Manual de Servicio PDF

Copyright
521D Loader
Service Manual
6-40742
Table of Contents
Description
Section No.
General
Form No.
Tab 1
Section Index - General
6-42730
Standard Torque Specifications
1001
8-71602
Fluids and Lubricants
1002
6-40762
Metric Conversion Chart
1003
7-52950
Loctite Product Chart
8-98902
Engines
Tab 2
Section Index - Engines
6-42281
Engine and Radiator Removal and Installation
2000
6-42290
Engine and Radiator Removal and Installation P.I.N. JEE0135501 and Above
2000
6-48920
Stall Tests
2002
6-40770
For Engine Repair, See the Engine Service Manual

Fuel System
Tab 3
Section Index - Fuel System
6-42300
For Fuel System Repair, See the Engine Service Manual

Electrical
Tab 4
Section Index - Electrical
6-42311
Removal and Installation of Starter and Alternator
4001
6-42321
Electrical Specifications and Troubleshooting
4002
6-40782
Electrical Specifications and Troubleshooting P.I.N. JEE0135501 and Above
4002
6-48930
Batteries
4003
6-42330
Information and Diagnostic Center
4005
6-42351
Alternator - 65 Ampere
4007
7-12260
Alternator - 45 Ampere
4008
6-42360
Steering
Tab 5
Section Index - Steering
6-42370
Removal and Installation of Steering Components
5001
6-42380
Steering Specifications, Pressure Checks, and Troubleshooting
5002
6-40790
Steering Control Valve
5003
6-42390
Steering Priority Valve
5004
6-42400
Steering Cylinders
5005
6-42410
Center Pivot
5006
6-42420
Auxiliary Steering Motor and Pump
5008
6-42430
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION
3350 South Service Road
Hamilton, ON L7N 3M6 CANADA
Bur 6-42722
Copyright 2003 Case Corporation

Printed in U.S.A.
August, 2001 (Revised February, 2003)
Copyright
521D Loader
Service Manual
6-40742
Table of Contents
Description
Power Train
Section No.
Form No.
Tab 6
Section Index - Power Train
6-42442
Removal and Installation of Power Train Components
6001
6-42451
Transmission Specifications, Pressure Checks, and Troubleshooting
6002
6-40800
Transmission
6003
6-42460
Front and Rear Axle
6004
6-42470
Front and Rear Axle P.I.N. JEE0135501 and Above
6004
6-48970
Drive Shafts, Center Bearing, and Universal Joints
6005
6-42480
Wheels and Tires
6006
6-42490
Transmission Control Valve
6007
6-42500
Brakes
Tab 7
Section Index - Brakes
6-42510
Removal and Installation of Brake Components
7001
6-42521
Hydraulic Brake Troubleshooting
7002
6-40811
Brake Accumulators
7004
6-42531
Parking Brake
7008
6-42540
NOTE: For parking brake and brake pedal adjustments, see Section 9001.
Hydraulics
Tab 8
Section Index - Hydraulics
6-42550
Removal and Installation of Hydraulic Components
8001
6-42560
Hydraulic Specifications, Troubleshooting, and Pressure Checks
8002
6-40820
Cleaning the Hydraulic System
8003
7-49640
Cylinders
8006
6-42590
Coupler Solenoid Locking Valve
8007
6-42600
Pilot Pressure Accumulator and Ride Control Accumulator
8013
6-42621
Mounted Equipment
Tab 9
Section Index - Mounted Equipment
6-42640
Pedals and Levers
9001
6-40830
Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a
Refrigerant
9002
6-42650
Air Conditioner System Service
9003
6-42660
Removal and Installation of Air Conditioning Components For Systems with

HFC-134a Refrigerant
9004
6-42671
Loader
9006
6-42690
ROPS Cab and ROPS Canopy
9007
6-42700
Cab Glass Installation
9010
6-42710
Bur 6-42722
Revised 2-03
Printed in U.S.A.
Copyright
521D Loader
Service Manual
6-40742
Table of Contents
Description
Section No.
Form No.
Electrical Schematic Foldouts and Hydraulic Schematic Foldout
In Rear Pocket
6-40841
Electrical Schematic Foldouts and Hydraulic Schematic Foldout P.I.N

