0.8
TO
6 6 55B W-0.8 7 7 0_B1 Bk-0.8

53P_F W-0.8
54B_A W-0.8
53B_B W-0.8
sht9,GND_ENG7 TRAVEL
1 RFL 0_BAE Bk-1.0
PHF 72 PL23 ONLY 9 19P_E Or-0.8 F EM 8 8 49_N S-0.8 sht10,SPL_PED_BL
0_HR Bk-1.0 ELECTROMAGNETIC

58_G W-1.0
S PARKING 3 3 52AU W-0.8 1
52P W-1.0 1 1 67 DETENTS
33R_A Y-1.0

FUEL HYDRAULIC FILTER BRAKE 2 2 52J W-0.8 64_A Or-0.8 9

0_AN Bk-1.0 2 2 sht10,SPL_BCK_LGT2 HN1
LEVEL G 1 0_BU Bk-1.0 RESTRICTION SWITCH SOLENOID FAN CONTROL SWITCH
SFC F 49_S S-0.8 ` 5
YPB E 49_V S-0.8 sht9,SPB CAB_F 6
SENDER RFLG N.O. CLOSES AT 36H P-1.0 (OPTION) 811129
40 PSIG (276KPA) D 49_X S-0.8 64 Or-1.0 4 LOCKOUT ENGAGED WHEN SWITCH IS CLOSED.
33-240
65 SPL_A4
0_AK Bk-1.0 AIC_1 C 49_D S-0.8 sht6,SHZ 99 FRONT
811129
3 3 31L Y-0.8
HYDRAULIC B 49_N S-0.8 sht10,SPC JUMPER PL18 ONLY 0_AF Bk-1.0 2 2 19C_F Or-0.8

19P_D Or-0.8

19P_E Or-0.8
FUEL 75 A A
49_W S-0.8 sht13,SJS SPC

53P_G W-1.0
54B W-1.0
OIL TEMP. AIC_1 AIC_1 AIC_2 AIC_2

53B W-1.0
A A A HN2
PL23
ONLY
LEVEL B B
460 Y-1.0
SENDER
B B
2 2
BRAKE WARNING
69
``` 57_D W-1.0 A A 44 HORN PILOT CONTROL SWITCH
` RTD HARNESS FOR
31F Y-1.0

0_HM Bk-1.0 REDUNDANT BRAKE HOT 0_AL Bk-1.0 PRESSURE SWITCH SPL_PED_BL
SENDER RFL_23 SPL_RD B B PRESSURE SWITCH 3521 SENSOR POWER POWER CHASSIS 1 1 N.C. OPENS AT SIGNAL LOW SPL_A1
sht6,LLF 39 XT CHASSIS ONLY
33-240 33R_C Y-1.0 A A N.O. CLOSES AT AT 20°C 73 1600 PSIG (11032KPA) 23 SW_PD 0_AW Bk-1.0 B B 0_AE Bk-1.0 0_AJ Bk-1.0
28

0_AK Bk-1.0
FAN 3 3 GRND GRND GRND GRND PBW 0_AH Bk-1.0 sht6,LRF
PL23 900PSIG (6205KPA) 86 30 YPE1 YPE
SPEED 1 1 PRB1 6 12 15 22 ECB 0_AG Bk-2.0 53B W-1.0 A A 53B_A W-1.0 A A C RETURN TO DIG

0_AD Bk-1.0
ONLY, 33P Y-1.0

56 W-0.8
``` YPE2
38

61H Or-0.8

52 W-0.8
2 2 B B B B PROXIM.

0_HW Bk-1.0
SENSOR 0_AC Bk-1.0 0_AM Bk-1.0 -

0_DB Bk-0.8
USED PIN ENGAGE SPL_A3 SWITCH XT N.C.
WITH HVT FSS 76 FAN RVSR LIGHTS HIGH
B B
A A SOLENOID JUMPER ON
40
53P_H W-1.0 C C 53P_I W-1.0 C C +
ZBAR N.O.
CAB_B PL18 ONLY PXF PXM PXT

0_DW Bk-0.8
REDUNDANT BRAKE 3 (OPTION) YRC_J
AIR FILTER L K4 SPL_A2
0_HL Bk-1.0 B B PRESSURE SWITCH 33P_A Y-0.8 L (OPTION) 28.8 AT 20°C RIDE CONTROL
1 1 RESTRICTION SWITCH M 2 2 0_RD Bk-1.0 2 2
33R_B Y-1.0 A A N.O. CLOSES AT 52P_A W-0.8 M 52P W-1.0 SOLENOID
34
0_HM Bk-1.0

0_BY Y-1.0 2 2 N.O. CLOSES AT N 1 1 58_H W-1.0 1 1 54B W-1.0 A A C HEIGHT CONTROL/
900PSIG (6205KPA) N
017A Bk-1.0

-0.928 PSIG (-6.4KpaG) PRB2 P 58 W-1.0 (OPTION) 0_AA Bk-1.0 B B - PROXIM.

PAF P 85 87A 87 YRC YRC_J2 RETURN TO
30
SWITCH
22.7 AT 20°C 53P_J W-1.0 C C +
0_DA Bk-0.8 TRAVEL N.C.
66 0_DX Bk-0.8 BTM_C 52 W-0.8 PXH
FAN 44
PRBF 202M ROLLBACK PRESSURE
0_HR Bk-1.0 GND_PDST1
CAB_E 52A_A W-1.0 1 1 A A A SWITCH (OPTION) REAR CHASSIS FRONT CHASSIS REAR CHASSIS
SENSOR GROUND 2 2 REVERSING B B 58_A W-1.0 B N.C. OPENS AT GROUND GROUND M 0_B7 Bk-0.8 sht10,SFC
CAB_E
BTM_E 2
82322 BELOW CAB GRND
ON ENGINE BLOCK BELOW CAB SENSOR GROUND SOLENOID L sht10,SPL_PED_BL_GD
42 WELD STUD WELD STUD
171920 52A_B W-1.0 90 PSIG (621KPA) 0_B11 Bk-0.8
NEAR OIL FLTR ON ENGINE BLOCK BELOW PEDESTAL PIVOT ENG 82322 YFR 39.3 at 20°C sht10,SFL
ENG
171920
ON FUEL FILTER
ABOVE PEDESTAL
CAB FLOOR ENG_B 2 K 0_29 Bk-0.8
NEAR OIL FLTR PIVOT ` sht10,SRC
NEAR AIC 0_BB Bk-1.0 F 0_B11 Bk-0.8 REPLACE JUMPER WITH ROLLBACK PRESSURE SWITCH J 0_B20 Bk-0.8
0_BK Bk-1.0 GND_ENG7 HEAD BRKT FAN 41
PWM 43
GND_ENG6 WITHIN 4 INCHES 56_A W-1.0 A A E 0_B29 Bk-0.8 H
GND_TRANS
0_BAR Bk-1.0 SPL_FAN FOR XT CHASSIS WITH RIDE CONTROL ONLY
0_BQ Bk-1.0 B B G