JEE0135501 and Above
In Rear Pocket
6-49280
NOTE: Case Corporation reserves the right to make improvements in design or

changes in specifications at any time without incurring any obligation to install
them on units previously sold.
CASE CORPORATION
700 State Street
Bur 6-42722

Printed in U.S.A.
Copyright
Copyright
SECTION INDEX
GENERAL
Section Title
Section Number
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Loctite Product Chart
CASE CORPORATION
700 State Street
Bur 6-42730

Printed in U.S.A.
August, 2001
Copyright
1001
Copyright
Section
1001
STANDARD TORQUE SPECIFICATIONS
CASE CORPORATION
700 State Street
450 Sherman Avenue
Hamilton, ON L8N 4C4 CANADA
Rac 8-71602
1999 Case Corporation

Printed in U.S.A.
Revised May, 1999
Copyright
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
NOTE: Case Corporation reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install
them on units previously sold.
Rac 8-71602
Revised 5-99
Printed in U.S.A
Copyright
1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques are not
given. These torques apply to fasteners with both UNC and
UNF threads as received from suppliers dr y, or when
lubricated with engine oil. Not applicable if special graphities,
Molydisulfide greases, or other extreme pressure lubricants
are used.
Grade 8 Bolts, Nuts, and Studs
PoundInches
Newton
metres
1/4 inch
144 to 180
16 to 20
5/16 inch
288 to 348
33 to 39
3/8 inch
540 to 648
61 to 73
PoundFeet
Newton
metres
Size
Grade 5 Bolts, Nuts, and Studs
Size
PoundInches
Newton
metres
1/4 inch
108 to 132
12 to 15
Size
5/16 inch
204 to 252
23 to 28
7/16 inch
70 to 84
95 to 114
3/8 inch
420 to 504
48 to 57
1/2 inch
110 to 132
149 to 179
9/16 inch
160 to 192
217 to 260
Newton
metres
5/8 inch
220 to 264
298 to 358
Size
PoundFeet
3/4 inch
380 to 456
515 to 618
7/16 inch
54 to 64
73 to 87
7/8 inch
600 to 720
814 to 976
1/2 inch
80 to 96
109 to 130
1.0 inch
900 to 1080
1220 to 1465
9/16 inch
110 to 132
149 to 179
1-1/8 inch
1280 to 1440
1736 to 1953
5/8 inch
150 to 180
203 to 244
1-1/4 inch
1820 to 2000
2468 to 2712
3/4 inch
270 to 324
366 to 439
1-3/8 inch
2380 to 2720
3227 to 3688
7/8 inch
400 to 480
542 to 651
1-1/2 inch
3160 to 3560
4285 to 4827
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
Rac 8-71602
NOTE: Use thick nuts with Grade 8 bolts.
Revised 5-99
Printed in U.S.A
Copyright
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 when lubricated
with engine oil. These values do not apply if graphite or
Molydisulfide grease or oil is used.

8.8
10.9
Size
PoundInches
Newton
metres
M4
36 to 48
4 to 5
M5
84 to 96
9 to 11
M6
132 to 156
15 to 18
M8
324 to 384
37 to 43
Size
PoundFeet
Newton
metres
M10
54 to 64
73 to 87
M12
93 to 112
125 to 150
M14
149 to 179
200 to 245
M16
230 to 280
310 to 380
M20
450 to 540
610 to 730
M24
780 to 940
1050 to 1275
Size
PoundInches
Newton
metres
M4
24 to 36
3 to 4
M5
60 to 72
7 to 8
M6
96 to 108
11 to 12
M8
228 to 276
26 to 31
M10
456 to 540
52 to 61
Size
PoundFeet
Newton
metres
M12
66 to 79
90 to 107
M30
1470 to 1770
2000 to 2400
M14
106 to 127
144 to 172
M36
2580 to 3090
3500 to 4200
M16
160 to 200
217 to 271
M20
320 to 380
434 to 515
M24
500 to 600
675 to 815
M30
920 to 1100
1250 to 1500
M36
1600 to 1950
2175 to 2600

12.9
Usually the torque values specified for grade 10.9 fasteners

can be used satisfactorily on grade 12.9 fasteners.
Rac 8-71602
Revised 5-99
Printed in U.S.A
Copyright
1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube OD
Hose ID
Thread
Size
PoundInches
Newton
metres
Tube OD
Hose ID
37 Degree Flare Fitting
Thread
Size
PoundInches
Newton
metres
Straight Threads with O-ring
1/4 inch
6.4 mm
7/16-20
72 to 144
8 to 16
1/4 inch
6.4 mm
7/16-20
144 to 228
16 to 26
5/16 inch
7.9 mm
1/2-20
96 to 192
11 to 22
5/16 inch
7.9 mm
1/2-20
192 to 300
22 to 34
3/8 inch
9.5 mm
9/16-18
120 to 300
14 to 34
3/8 inch
9.5 mm
9/16-18
300 to 480
34 to 54
1/2 inch
12.7 mm
3/4-16
180 to 504
20 to 57
1/2 inch
12.7 mm
3/4-16
540 to 804
57 to 91
5/8 inch
15.9 mm
7/8-14
300 to 696
34 to 79
Tube OD
Hose ID
Thread
Size
PoundInches
Newton
metres
Tube OD
Hose ID
Thread
Size
PoundInches
Newton
metres
5/8 inch
15.9 mm
7/8-14
58 to 92
79 to 124
3/4 inch
19.0 mm
1-1/16-12
40 to 80
54 to 108
3/4 inch
19.0 mm
1-1/16-12
80 to 128
108 to 174
7/8 inch
22.2 mm
1-3/16-12
60 to 100
81 to 135
7/8 inch
22.2 mm
1-3/16-12
100 to 160
136 to 216
1.0 inch
25.4 mm
1-5/16-12
75 to 117
102 to 158
1.0 inch
25.4 mm
1-5/16-12
117 to 187
159 to 253
1-1/4 inch
31.8 mm
1-5/8-12
125 to 165
169 to 223
1-1/4 inch
31.8 mm
1-5/8-12
165 to 264
224 to 357
1-1/2 inch
38.1 mm
1-7/8-12
210 to 250
285 to 338
1-1/2 inch
38.1 mm
1-7/8-12
250 to 400
339 to 542
Split Flange Mounting Bolts

PoundInches
Newton
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
Size
PoundFeet
Newton
metres
1/2-13
55 to 65
74 to 88
5/8-11
140 to 150
190 to 203
Size
Rac 8-71602
Revised 5-99
Printed in U.S.A
Copyright
1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Nom.
SAE
Dash
Size
Tube OD
Thread
Size
PoundInches
Newton
metres
Thread
Size
PoundInches
Newton
metres
O-ring Boss End

Fitting or Lock Nut
O-ring Face Seal End

-4
1/4 inch
6.4 mm
9/16-18
120 to 144
14 to 16
7/16-20
204 to 240
23 to 27
-6
3/8 inch
9.5 mm
11/16-16
216 to 240
24 to 27
9/16-18
300 to 360
34 to 41
-8
1/2 inch
12.7 mm
13/16-16
384 to 480
43 to 54
3/4-16
540 to 600
61 to 68
Thread
Size
PoundInches
Newton
metres
7/8-14
60 to 65
81 to 88
1-1/16-12
85 to 90
115 to 122
-10
Nom.
SAE
Dash
Size
5/8 inch
15.9 mm
Tube OD
1-14
552 to 672
62 to 76
Thread
Size
PoundInches
Newton
metres
1-3/16-12
95 to 100
129 to 136
-12
3/4 inch
19.0 mm
1-3/16-12
65 to 80
90 to 110
1-5/16-12
115 to 125
156 to 169
-14
7/8 inch
22.2 mm
1-3/16-12
65 to 80
90 to 110
1-5/8-12
150 to 160
203 to 217
-16
1.0 inch
25.4 mm
1-7/16-12
92 to 105
125 to 140
1-7/8-12
190 to 200
258 to 271
-20
1-1/4 inch
31.8 mm
1-11/16-12
125 to 140
170 to 190
-24
1-1/2 inch
38.1 mm
2-12
150 to 180
200 to 254
Rac 8-71602
Revised 5-99
Printed in U.S.A
1002
Copyright
Section
1002
FLUIDS AND LUBRICANTS
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA
Bur 6-40762