0_BG Bk-0.8
D
SOLENOID PRESSURE SWITCH NOT USED ON PL18. GND_FC sht7,
0_BAE Bk-1.0

0_BBR Bk-1.0
F

0_BH Bk-0.8
C 0_B24 Bk-0.8 0_AG Bk-2.0 0_AB Bk-1.0 0_B6 Bk-1.0

0_BJ Bk-0.8
0_BZ Bk-1.0 YFN 29.3 at 20°C GND_S1 GND_S2 SPL_BCK_LT_GD
GND_PDST GND_PDST2
0_BG Bk-0.8

sht5,SPL_DCUG B 0_B1 Bk-0.8 E 0_B5 Bk-0.8

0_BJ Bk-0.8

GND_WIF
0_BH Bk-0.8

sht11,SPL_ENG` D

0_AP Bk-5.0

0_AP Bk-5.0
0_BS Bk-1.0 A 0_B4 Bk-0.8
C 0_B3 Bk-0.8 sht10,SPE
0_BU Bk-1.0 HEAT SPL_PED_BL_GD sht10,SPL_BCK_LT_GD2
61H_A Or-1.0 1 1 61H_B Or-1.0 1 1 B 0_B2 Bk-0.8 sht10,SRTD
0_BBF Bk-3.0 0_HW Bk-1.0 0_BAR Bk-1.0 LOAD VALVE
0_LD Bk-1.0 2 2 0_LE Bk-1.0 2 2 A 0_B31 Bk-0.8 sht8,SDA
0_BA Bk-5.0 SOLENOID
sht11,SPL_ENG sht9,RECT sht11,GND_ENG3 YLV YLV2 YLV3 39.3 at 20°C SPL_BCK_LT_GD2
sht9,GND_WIF sht9,ENG sht9,ENG sht9,ENG sht9,GND_ENG6 sht9,GND_ENG6
sht9,GND_ENG6 sht10,SPC sht6,SHZ sht9,SPB sht10,SFL sht10,SHC
sht9,GND_ENG6
CHASSIS GROUND `
CHASSIS GROUND
DEDICATED GRND DEDICATED GRND

INSTRUMENT CLUSTER 9 MACHINE CONTROLS 10

UNSWITCHED POWER sht10,ECC
sht9,ECA sht10,ECA IGN POWER sht9,ECC sht8,ECC
sht 12 sht12,ECA ACC POWER sht12,ECA sht6,ECA UNSWITCHED POWER
, ECA ILLUM POWER
sht4,PRMB_L1 IGN POWER sht11,ECA sht11,ECA sht7,ECA
ACC POWER sht6,ECA
sht11,ECA sht7,SPL_BCK_LGT
J4 BUSS-ECA
J5 BUSS-ECA

ILLUM POWER sht4,PRM_A1

15 AMP
19Y_B Or-1.0 J19 BUSS-ECA 19L Or-3.0
J12 BUSS-ECA

A B
J18 BUSS-ECA

J12 BUSS-ECA
7.5 AMP J15 BUSS-ECA J18 BUSS-ECA
J17 BUSS-ECA

J13 BUSS-ECA

L2_8 C8 CNV
J17 BUSS-ECA CIGAR LIGHTER 24V

J11 BUSS-ECA
AIC_2 SPL_CNV CNV 24V TO 12V PWR CONVERTER
A B 19RR Or-0.8 15 AMP ECA-F18 (OPTION) 19L_A Or-2.0 1
15 AMP 1 +24V
L1_4
EMERG STRG
A4
EMERGENCY SPL_HOOD A B 19N Or-1.0
19L_B Or-2.0 2
2 ACC 121

J9_ECC BUSS-'
J7_ECC BUSS-' A B 19Y Or-1.0 3
ECA-F4 / ALT D+ 10 AMP 25 AMP AIC_2 L2_6 C6 3 GROUND
7.5 AMP L1_7 A7 SEAT COMPRESSOR SPL_12V 4
LOW HOOD CONTROL A B 19J Or-0.8 A B
4 +12V(MEMORY)
ECA-F16 (OPTION) 12V_C Or-2.0 5
11 ECC-F7 (OPTION) AC 5 +12V(SWITCHED)
A B 19M Or-0.8 L2_2 C2 L2_1 C1 19W Or-3.0 0_ER Bk-1.0 6
L2_7 C7 FRONT WIPER/WSH BLOWER MOTOR 6 GROUND OPT
J16 BUSS-ECA
EMERG STRG DM 60D W-1.0 ECA-F12 ECA-F11 HIGH
SPL_FW ENG
12 10 AMP
ECA-F17 (OPTION) 19RR Or-0.8 A 59D W-1.0 1 1 CIGAR PO1
29
sht4,216F
19R_D Or-0.8
SPL_2
19R Or-0.8
B
C
113 60U W-1.0
86 30
19J_C Or-0.8
61R W-1.0
61A W-1.0
29
30
61R_B W-0.8
61A_B W-0.8
SPL_AC
61A_G W-0.8
2 2 LIGHTER
(OPTION)
12V_D Or-1.0 A
A1
B
B1
12V Or-1.0
A A POWER
ECC 30

SPL_ACP
sht12,GND_CAB_SPL CL REMOTE 12V B B OUTLET 1
DIODE 155 SPL_PK3 0_DT Bk-0.8

SPL_ACS
CAB_E C C
86 30 ECB-F1 (OPTION) 0_EK Bk-1.0 (OPTION)

18N Or-3.0
MODULE ECC 19J_D Or-0.8 19J_B Or-0.8 A/C HIGH PRESSURE SWITCH
HOOD DOWN 19J_E Or-0.8 61A_D W-1.0 A A CLOSES W/ PRESS ABOVE 27.6± 0.7 bar
SPL_19S
K2 SFWW SFWW FRONT WIPER/WASHER
61R_D W-1.0
B B OPENS W/ PRESS BELOW 20.7±0.7 bar Seat heater B B
10 AMP sht12,GND_CAB5 122
86 30 PO2
19Y_A Or-1.0

HOOD UP (OPTION) ECD 1 1 NONE (OPTION) add A A 19N Or-1.0 12V_E Or-1.0 A B 12V_A Or-1.0
19R_E Or-0.8

PRH
K1
104

61A_CW- 1.0
2 2 GROUND 1 61A_F W-0.8 SPL_BLWR SC A2 B2 A A POWER
19S2 Or-1.0
35X Y-0.8

SEAT REMOTE 12V

19M Or-0.8

(OPTION) 3 HVAC1 2 86 30 12V_F Or-1.0 B B OUTLET 2

3 LOW SPEED CONTROL
85 87A87
129 ECD COMP

61R_C W-1.0
FRONT WIPER HS 4 3 18N_A
49A S-0.8Or-0.8 10 AMP ECB-F2 (OPTION) C C (OPTION)
154
4 NONE
128 MOTOR
19J_G Or-0.8
19S1 Or-3.0

19Y_B Or-1.0 K1 5 5 15 KEY POWER 4 61B_A W-0.8

85 87A87
6 6 NONE AIR COND
AIR SEAT
OPTION
A
A9
B
B9
15 AMP
122
CAB_T A/C LOW PRESSURE SWITCH 12V_G Or-1.0 A B
34626
63W W-0.8 7 7 FRONT WASHER K5 ONLY RADIO 12V
49_T S-0.8 8 8 ILLUMINATION 8 8 61A_E W-1.0 A A OPENS W/ PRESS ABOVE 1.4± 0.2 bar ECB-F9 (OPTION) A10 B10
0_B25 Bk-1.0

SPL_HC
85 87A87
126 TWO WAY RADIO (OPTION)
19Y_C Or-1.0

TRANS 34626
30 30 63HC W-0.8 9 9 HIGH SPEED CONTROL 7 7 61R_E W-1.0 B B CLOSES W/ PRESS BELOW 0.3± 0.1 bar

12V_B Or-1.0
60D W-1.0
59D W-1.0
60U W-1.0
59U W-1.0

87 87 63HC_B W-0.8 10 10 (OPTION)