Printed in U.S.A.
March, 2001 (Revised June, 2002)
Copyright
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION FORMULAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-40762
Revised 6-02
3
3
4
5
5
5
6
6
7
7
Printed in U.S.A.
Copyright
1002-3
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ......................................................................................... 11.3 litres (12 U.S. quarts)
Type of oil ..................................................... Case No. 1 engine oil - see engine oil recommendations on page 4
Engine Cooling System
Capacity........................................................................................................................ 34.1 litres (36 U.S. quarts)
Type of Coolant ................ Ethylene glycol and water mixed for lowest ambient temperature (at least 50/50 mix)
Fuel Tank
Capacity ...................................................................................................................... 189 litres (50 U.S. gallons)
Type of Fuel ............................................................................................ See Diesel fuel specifications on page 5
Hydraulic System
Hydraulic Reservoir Refill Capacity with Filter Change ................................................. 68.5 litres (72 U.S. quarts)
Total System Capacity........................................................................................................113.6 litres (30 gallons)
Type of Oil ...................................................................................................................... MS-1209 Hy-Tran Ultra
Transmission
Refill Capacity with Filter Change ................................................................................. 18.9 litres (20 U.S. quarts)
Total System Capacity................................................................................................... 26 litres (27.5 U.S. quarts)
Type of Oil ...................................................................................................................... MS-1209 Hy-Tran Ultra
Axles
Capacity
Front..................................................................................................................................21.8 litres (23 quarts)
Rear ..................................................................................................................................20.8 litres (22 quarts)
Type of Lubricant.............................................................................................................................. SAE 80W140
Brake System
Type of Fluid (Same as Hydraulic System)............................................................... MS-1209 Hy-Tran Ultra
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.
CONVERSION FORMULAS
Imperial quart = litres x 0.879877
Imperial gallons = litres x 0.219969
Bur 6-40762
Revised 6-02
Printed in U.S.A.
Copyright
1002-4
ENGINE OIL RECOMMENDATIONS

Case IH No. 1 Engine oil is recommended for use
in your Case engine. Case IH No. 1 Engine Oil will
lubricate your engine correctly under all operating
conditions.
If C ase No. 1 Multi-Viscosity or Single G rad e
Engine Oil is not available, use only oil meeting
API engine oil service category CH .
See the chart below for
r e c o m m e n d e d v i s c o s it y a t
ambient air temperature
ranges.
RH99K130
NOTE: Do not put performance

additives or other oil additive
products
in
the
engine
crankcase. The oil change
intervals given in this manual
are according to tests with Case
lubricants.
BP99J241
BS99M162
Bur 6-40762
Revised 6-02
Printed in U.S.A.
Copyright
1002-5
DIESEL FUEL SYSTEM

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

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

API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60C (140F)
Cloud point (wax appearance point), maximum ...........................................................-20C (-5F) See Note above
Pour point, maximum ..................................................................................................-26C (-15F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338C (540 to 640F)
Viscosity, at 38C (100F)
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%
Bur 6-40762
Revised 6-02
Printed in U.S.A.
Copyright
1002-6
MAINTENANCE SCHEDULE
Model 521D
Instructions
AS REQUIRED
22 SERVICE THE AIR CLEANER IF THE AIR CLEANER WARNING LAMP ILLUMINATES................................... SEE OPERATORS MANUAL
30 REPLACE THE TRANSMISSION FILTER
IF THE TRANSMISSION FILTER RESTRICTION WARNING LAMP ILLUMINATES ......................................................... USE CASE FILTER
19 CHECK THE RADIATOR COOLANT LEVEL IF THE WARNING LAMP ILLUMINATES ...................................... SEE OPERATORS MANUAL
6.REPLACE THE HYDRAULIC FILTER IF THE HYDRAULIC FILTER WARNING LAMP ILLUMINATES............................... USE CASE FILTER
CHECK THE AIR CONDITIONING DRIVE TENSION (IF EQUIPPED) NOT SHOWN ...............................................ADJUST AS REQUIRED
EVERY 10 HOURS OF OPERATION OR EACH DAY - WHICHEVER OCCURS FIRST

16 CHECK THE ENGINE OIL LEVEL........................................................................................................................ SEE OPERATORS MANUAL
EVERY 50 HOURS OF OPERATION

1.CHECK THE COOLANT RESERVOIR FLUID LEVEL ................................................................................. ETHYLENE GLYCOL AND WATER
29 CHECK THE TRANSMISSION OIL LEVEL (ENGINE RUNNING AND OIL WARM)............................................ SEE OPERATORS MANUAL
5.CHECK THE HYDRAULIC RESERVOIR FLUID LEVEL ........................................................................................ SEE OPERATORS MANUAL
38.LUBRICATE THE BUCKET AND BELLCRANK PIVOT POINTS (10 FITTINGS) XT .................................. CASE MOLYDISULFIDE GREASE
39 LUBRICATE THE BELLCRANK AND BUCKET PIVOTS (6 FITTINGS) Z-BAR .......................................... CASE MOLYDISULFIDE GREASE

7.LUBRICATE THE STEERING CYLINDER PIVOTS - ROD AND CLOSED END (4 FITTINGS) ................... CASE MOLYDISULFIDE GREASE
40 LUBRICATE THE LOADER LIFT ARM AND CYLINDER PIVOTS (7 FITTINGS) Z-BAR............................ CASE MOLYDISULFIDE GREASE
26 LUBRICATE THE FRONT DRIVE SHAFT SUPPPORT BEARING (1 FITTING) ......................................... CASE MOLYDISULFIDE GREASE
8.LUBRICATE THE LOADER LIFT ARM AND CYLINDER PIVOTS (14 FITTINGS) XT .................................. CASE MOLYDISULFIDE GREASE

19 CHECK THE RADIATOR COOLANT LEVEL.............................................................................................. ETHYLENE GLYCOL AND WATER
2.CHANGE THE ENGINE OIL AND REPLACE THE ENGINE OIL FILTER.............................................................. SEE OPERATORS MANUAL
34 CHECK THE BATTERY FLUID LEVEL................................................................................................................. SEE OPERATORS MANUAL
36 CHECK THE TIRE CONDITION AND AIR PRESSURE....................................................................................... SEE OPERATORS MANUAL
12 CLEAN THE CAB AIR FILTERS (IF EQUIPPED) ................................................................................................. SEE OPERATORS MANUAL

3.REPLACE THE FUEL FILTER .............................................................................................................................................. USE CASE FILTER
33 DRAIN WATER AND SEDIMENT FROM THE FUEL TANK ................................................................................. SEE OPERATORS MANUAL
14 REPLACE THE IN-LINE FUEL FILTER ............................................................................................................................... USE CASE FILTER

21 CHECK THE ENGINE VALVE CLEARANCES ............................................................................................................SEE SERVICE MANUAL
6.REPLACE THE HYDRAULIC FILTER ................................................................................................................................... USE CASE FILTER
30 REPLACE THE TRANSMISSION OIL FILTER .................................................................................................................... USE CASE FILTER
28 CHANGE THE TRANSMISSION OIL.................................................................................................................... SEE OPERATORS MANUAL
23 CLEAN THE TRANSMISSION BREATHER ................................................................................................................CLEAN WITH SOLVENT
24 LUBRICATE THE UPPER AND LOWER CHASSIS PIVOTS (2 FITTINGS) ............................................... CASE MOLYDISULFIDE GREASE
31 CHANGE THE FRONT/REAR AXLE OIL ............................................................................................................. SEE OPERATORS MANUAL
EVERY 2000 HOURS OF OPERATION OR EACH YEAR - WHICHEVER OCCURS FIRST