ACT ECB-F10 (OPTION)
0_B22 Bk-1.0

NONE ENG_B BTM_E PRL

sht4,PRMB_L2 87a 87A 11 11 85 87A87
NONE
85 85 63HC_A W-0.8 108 12 12 NONE 1 18N_B Or-3.0 CAB_RF
ROOF RADIO JUMPER SUPPLIED WITH RADIO
19M_A Or-1.0

sht12,GND_CAB4 RAD RAD_J1 RAD_J3

2 0_ED Bk-3.0 A/C
19R_A Or-1.0

86 86 CAB_E ENG
19S1_E Or-1.0

SSD CABE2
35X_B Y-1.0

J10_ECC BUSS-`
TUVWX 19J_F Or-0.8 J14 BUSS-ECA HVAC2 SW_PD SW_PD COMPRESSOR 0_EN Bk-0.8 8 8 Bk/W-0.8 5 5
0_CH Bk-1.0 A KWCO sht8,TECM M M
ENG2 TUVWX WIPER CUT J13 BUSS-ECA 61C Or-0.8 2 2 61C_A Or-1.0 CLUTCH 12V_HA Or-0.8 7 7 G/W-0.8 12 12
B
C
114 OUT RELAY 105 63C3 W-0.8
10 AMP
SW_PAD SW_PAD sht8,TECM
(OPTION)
N N
SPL_RAD 6 6 14 14
0_B25 Bk-1.0 A B 19K Or-1.0 31 31 20G_A W-0.8 0_DK Bk-1.0 12V_H Or-0.8 5 5 13 13
DIODE SPL_HOOD_GRND
ECD
86 30
L2_3 C3 CAN_HI CAN_LO 130 12V_HB Or-0.8 4 4 Or/W-0.8 7 7
60D_A W-1.0
51_D W-1.0

MODULE sht10,SPL_BCK_LGT2 REAR WIPER/WASH sht5,EDC7 6 6 12V ISO TOP CAB

59U_A W-1.0 0_B12 Bk-1.0 A 7 8
0_CG Bk-1.0

CAN_HD Y-0.8
63H_B W-0.8

CAN_LD G-0.8
ECA-F13 3 3
19Y_D Or-1.0

B B
63C2 W-0.8

0_B16 Bk-1.0 B LEFT 0_PA Bk-0.8 8 8 R/Bk-0.8 GROUND

10 10 RADIO
AIC_1
TR_SS ABCDEF TRANS 60U_A W-1.0 0_B22 Bk-1.0 C FRONT WIPER LS AIC_1 0_DJ Bk-0.8 SPEAKER A A 65L Or-0.8 7 7 R-0.8 123 WELD
SS_TR AFEDCB SEC STEER sht7,SPL_BCK_LT_GD 4 4STUD

CAN_LF G-0.8
D K2 0_B23 Bk-0.8 0_DH Bk-0.8 0_DH Bk-0.8 6 6 W/Bk-0.8
10 AMP
125

CAN_HF Y-0.8
CAN
59D_A W-1.0 0_B10 Bk-1.0 E 106 SRWP
sht7,SPL_BCK_LGT
CAN
A B
LSPK 5
4
5
4
W-0.8
U/Bk-0.8
11 11
2 2
51_B W-1.0 F 77 49_C S-0.8 CAN_LO
63L_B W-0.8

1_ND R-62 8 8 CAN_HI L1_9 A9 3 3 U-0.8 9 9

85 87A87 SPL_RWW 4 DIAGNOSTIC
sht4,B4 55 19K_B Or-0.8 3 RIGHT B B 0_PB Bk-0.8 2 2 Y/Bk-0.8 1 1
244F ECC-F9
19S1_X Or-1.0
35X_C Y-1.0

SPEAKER A A 65R Or-0.8 1 1 Y-0.8 8 8

19R_C Or-1.0

19Y_D Or-1.0 10 SPL_CAN_L SPL_CAN_TRANS_L

SSS CAN_LG G-0.8 CAN_LE G-0.8

18K_A Or-0.8
68W W-0.8

63LC W-0.8
63L_B W-0.8 66
9
68W W-0.8 124 RSPK SPK RAD_J2 7.5 AMP
19K_C Or-1.0

A B 18V Or-1.0
63W W-0.8

245F 11 68C Or-1.0 SPL_CAN SPL_CAN_TRANS

NOT PL10 4 CAN_HG Y-0.8 CAN_HE Y-0.8 CAN_HC Y-0.8 L2_5 C5

CAN_LC G-0.8
SPL_WHS MIRROR HEAT
A A 63H_A W-0.8 33 19K_A Or-1.0 TRLY TIMER RELAY 69F W-1.0
115 1 ``
FRONT B B 63L_A W-0.8
SPL_WLS
22 68L Or-1.0
sht5,DIA_2
119 1 SIGNAL 1 87 0_VC Bk-1.0 ECA-F15

M M C 2 GROUND 2 87A SPL2

60D_A W-1.0

AA WIPER 19J_A Or-0.8 19J_A Or-0.8 SPL_PK1

60U_A W-1.0

C
242F
117 SPL_SS
51_C W-1.0
SEC. STRG.
3 C C 59U_A W-1.0 MOTOR D D 63C W-0.8 CAB_E REAR WIPER SWITCH
107 18K_B Or-0.8 DIA
A
DIA DIAGNOSTIC 3 BATT B+ 3 30
85
18V_B Or-1.0 18V_A Or-1.0 A A
1 A 2 BB FWM 2524 A GROUND 4 OUT NC 4 SPL_1
SOLENOID 2524 B B DIAG_FUSED_PWR 5 OUT 5 86 B B sht12,GND_CAB_SPL
SECONDARY 2 B
HOOD SWITCH 109 1 A 0_B8 Bk-0.8
140M
ENG
REAR SPL_CAN_DIAG 18K_D Or-0.8
C
69_A W-1.0 0_VB Bk-1.0 0_VA Bk-1.0
(OPTION) HD FWMG
111 CAN_HB Y-0.8 C CAN_HIGH TRLY
M
STEERING MOTOR 68W_A W-1.0 1 1 WASHER TIMER RELAY
YSS
127 49Y_A S-0.8 sht10,SPL_BCK_LGT2

20G_B W-0.8
39.3 AT 20°C HDM SPL_CAN_DIAG_L CAN_LB G-0.8 D D CAN_LOW M02 BA 292XX 49Y_B S-0.8 C C
(OPTION) A A 2 2
156 63H_C W-0.8 MOTOR
63W_A W-1.0

12 20G_B W-0.8 E E DIAG_ISO_K_LINE MH_C MH

sht12,GND_CAB_SPL 63L_C W-0.8 B B RWW ` MHS
1 2 F F SPL3
116 sht10,SPL_D26
0_EE Bk-0.8
58_D W-0.8
C
D
C
D
G G 10 10 69_B W-1.0
2 pin grommet
H H 7 7 0_VE Bk-1.0 MIRROR

CAN_HL Y-0.8
68L Or-1.0

SSM SEC STR MOD BLUEBROWN E E FRONT

J J 8 8 49Y_B S-0.8 69_D W-1.0 1 1 HEATER
M 112
F F 63W_A W-1.0 1 1 WASHER

CAN_LY G-0.8
1 1 SEC_STR_IGNITION M 68L_C Or-1.0 2 2
2 2 1 0_VJ Bk-1.0 30 WATTS
51_A W-1.0 2 2 SEC_STR_MTR_REL 0_B Bk-1.0 MOTOR
3 3 SEC_STR_MOD_B+
DOWNUP
LIMITLIMIT
SWITCHSWITCH
113 DIODE MODULE
FWW ` sht4,SPL_TEL
0_DU Bk-0.8 6
5 MH_R
X
4 4 SEC_STR_CHASSIS_GRND 0_BL Bk-1.0 sht5,SPL_CAN_GH 4
5 0_B Bk-1.0 SPL_CAN_JS_H1 SPL_CAN_JS_H2 SPL_CAN_TEL 18U_F Or-0.8 M MIRROR
5 NONE SPL_ENG CAN_HA Y-0.8 CAN_HN Y-0.8 CAN_HJ Y-0.8 TEL TELEMATICS 9 9 0_VD Bk-1.0 69_E W-1.0 1 1 HEATER
0_B10 Bk-1.0

sht10,SPL_FAN TEL L
6 6 NONE 0_BS Bk-1.0 SPL_3 sht5,SPL_CAN_GL sht10,SPL_D24 2 2
SPL_CAN_JS_L1 SPL_CAN_JS_L2 SPL_CAN_TEL2 A A B+ BATT K 3 3 69F W-1.0 0_VH Bk-1.0 30 WATTS
CHASSIS CONNECTION SPL_C3 19M_C Or-1.0 7 7 SEC_STR_ACCESSORY HOOD 68L_C Or-1.0
CAN_LA G-0.8 CAN_LQ G-0.8 CAN_LH G-0.8 19C_E Or-0.8 B B OPEN J 0_DK Bk-1.0 2 2 18V_C Or-1.0
NEAR MOTOR/PUMP
GROUND
SPL_SEC 0_CF Bk-1.0 35X_D Y-1.0 8 8 SEC_STR_LOW_PRES_SIG NOT PL10 MOTOR 157 0_BM Bk-1.0
sht4,SPL_ALT C C B+ KEY SW H 0_VA Bk-1.0 sht12,MH 2 pin grommet MH_L
X
51P_A W-1.0 9 9 SEC_STR_HIGH_PRES MIRROR HEAT SWITCH
14_AC LG-0.8 D D ALT D+ G 0_DT Bk-0.8
0_CC Bk-1.0 10 10 NONE 0_BY Y-1.0 A A

CAN_HH Y-0.8
ON ENG BLOCK L 67A Or-0.8 E E WORK IN F

CAN_LM G-0.8
0_CA Bk-1.0 11 REAR B B 68L_A Or-1.0 L 68L_B Or-1.0
11 SEC_STR_SIGNAL_GRD RIGHT NEAR STARTER
110113113113 M J sht9,SPL_PTM F F OPEN E 23B_C Bk-0.8 sht5,ECD 0_EJ Bk-1.0

CAN_HR Y-0.8
0_CB Bk-1.0 12 12 SEC_STR_SIGNAL_GRD WIPER C C 19K_D Or-1.0 J 19K_C Or-1.0 sht6,SRHSTLK RIGHT
CONSOLE K G G OPEN D 0_EL Bk-1.0
0_CD Bk-1.0

MOTOR D D 68C_A Or-1.0 K 68C Or-1.0 CONSOLE

SSM
RWM 0_L Bk-1.0 gxl H H GRND C 0_EP Bk-0.8
GND_SSCHAS GND_CAB2 GND_ENG3 J J OPEN B 0_EM Bk-0.8 RIGHT
A 1 CAB_RF
0_MA Bk-1.0 sht9,CAB_E K OPEN CONSOLE RIGHT
SECONDARY STEERING RWMG ROOF K A
A A N.O. 1 CAN_LP G-0.8 L CAN HI
0_CC Bk-1.0 B B COM PRESSURE SWITCH
118 L GND_CAB_SPL CONSOLE
0_BM Bk-1.0

0D_C Bk-0.8
FORM C (OPTION) 12 CAN_HP Y-0.8 M M CAN LO
CHASSIS CONNECTION 35X_A Y-1.0 C C N.C. GND_CAB3 GND_CAB4 GND_CAB5
0_BBR Bk-1.0

0_EE Bk-0.8
CLOSES AT 35 PSIG (241KPA) CAN_LR G-0.8 N N OPEN
0_B26 Bk-0.8

NEAR SS MODULE
0_ND Bk-62

PSS 7 CAN_HR Y-0.8 P P OPEN

0_CE Bk-1.0

0_ED Bk-3.0
GROUND

0_EK Bk-1.0
JSS_CAB R R OPEN
0_CD Bk-1.0 GND_SSMOD CONNECT TO CAB_ARM_FRM,
CAN 21J W-0.8 S S RESTART PREVENT
0_DG Bk-1.0
0_B8 Bk-0.8 sht9,ENG_B SHEE SHEET 12, ZONE 3D COMMUNICATION sht4,ECC sht5,DIA_2 0_DV Bk-3.0
sht9,PAF sht7,SPL_ROOF
CHASSIS GROUND sht9,SPL_BUZ sht10,YPP sht11,140M sht11,SFWW sht12,HVAC2 sht12,PO1
DEDICATED GRND CHASSIS GROUND
DEDICATED GRND

HOOD LIFT 11 HVAC AIR SEAT RADIO POWER/CONVERTER 12

ELECTRICAL SCHEMATIC SIDE 3
621F TIER 3 WHEEL LOADER
Additional copies of this schematic can be ordered through Technical Publications Distribution System.
 UNSWITCHED POWER 145
IGN POWER
ACC POWER DNS_ELECT_WATER_VALVE_S
ILLUM POWER
175942200:BRIGLIA
144 M

COLL. STEPPER MOTOR

CAN_MOD_2 CAN_MOD_2 CAN_MOD_2 CAN_MOD_2 CAN_MOD_2 CAN_MOD_2 CAN_MOD_2 CAN_MOD_2 CAN_MOD_2 CAN_MOD_2
DNS_DRIVER
JSS JSS NEUTRAL JSS VALVE ARMREST ``` ```` ```` ``` ``` DNS_RESISTOR
ACT SW
XX
OUTPUT
XX
N.C. SW
XX
FEEDBACK
XX
RAISE
XX
````
````
CAN
HIGH
CAN
LOW
B+
```
GROUND
``` 86 30
143 KOSTAL
JSS_RLY 61 5 4 3 2
1 2 3 4 5 6 7 8 9 10 DNS_ACTUATOR
4 5 2 10 11 3 12 13 6 1 14 7 8 9 6 51 4 3 2
146
M.LOCK070-PM
184

51B_E W-0.8
0_SE Bk-0.8

M
17P_E Bk-0.8
4521011312136114789 654321 12345
51B_J Bk-0.8

CANS_HA Y-0.8

CANS_LA G-0.8
M.LOCK070-PF

51S_D Bk-0.8
51PW_U Bk-0.8

51NC Bk-0.8
51R Bk-0.8 85 87A87 56

DNS51 OrW-0.5
DNS50 Or-0.5

DNS52 Bk-0.5

DNS55 U-0.5
DNS53 N-0.5
DNS49 K-0.5
DNS48 R-0.5

DNS54 S-0.5
177 S113 LOW
3

DNS48 R-0.5
DNS49 K-0.5

DNS63 LUBk-1.5
1

DNS64 LUR-1.5
DNS62 GBk-1.5
JOYSTICK
175 2

DNS60 Or-0.5
GND
PVRES 1

DNS61 S-1.0
RAISE CANS_HA Y-0.8 1 CANS_HB Y-0.8

51PW_P W-0.8
CANS_LA G-0.8 12 12 CANS_LB G-0.8
ARM_POS

51D_B Bk-0.8
DNS59 WBk-0.5

51B_G W-0.8
51E_B Or-0.8 51E_B Or-0.8 3 3 51E_A Or-0.8
17P_E Bk-0.8 4 4 17P_D Or-0.8 DNS58 WR-0.5
SPL_JSS_10
0_SH Bk-0.8 2 2 0_SJ Bk-0.8 DNS57 WU-0.5
0_SG Bk-0.8 DNS56 WG-0.5
51B_J Bk-0.8 6 6 51B_H W-0.8
A 0_SC Bk-0.8 7 7 0_SD Bk-0.8
B SPL_JSS_13
51PW_S W-0.8 8 8 51PW_R W-0.8
SPL_JSS_15
51S_C W-0.8 9 9 51S_B W-0.8
A 10
B S 51H_C Y-0.8 10 51H_B Y-0.8
51NO Y-0.8 11 11 51NO_A P-0.8