4.CHANGE THE HYDRAULIC OIL ............................................................................................................................ SEE OPERATORS MANUAL
18 DRAIN, FLUSH AND REFILL THE ENGINE COOLING SYSTEM ............................................................. ETHYLENE GLYCOL AND WATER
22 REPLACE THE AIR CLEANER ELEMENTS .....................................................................................................................USE CASE FILTERS
Bur 6-40762
Revised 6-02
Printed in U.S.A.
Copyright
1002-7
MAINTENANCE SCHEDULE
Model 521D
12
19
1
14
40
3
16
34
33
6
36
39
23
36
28
30
5
22
38
21
2
34
31
26
39
29
24
31
7
4
18
38
BS01B021
If you operate the machine in severe conditions,

lubricate and service the machine more frequently. It
is recommended that you see your Case dealer for
in fo rmatio n o n the Syste m G u ard L ub ricatio n
Analysis System.
Bur 6-40762
See your Operators manual for maintenance of

safety related items and for detailed information of
the service items on this chart. Operators and
service manuals are available for this machine from
your Case dealer.
Revised 6-02
Printed in U.S.A.
Copyright
1002-8
NOTES
Bur 6-40762
Revised 6-02
Printed in U.S.A.
Copyright
1003
Section
1003
METRIC CONVERSION CHART
CASE CORPORATION
700 State Street
450 Sherman Avenue
Bur 7-52950

Printed in U.S.A.
June, 1997
Copyright
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS ............................................................................................................................................. 3
Metric to U.S. .......................................................................................................................................................... 3
U.S. to Metric ......................................................................................................................................................... 4
Bur 7-52950
Issued 6-97
Printed in U.S.A
Template Name: SM_1_col

Template Date: 1994_04_05
Alt= to hide template information

Copyright
Alt+ to display template information
1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY
BY
TO OBTAIN
Area:
sq. meter
hectare
10.763 91
2.471 05
square foot
acre
Force:
newton
newton
3.596 942
0.224 809
ounce force
pound force
Length:
millimeter
meter
kilometer
0.039 370
3.280 840
0.621 371
inch
foot
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
bar
0.145 038
14.50385
lb/sq. inch
lb/sq. inch
Temperature:
degree C
1.8 x C +32
degree F
Torque:
newton meter
newton meter
8.850 748
0.737 562
lb/inch
lb/foot
Velocity:
kilometer/hr.
0.621 371
miles/hr.
Volume:
cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre
0.061 024
35.314 66
1.307 950
0.033 814
1.056 814
0.879 877
0.264 172
0.219 969
cubic inch
cubic foot
cubic yd.
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US liquid)
gallon (Imperial)
Volume/Time:
litre/min.
litre/min.
0.264 172
0.219 969
gallon/min. (US liquid)

gallon/min. (Imperial)
Bur 7-52950
Issued 6-97
Printed in U.S.A.


Copyright
1003-4
U.S. to Metric
MULTIPLY
BY
TO OBTAIN
Area:
square foot
acre
0.092 903
0.404 686
square meter
hectare
Force:
ounce force
pound force
0.278 014
4.448 222
newton
newton
Length:
inch
foot
mile
25.4 *
0.304 8 *
1.609 344 *
millimeter
meter
kilometer
Mass:
pound
ounce
0.453 592
28.35
kilogram
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.
lbs/sq. in.
lbs/sq. in.
6.894 757
0.069
0.070 303
kilopascal
bar
kg/sq. cm
Temperature:
degree F
1.8 F - 32
degree C
Torque:
pound/inch
pound/foot
0.112 985
1.355 818
newton meter
newton meter
Velocity:
miles/hr.
1.609 344 *
kilometer/hr.
Volume:
cubic inch
cubic foot
cubic yard
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US)
gallons (Imperial)
16.387 06
0.028 317
0.764.555
29.573 53
0.946 353
1.136 523
3.785 412
4.546 092
cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre
Volume/Time:
gallon/min.
3.785 412
litre/min.
* = exact
Bur 7-52950
Issued 6-97
Printed in U.S.A.
Yellow
Clear
Blue
Purple
Purple
Brown
Blue
Red
Green
Red
Red
Green
Red
Green
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
White/Black
Clear
Clear
Clear
Brt Orange
Light Blue
Red
Purple
80
123
220
221
222
225
242
262
270
271
272
275
277
290
*404
*406
*409
*414
*415
*416
*420
*422
*430
*445
*454
*495
*496
504
509
510
515
515
454
454
454
454
495
271
271
262
620
277
222
290
222
0.004
0.005
0.030
0.020
0.020
0.010
0.010
0.010
0.005
0.005
0.007
0.007
0.007
0.010
0.010
0.003
0.006
0.004
0.008
0.006
0.010
0.010
0.002
0.020
0.005
0.250
0.005
0.003
0.005
2500 psi
2500 psi
750 psi
750 psi
1000 psi
750 psi
3200 psi
45/25 in lbs
80/50 in lbs
160/190 in lbs
160/320 in lbs
160/320 in lbs
180/220 in lbs
210/300 in lbs
225/300 in lbs
85/350 in lbs
3200 psi
3200 psi
2500 psi
2500 psi
2500 psi
2500 psi
2500 psi
2800 psi
2500 psi
2000 psi
53/30 in lbs
57/143 in lbs
75/44 in lbs
Strength
(Steel/Steel)
Printed in U.S.A.
Working
Fixture/Full Cure
Temperature
(Steel/Steel) Time
Range-Farenheit
Primer
Description
N/A Form a Gasket (works with oil, fuel or
24 hr
grease) Pliable
Fast
N/A Weatherstrip Adhesive
N/A
N/A Parts Cleaner Fluid
-65 to +250
6 min/24 hrs
747 Wicking Threadlocker
-65 to +300
2 min/24 hrs
747 Low Strength Threadlocker
Low Strength Threadlocker
-65 to +300
20 min/24 hrs
764 (Small Screws)
-65 to +300
7 min/24 hrs
747 Low Strength Threadlocker
-65 to +300
10 min/24 hrs
764 Medium Strength Threadlocker
-65 to +300
5 min/24 hrs
747 High Strength Threadlocker
-65 to +300
3 min/24 hrs
-65 to +300
10 min/24 hrs
-65 to +450
30 min/24 hrs
764 High Temperature, High Strength
-65 to +300
3 min/24 hrs
-65 to +300
60 min/24 hrs
-65 to +300
6 min/24 hrs
764 Wicking Threadlocker
-65 to +180
30 sec/24 hrs
NA
Instant Adhesive
-65 to +180
15 sec/24 hrs
N/A Surface Insensitive Adhesive
-65 to +180
50 sec/24 hrs
N/A Gel Instant Adhesive
-65 to +180
30 sec/24 hr
N/A Instant Adhesive
-65 to +180
50 sec/24 hrs
N/A Gap Filling Instant Adhesive (Metals)
-65 to +180
50 sec/24 hrs
N/A Gap Filling Instant Adhesive (Plastics)
-65 to +180
15 sec/24 hrs
N/A Wicking Instant Adhesive
-65 to +180
60 sec/24 hrs
N/A Gap Filling Instant Adhesive
-65 to +180
20 sec/24 hrs
N/A Metal Bonding Adhesive
-65 to +180
5 min/24 hrs
N/A Fast Setting 2 Part Epoxy
Surface Insensitive Gen
-65 to +180
15 sec/24 hrs
N/A Instant Adhesive
-65 to +180
20 sec/24 hrs
N/A General Purpose Instant Adhesive
-65 to +180
20 sec/24 hrs
N/A Metal Bonding Adhesive
-65 to +300
90 min/24 hrs
None Rigid Gasket Eliminator
-65 to +320
6 hr/72 hrs
764 Flange Sealant
-65 to +400
30 min/24 hrs
764 High Temperature, GAsket Eliminator
-65 to +300
1 hr/24 hrs
764 Gasket Eliminator 515
* Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity
Dark Brown
#3
Rac 8-98902
Color
Product
Similar
Gap
Products (In Inches)
LOCTITE PRODUCT CHART
Copyright
Color
Red
Brown
Purple
Orange
Red
White
Orange