VEHICLE SIDE
5 5
SPL_JSS_21 SPL_JSS_7
5 32J_G Y-0.8 32J_F Y-0.8 5 JSS_ARM CAB_ARM

HVAC
6 25Y_F LU-0.8 25Y_D LU-0.8 6 SPL_JSS_6
U+ + US1 + U- NC TO 197M 1 0_SS Bk-0.8 19B_A W-0.8 1 51PW_W W-0.8 17P_C Or-0.8 sht9,SPL_SW_PD
51PW_V W-0.8
51NC Bk-0.8

SHEET 7 TO 197F
2 26F_D LU-0.8 26F_C LU-0.8 2
147
STANDARD
SHEET 7 AIC_1
4 26R_D LU-0.8 16R_C LU-0.8 4
R U+ VOLTAGE SOURCE SGNL

SPL_JSS_4
W NC NEUTRAL SWITCH NC
+ NEUTRAL SWITCH NO

3 A3 3
Us1 SGNL VOLTAGE S1

26N_D LU-0.8 26N_C LU-0.8

+ JSS POWER SUPPLY

C3 JSS sht4,GND_CAB_SPL2 ``S3_S

DENSO BOX DNS65 UR-2.5

U- GROUND
PVRES JSS JOYSTICK

JSS_197F B3 A3 JSS_197M
A3 M

51PW_Q W-0.8
C3 C3 RELAY DNS66 Bk-2.5

51B_K W-0.8
21

0_BBC Bk-0.8
B3

0_SD Bk-0.8
RVS_DIODE B3
TRANS

51E_A Or-0.8

0_SL Bk-0.8
DNS_ELECTRIC_FAN
KICK-DOWN KD_DIODE
176

51PW_T W-0.8
51S_E W-0.8

1 2 SWITCH A3 FWD_DIODE

185 JOYSTICK STR SW

0_SC Bk-0.8

` C3

51D_A Bk-0.8
B3 (OPTION) DNS_THERMOSTAT_1
1 2 SPL_JSS_1
25Y_E LU-0.8 30 17P_D Or-0.8 0_BBE Bk-0.8 9 9
U

86
V
T
S

21M 12 FNR_RLY 1 DNS67 G-0.5 DNS67 G-0.5 1

10 10
PVRES RSTUVW
25Y_G LU-0.8
NTRL_DIODE
26R_E LU-0.8
26F_E LU-0.8 SPL_JSS_18
17P_G Or-0.8 2 2
51PW_N W-0.8
51C_A Y-0.8 5 5
2 DNS76 Or-0.5 148
19B_D Or-0.8 26N_E LU-0.8 ```` SPL_JSS_5 3 3 0_BBA Bk-0.8 4 4 HVAC1 3 DNS69 YBk-0.5 1
4
SAJ
25Y_G LU-0.8
179 51D_B Bk-0.8
51B_D W-0.8
4 4
5 5 51B_C W-0.8
SPL_JSS_2
51B_B W-0.8 6 6
DNS77 Y-0.5
SPL_JSS_9
7 7 32J_J Y-0.8 0_SK Bk-0.8 8 8 0_BBD Bk-0.8 1 1 DNS_HVAC1_S DNS_THERMOSTAT_2
```S2_S
8 8 19B_F Or-0.8 SPL_AJ 51PW_M W-0.8 9 9 51PW_N W-0.8

DNS78 Y-0.5
5 5 19B_E Or-0.8 5 5 32J_H Y-0.8 85 87A87 51C_B Y-0.8 10 10 51C_A Y-0.8 51B_A W-0.8 3 3 CLOSED ABOVE 5±1C
4 4 19B_D Or-0.8 6 6 25Y_E LU-0.8 0_SS Bk-0.8 18S_D Or-0.8 11 11 18S_C Or-0.8 18S_B Or-0.8 2 2
``S1_S OPEN BELOW 0±1C
51NO Y-0.8 9 19B_C Or-0.8 1 1 19B_B Or-0.8 19B_B Or-0.8 0_BBB Bk-0.8 7 7
6 6 26F_F LU-0.8 2 2 26F_E LU-0.8 CAB_ARM_FRM JSS_CAB 49_W S-0.8 8 8 HVAC2 2
1
DNS75 Bk-2.5
51H_C Y-0.8 1 1 26R_F LU-0.8 4 4 26R_E LU-0.8 0_ST Bk-0.8 DNS74 LU-2.5
SJS
10 3 3 26N_E LU-0.8 ``S4_S
3 3 26N_F LU-0.8 51F_A G-1.0 CANS_LB G-0.8 1 CONNECT TO sht10,SPL_PED_BL DNS_HVAC2_S
ARM_FNR CAB_FNR SPL_JSS_3
178 2 2 26K LU-0.8 51F_C G-1.0 A A 51F_B G-0.8 SPL_JSS_11 CANS_HB Y-0.8 12 JSS_CAB, 18S_A Or-0.8 (C4)

DNS63 LUBk-1.5
B B

DNS62 GBk-1.5
51J_C P-1.0 51J_A P-0.8 CANS_LD G-0.8 6 SHEET 11, 10 AMP

DNS74 LU-2.5

DNS73 UR-2.5

DNS72 Or-0.5
F-N-R SWITCH

DNS71 Bk-0.5
J3 BUSS-ECA

DNS53 N-0.5
DNS55 U-0.5
C C

DNS54 S-0.5
51K_C G-1.0 51K_B G-0.8 CANS_HD Y-0.8 7

DNS61 S-1.0
ZONE 11B

DNS51 OrW-0.5
(OPTION) A B

DNS68 Y-0.5

DNS69 YBk-0.5
sht9,ECA

DNS70 Bk-0.5
51L Y-1.0 D D 51L_A Y-0.8

51J_D P-0.8
CAB_ARM_FRM L1_2 A2

0_SU Bk-0.8
VOLTAGE SIGNAL 1 U S1 1 51L Y-1.0 E E JSS
VOLTAGE SOURCE SIG. 4 51S_J W-1.0 51S_J W-1.0 F F 51S_F W-0.8 SPL_JSS_14 R1 J2 BUSS-ECA
U+ ECA-F2
ALRAM ALM 2 51J_C P-1.0 0_AS Bk-1.0 G G 0_SF Bk-0.8 820 OHMS sht8, ECA
2W 5% JSS_CNT JSS_CNT JSS CONTROLLER
GROUND U - 3 0_AT Bk-1.0 51PW_H W-1.0 H H 51PW_T W-0.8
18S_E Or-1.0 J J 18S_D Or-0.8 AB CANS_HD Y-0.8 1 1 CAN HI
JSS_VALVE
181 K K CANS_LD G-0.8 2
3
2
3
CAN LO
B+
SPL_JSS_17 JSS_FRM CAB_FRM 0_SP Bk-0.8 17P_F Or-0.8
0_AU Bk-1.0 51H_B Y-0.8 4 4 PVRES SIG
51PW_K W-1.0 LOAD SENSE A A A 51S_A W-0.8 5 5 PVG 32/PVRES SOURCE SIG 12345 1234 21 12345
6 6 ARMREST LOWER
182 PRESSURE B B
C C
B
C
51E_A Or-0.8
51L_A Y-0.8 7 7 PVG SIGNAL S1
0 1 2 3 4
SENSOR 153

0_SR Bk-0.8
PILOT DUMP 8
1 1
VALVE JSS_LS2 JMP2 51K_B G-0.8 8 PILOT PRESS SW
149 151
2 2 SPL_JSS_16 SPL_JSS_20 51PW_Q W-0.8 9 9 K2:30 150
JSS_PIL_DUMP 180 51PW_L W-1.0 0_SM Bk-0.8 10
11
10 GROUND
0_SN Bk-0.8 11 GROUND
51J_B P-0.8 12 12 VALVE ALARM
PL18 ONLY
183 51C_B Y-0.8 13 13 JSS ACT BUTTON DNS_SPEED_SELECTOR DNS_AC_SWITCH
152 DNS_RECIRCULATING_SWITCH
51K_C G-1.0 B B PILOT 51NO_A P-0.8 14 14 JSS NUETRAL N.O. DNS_CTRL_PANEL_LIGHT
18S_E Or-1.0 A A PRESSURE SWITCH 0_SR Bk-0.8 15 15 JOYSTICK GND
GND_JSS 16 16 LS PRESS NOT USED ON DNS_WATER_VALVE_POT
51F_A G-1.0 B B JSS_PIL_PR 51F_B G-0.8 HEATER ONLY UNITS
51PW_J W-1.0 A A 51F_D BK-0.8
0_AV Bk-1.0 JSS_LS
JMP1 51PW_X W-0.8 186
CHASSIS GROUND
DEDICATED GRND HVAC CONTROL PANEL

JOYSTICK STEERING 13 STANDARD HVAC 14

COMPONENT NUMBERS
# SHT COMPONENT # SHT COMPONENT # SHT COMPONENT # SHT COMPONENT
1 4 STARTING RELAY 61 8 DIAGNOSTIC CONNECTOR 119 12 DIAGNOSTIC CONNECTOR 177 13 ARM POS
2 4 RESISTOR - 75 OHM 62 1 INSTRUMENT CLUSTER CONNECTOR 1 121 12 POW ER CONVERTER - 24 TO 12 VOLT 178 13 FNR SW ITCH (OPTION)
3 4 ALTERNATOR 63 9 W ARNING BUZZER 122 12 12 VOLT POW ER OUTLETS (OPTION) 179 13 FNR RELAY
4 4 CRANK CONTROL RELAY 64 9 PARKING BRAKE RELAY 123 12 RADIO 180 13 PILOT DUMP VALVE
5 4 BATTERIES 65 9 FUEL LEVEL SENDER 124 12 RIGHT SPEAKER 181 13 JSS VALVE
6 4 CRANK REQUEST RELAY 66 9 AIR FILTER RESTRICTION SW ITCH 125 12 LEFT SPEAKER 182 13 LOAD SENSE PRESSURE SENSOR
8 4 MASTER DISCONNECT SW ITCH 67 9 PARKING BRAKE SOLENOID 126 12 AIR SEAT 183 13 PILOT PRESSURE SW ITCH
9 4 STARTER 68 9 RADIATOR COOLANT TEMPERATURE SENDER 127 12 TIMER RELAY 184 13 JSS RELAY
10 4 IGNITION SW ITCH 69 9 BRAKE PRESSURE W ARNING SW ITCH 128 12 AIR CONDITIONING CLUTCH RELAY 185 13 JOYSTICK STR SW ITCH (OPTION)
11 4 NEUTRAL START RELAY 70 1 SW ITCH PAD 129 12 AIR CONDITIONING HIGH-LOW PRESSURE SW ITCH 186 13 JSS CONTROLLER
13 4 POW ER RELAY MODULE A 71 1 INSTRUMENT CLUSTER CONNECTOR 2 130 12 AIR CONDITIONING COMPRESSOR CLUTCH
14 4 POW ER RELAY MODULE B 72 9 HYDRAULIC FILTER RESTRICTION SW ITCH 131 NA ELECTRONIC PANEL
15 4 POW ER RELAY MODULE C 73 9 HYDRAULIC OIL TEMPERATURE SENDER 132 NA EXTERNAL AIR TEMPERATURE SENSOR
16 4 GRID HEATER RELAY 74 9 PARK BRAKE SW ITCH 133 NA INTERNAL AIR TEMPERATURE SENSOR
17 4 GRID HEATER 75 9 REDUNDANT BRAKE PRESSURE SW ITCH 1 134 NA SUN SENSOR
18 4 POW ER RELAY MODULE D 76 9 REDUNDANT BRAKE PRESSURE SW ITCH 2 135 NA BLOW ER FAN RESISTOR
20 4 W ATER SEPARATOR HEATER 78 6 BACKUP ALARM RELAY 136 NA BLOW ER MOTORS
21 4 FUEL FILTER HEATER 79 6 BACKUP ALARM DISABLE SW ITCH 137 NA THERMOCOUPLE SENSOR
22 5 W ATER IN FUEL SENSOR 80 7 W ORK LAMPS SW ITCH 138 NA MIXED AIR SENSOR
23 5 THROTTLE POTENTIOMETER 81 7 DOOR SW ITCH 139 NA COMPRESSOR RELAY
24 5 ENGINE CONTROLLER 82 7 ROTATING BEACON (OPTIONAL) 140 NA RECYCLING MOTOR
25 10 RETURN TO TRAVEL FLOAT SW ITCH 83 7 DOME LAMP 141 NA ELECTRONIC W ATER VALVE
621F Tier 3 Wheel Loader 26 10 HEIGHT CONTROL SW ITCH
ELECTROMAGNETIC DETENTS
84 7 ROTATING BEACON SW ITCH (OPTIONAL) 142 NA 24 TO 12 VOLT CONVERTER
27 10 85 7 LEFT HAND FRONT W ORK LAMP 143 14 ACTUATOR
ELECTRICAL SCHEMATIC 28 10 RETURN TO DIG PROXIMITY SW ITCH 86 7 RIGHT HAND FRONT W ORK LAMP 144 14 DRIVER
29 10 PILOT CONTROL RELAY ECD-K3 87 7 LEFT HAND REAR W ORK LAMP 145 14 ELECTRONIC W ATER VALVE
30 10 HEIGHT CONTROL AND RETURN TO TRAVEL PROXIMITY SW 88 7 RIGHT HAND REAR W ORK LAMP 146 14 BLOW ER FAN RESISTOR
31 10 RETURN TO DIG SW ITCH 89 7 DIODES 147 14 BLOW ER MOTOR
32 10 PIN ENGAGE SW ITCH (OPTION) 90 6 BRAKE LAMP SW ITCH 148 14 THERMOSTAT
LEGEND 33 10 PILOT PRESSURE SOLENOID 91 6 BRAKE LAMP RELAY 149 14 FAN SPEED SW ITCH
34 10 PIN ENGAGE SOLENOID (OPTION) 92 6 FLASHER MODULE 150 14 AIR CONDITIONING SW ITCH
35 10 RIDE CONTROL SW ITCH (OPTION) 93 6 HAZARD SW ITCH 151 14 CONTROL PANEL LAMPS
36 10 RIDE CONTROL RELAY (OPTION) 94 6 TURN SIGNAL, HIGH-LOW BEAM, AND HORN SW ITCH 152 14 W ATER VALVE POTENTIOMETER
INDICATES CONSTANT POWER 37 10 FAN CONTROL SW ITCH (OPTION) 95 6 DRIVING LAMPS SW ITCH 153 14 AIR RECIRCULATING SW ITCH
38 10 FAN REVERSE RELAY (OPTION) 96 6 LEFT HAND FRONT COMBINATION LAMPS 154 11 HOOD UP RELAY
INDICATES POWER WHEN KEY 39 10 PILOT CONTROL SW ITCH 97 6 RIGHT HAND FRONT COMBINATION LAMPS 155 11 HOOD DOW N RELAY
40 10 RIDE CONTROL SOLENOID (OPTION) 98 10 HORN RELAY 156 11 HOOD SW ITCH
SWITCH IS ON 41 10 ROLLBACK PRESSURE SW (XT W ITH RIDE CONTROL ONLY) 99 10 HORN RELAY 157 11 HOOD MOTOR
INDICATES POWER WHEN KEY 42 10 ROLLBACK JUMPER 100 6 RIGHT HAND REAR COMBINATION LAMPS 158 4 IGNITION POW ER LATCH
43 10 FAN PW M SOLENOID 101 6 LEFT HAND REAR COMBINATION LAMPS 159 4 IGNITION POW ER CONTROL
SWITCH IS IN START POSITION 44 10 FAN REVERSE SOLENOID (OPTION) 102 6 LICENSE PLATE LAMP 160 4 START LOCKOUT
45 8 OUTPUT SPEED SENSOR 103 6 BACKUP ALARM 161 5 NOX SENSOR
46 8 TRANSMISSION SOLENOID VALVE AND TEMP SENDER 104 11 FRONT W IPER HIGH SPEED RELAY 162 5 HUMIDITY AND AMBIENT TEMPERATURE SENSOR
POWER RELAY A 47 8 FILTER MAINTENANCE SW ITCH 105 11 W IPER CUTOUT RELAY 163 5 NOX SENSOR (NOXS)
POWER RELAY B 48 8 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 106 11 FRONT W IPER LOW SPEED RELAY 164 5 TANK HEATER CONTROL VALVE
49 8 ENGINE SPEED SENSOR 107 11 REAR W IPER AND W ASHER SW ITCH 165 5 DEF LEVEL AND TANK TEMPERATURE
POWER RELAY C 50 8 INTERMEDIATE SPEED SENSOR 108 11 FRONT W IPER AND W ASHER SW ITCH 166 5 UPSTREAM TEMPERATURE SENSOR
51 8 TURBINE SPEED SENSOR 109 11 FRONT W IPER MOTOR 167 5 DOW NSTREAM TEMPERATURE SENSOR
POWER RELAY D 52 8 TRANSMISSION SHIFTER 110 11 REAR W IPER MOTOR 168 5 DOSER METERING VALVE
53 8 TRANSMISSION ELECTRONIC CONTROL MODULE 111 11 REAR W ASHER MOTOR 169 5 DNOX CONTROLLER
ILLUMINATION 54 8 TRANSMISSION ENABLE SW ITCH 112 11 FRONT W ASHER MOTOR 170 7 REAR VIEW CAMERA/MONITOR
55 8 FNR SW ITCH FOR JOYSTICK CONTROLS 113 11 DIODES 171 8 DIFFERENTIAL LOCK SW ITCH (MANUAL)
56 8 TRANSMISSION KICK DOW N SW ITCH 114 11 SECONDARY STEERING DIODES 172 8 DIFFERENTIAL LOCK SW ITCH
57 8 FNR SW ITCH FOR SINGLE AXIS CONTROLS 115 11 SECONDARY STEERING SOLENOID 173 8 DIFFERENTIAL LOCK SOLENOID
58 8 TRANSMISSION AUTO SW ITCH 116 11 SECONDARY STEERING MODULE 174 8 LOCKUP SOLENOID
59 8 BRAKE DECLUTCH PRESSURE SW ITCH 117 11 SECONDARY STEERING MOTOR 175 13 JOYSTICK PVRES
60 8 DECLUTCH SW ITCH 118 11 SECONDARY STEERING PRESSURE SW ITCH 176 13 TRANSMISSION KICK DOW N SW ITCH

ELECTRICAL WIRING INFORMATION 15 COMPONENT NUMBERING INFORMATION 16

ELECTRICAL SCHEMATIC SIDE 4
621F TIER 3 WHEEL LOADER
Additional copies of this schematic can be ordered through Technical Publications Distribution System.
 14 15
7 a1
17 19
YPP
P 16

UNLOCK
T X2
6

LOCK
MX
1 2 b1
a2
T

8
280 BAR

5 13
b2
R R1 F a3
YRC
3 YPB

OPTIONAL
CUT IN
157-167 BAR
CUT OUT b3

AUXILIARYAUXILIARY
X
190-196 BAR a4
B A

OPTIONAL
4 P

20 b4 18
T1

9 T1'
N B

A3 B3B4 A4
T2
a2 a3 OPTIONAL
AUXILIARY
a4

889868
889868

889868
a1 A1 B1 A2 B2

ø2.0
ø2.0

ø2.0
ø0.8
ø0.8

ø0.8
R2
SX LS S
10

)(
1.8

......
......
0.8 )(

40 bar
12

14 mm^2
P 217
bar

227 bar
)(
TP11: REAR BRAKE TO AXLE

30 bar

......

......

......

......
TP10: FRONT BRAKE TO AXLE
S

0.7 L/min
11
)(

0.6
TP6: FRONT BRAKE ACCUMULATOR

45 bar
TP7: REAR BRAKE ACCUMULATOR

TP9: PILOT PRESSURE SUPPLY

TP3: LOAD SENSE SIGNAL

T

6.7 bar
TP1: STEERING PRESSURE

857047
21

290 bar

290 bar
290 bar
290 bar
936467
TP5: MAIN PUMP PRESSURE

936467

936467
936467
936467
290 bar

290 bar

936467
M2 P

33 34
YFN
b1

ø0.8

ø0.8
889868

ø0.8

889868
ø2.0

889868

ø2.0
ø2.0
M2 162 BAR IN
234 BAR

23cc
b2 b3 b4
M1 TANK
35
234 BAR

L
STANDARD FAN YFR

26
CONTROL
P
B X
M1 FAN REVERSE T
.71
DELTA = 24 BAR
OPTION
CUTOFF = 280 BAR LS 22

R
T
24 ORB-20 Orbitrol
5.5 LS SLS ST CF
2 983 CC PER REV 23
BAR
27
PVFC
10 MICRON 23cc YSS
0.7 3

MEDIA PSS R L

32 BYPASS
3.4 BAR 31 A10VO85
0.31
0.31
1 LS SIGNAL

37
0.32 LITER FROM
90 cc/rev 38
240BAR
60 BAR JOYSTICK
PHF P T
WARNING SW PRECHARGE
.75
2.7 BAR S L1 L P PVG 32 PIL_PR
WITH PVES 8 BAR
100 MESH T P SET POINT
.03 BAR CHECK JSSLSR 1.4

.35 BAR RELIEF

25
p
11cc

30
SIGNAL TO
PRESSURE KEYPAD

36
REDUCER PIL_DUMP C5.E
T

65 LITER
VENT CHECK

0.25
29 28 BAR
1. Rear Axle Brakes 8. Low Brake Pressure Warning Switch 18. Ride Control (Option) 25. Auxiliary Steering Pump 32. Oil Cooler Thermal Valve
2. Front axle Brakes 9. Brake Declutch 19. Ride Control Accumulator 26. Main Hydraulic Pump 33. Oil Cooler
3. Parking Brake 10. Brake Light Pressure Switch 3.78 Liter (4 Quart) Cut Off 280 BAR (4061 PSI) 34. Oil Cooler Fan
4. Brake Valve 11. Front Brake Accumulator 14.5 BAR (210 PSI) Precharge Delta 21 BAR (304 PSI) 35. Fan Reversing and Variable Valve
5. Parking Brake Accumulator 3.5 Liter (3.69 Quart) 20. Pilot Control Accumulator 27. Brake Pump 36. Steering Back Pressure Valve
0.16 Liter (0.17 Quart) 70 BAR (1015 PSI) Precharge 0.75 Liter (0.79 Quart) 28. 100 MESH Strainers (Reservoir) 8 - 10 BAR (116 - 145 PSI)
96 BAR (1392 PSI) Precharge 12. Redundant Accumulator Brake 13.8 BAR (200 PSI) Precharge 29. Reservoir 37. Steering Control Valve PVG 32
CIRCUIT DIAGRAM LEGEND 6. Rear Brake Accumulator Pressure Switch 21. Loader Valve 30. Reservoir Vent (Option)
3.5 Liter (3.69 Quart) 13. Coupler Solenoid Locking Valve 22. Steering Cylinders 31. Filter 10 Micron Media 38. LS Joystick Steering Valve
70 BAR (1015 PSI) Precharge 14. Coupler Locking Cylinders 23. Steering Control Valve Bypass 3.4 BAR (49.3 PSI) (Option)
RETURN / SUCTION PUMP SUPPLY 7. Redundant Accumulator Brake 15. Pilot Control Valve 24. Auxiliary Steering Control Valve Warning Switch 2.7 BAR
Pressure Switch 16. Bucket Cylinder Z BAR/XR Models (Option) (39 PSI)
LOAD SENSE 17. Lift Cylinders
CIRCUIT
HYDRAULIC SCHEMATIC
SHOWS CIRCUIT PILOT
CROSSING SHOWS CIRCUIT
COMPONENT WHEEL LOADER
CONNECTED CHECK VALVE RESTRICTOR OIL COOLER
NOT CONNECTED FILTER OR SCREEN LINE TYPES 621F / Z-BAR / XR MODELS
 14 15
7 a1
16 17 19
YPP
P

UNLOCK
T X2
6

LOCK
MX
1 2 b1
a2
T

8
280 BAR

5 13
b2
R R1 F a3
YRC
3 YPB

OPTIONAL
CUT IN
157-167 BAR
CUT OUT b3

AUXILIARYAUXILIARY
X
190-196 BAR a4
B A

OPTIONAL
4 P

20 b4 18
T1

9 T1'
N B

A3 B3B4 A4
T2
a2 a3 OPTIONAL
AUXILIARY
a4

889868
889868

889868
a1 A1 B1 A2 B2

ø2.0
ø2.0

ø2.0
ø0.8
ø0.8

ø0.8
R2
SX LS S
10

)(
1.8

......
......
0.8 )(

40 bar
12

14 mm^2
P 217
bar

227 bar
)(
TP11: REAR BRAKE TO AXLE

30 bar

......

......

......

......
TP10: FRONT BRAKE TO AXLE
S

0.7 L/min
11
)(

0.6
TP6: FRONT BRAKE ACCUMULATOR

45 bar
TP7: REAR BRAKE ACCUMULATOR

TP9: PILOT PRESSURE SUPPLY

TP3: LOAD SENSE SIGNAL

T

6.7 bar
TP1: STEERING PRESSURE

857047
21

290 bar

290 bar
290 bar
290 bar
936467
TP5: MAIN PUMP PRESSURE

936467

936467
936467
936467
290 bar

290 bar

936467
M2 P

33 34
YFN
b1

ø0.8

ø0.8
889868

ø0.8

889868
ø2.0

889868

ø2.0
ø2.0
M2 162 BAR IN
234 BAR

23cc
b2 b3 b4
M1 TANK
35
234 BAR

L
STANDARD FAN YFR

26
CONTROL
P
B X
M1 FAN REVERSE T
.71
DELTA = 24 BAR
OPTION
CUTOFF = 280 BAR LS 22

R
T
24 ORB-20 Orbitrol
5.5 LS SLS ST CF
2 983 CC PER REV 23
BAR
27
PVFC
10 MICRON 23cc YSS
0.7 3

MEDIA PSS R L

32 BYPASS
3.4 BAR 31 A10VO85
0.31
0.31
1 LS SIGNAL

37
0.32 LITER FROM
90 cc/rev 38
240BAR
60 BAR JOYSTICK
PHF P T
WARNING SW PRECHARGE
.75
2.7 BAR S L1 L P PVG 32 PIL_PR
WITH PVES 8 BAR
100 MESH T P SET POINT
.03 BAR CHECK JSSLSR 1.4

.35 BAR RELIEF

25
p
11cc

30
SIGNAL TO
PRESSURE KEYPAD

36
REDUCER PIL_DUMP C5.E
T

65 LITER
VENT CHECK

0.25
29 28 BAR
1. Rear Axle Brakes 8. Low Brake Pressure Warning Switch 18. Ride Control (Option) 25. Auxiliary Steering Pump 32. Oil Cooler Thermal Valve
2. Front axle Brakes 9. Brake Declutch 19. Ride Control Accumulator 26. Main Hydraulic Pump 33. Oil Cooler
3. Parking Brake 10. Brake Light Pressure Switch 3.78 Liter (4 Quart) Cut Off 280 BAR (4061 PSI) 34. Oil Cooler Fan
4. Brake Valve 11. Front Brake Accumulator 14.5 BAR (210 PSI) Precharge Delta 21 BAR (304 PSI) 35. Fan Reversing and Variable Valve
5. Parking Brake Accumulator 3.5 Liter (3.69 Quart) 20. Pilot Control Accumulator 27. Brake Pump 36. Steering Back Pressure Valve
0.16 Liter (0.17 Quart) 70 BAR (1015 PSI) Precharge 0.75 Liter (0.79 Quart) 28. 100 MESH Strainers (Reservoir) 8 - 10 BAR (116 - 145 PSI)
96 BAR (1392 PSI) Precharge 12. Redundant Accumulator Brake 13.8 BAR (200 PSI) Precharge 29. Reservoir 37. Steering Control Valve PVG 32
CIRCUIT DIAGRAM LEGEND 6. Rear Brake Accumulator Pressure Switch 21. Loader Valve 30. Reservoir Vent (Option)
3.5 Liter (3.69 Quart) 13. Coupler Solenoid Locking Valve 22. Steering Cylinders 31. Filter 10 Micron Media 38. LS Joystick Steering Valve
70 BAR (1015 PSI) Precharge 14. Coupler Locking Cylinders 23. Steering Control Valve Bypass 3.4 BAR (49.3 PSI) (Option)
RETURN / SUCTION PUMP SUPPLY 7. Redundant Accumulator Brake 15. Pilot Control Valve 24. Auxiliary Steering Control Valve Warning Switch 2.7 BAR
Pressure Switch 16. Bucket Cylinders TC Models (Option) (39 PSI)
LOAD SENSE 17. Lift Cylinders
CIRCUIT
HYDRAULIC SCHEMATIC
SHOWS CIRCUIT PILOT
CROSSING SHOWS CIRCUIT
COMPONENT WHEEL LOADER
CONNECTED CHECK VALVE RESTRICTOR OIL COOLER
NOT CONNECTED FILTER OR SCREEN LINE TYPES 621F / TC MODELS