Brown
Brown
Brown
White
White
Black
Green
Green
Green
Green
Green
Green
Silver
Green
Green
Clear
Amber
Amber
Amber
Yellow
Clear
Clear
Green
Silver
Product
518
542
545
549
554
567
568
569
570
571
572
592
593
601
609
620
635
638
640
660
675
680
706
707
736
738
747
751
755
764
767
N/A
609
635
755
680
680
620
640
609
504
277
592
277
545
592
592
578.575
0.010
0.015
0.007
0.020
0.005
0.015
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0.015
0.020
0.015
N/A
0.015
0.010
N/A
0.015
N/A
0.020
0.250
0.005
0.005
N/A
Similar
Gap
Products (In Inches)
515
0.030
569
N/A
Strength
(Steel/Steel)
500psi
132/92 in lbs
Printed in U.S.A.
Working
Fixture/Full Cure
Temperature
(Steel/Steel) Time
Range-Farenheit
Primer
Description
-65 to +300
1hr/24 hrs
764 Gasket Eliminator 518 for Aluminum
-65 to +300
2 hr/24 hrs
747 Hydraulic Sealant
Low Strength Pneumatic/Hydraulic
25/20 in lbs
-65 to +300
4 hr/24 hrs
747
Sealant
2500 psi
-65 to +300
2 hr/24 hrs
747 Instant Seal Plastic Gasket
240/240 in lbs
-65 to +300
2 to 4 hrs/24 hrs
764 Refrigerant Sealant
500 psi
-65 to +400
4 hrs/24 hrs
764 Pipe Sealant for Stainless Steel
2500 psi
-65 to +300
12 hrs/24 hrs
764 Plastic Gasket
40/25 in lbs
-65 to +300
1 hr/24 hrs
764 Hydraulic Sealant
25/40 in lbs
-65 to +300
6 hrs/72 hrs
764 Steam Sealant
40/20 in lbs
-65 to +300
2 to 4 hrs/24 hrs
764 Pipe Sealant
80/27 in lbs
-65 to +300
24 hrs/72 hrs
None Gasketing
500 psi
-65 to +400
4 hrs/72 hrs
736 Pipe Sealant with Teflon
400 psi
-95 to +400
30 min/24 hrs
N/A RTV Silicone
3000 psi
-65 to +300
10 min/24 hrs
764 Current PIN #609
3000 psi
-65 to +300
10 min/24 hrs
764 General Purpose Retaining Compound
High Temperature Retaining
3000 psi
-65 to +450
30 min/24 hrs
747
Compound
4000 psi
-65 to +300
1 hr/24 hrs
747 High Strength Retaining Compound
4100 psi
-65 to +300
10 min/24 hrs
3000 psi
-65 to +400
1 hr/24 hrs
747 High Temperature Retaining Compound
3000 psi
-65 to +300
20 min/24 hrs
764 Quick Metal
3000 psi
-65 to +300
20 min/24 hrs
747 General Purpose Retaining Compound
4000 psi
-65 to +300
10 min/24 hrs
N/A
N/A
N/A
N/A Cleaning Solvent
N/A
N/A
N/A
N/A Activaltor for Structural Adhesives
N/A
N/A
N/A
N/A Primer NF
N/A
N/A
N/A
N/A Depend Activator
N/A
N/A
N/A
N/A Primer T
N/A
N/A
N/A
N/A Activator for Structural Adhesives
N/A
N/A
N/A
N/A Cleaning Solvent
N/A
N/A
N/A
N/A Primer N
N/A
-65 to +1600
N/A
N/A Anti-Seize Lubricant
LOCTITE PRODUCT CHART
Copyright
Copyright
SECTION INDEX
ENGINES
Section Title
Section Number
Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000

Engine and Radiator Removal and Installation P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . .2000
Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002
FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL
CASE CORPORATION
700 State Street
Bur 6-42281

Printed in U.S.A.
Copyright
Copyright
Section
2000
CASE CORPORATION
700 State Street
Bur 6-42290

Printed in U.S.A.
August,2001
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
Copyright
2000-2
TABLE OF CONTENTS
ENGINE . . . .
Removal .
Installation
RADIATOR .
Removal .
Installation
.......
.......
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.......
.......
......
......
......
......
......
......
.......
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.......
.......
.......
.......
......
......
......
......
......
......
.......
.......
.......
.......
.......
.......
......
......
......
......
......
......
......
......
......
......
......
......
.......
.......
.......
.......
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..................
..................
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3
3
15
27
27
29
SPECIFICATIONS
Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 Liters (9 Gallons)
Engine Oil
Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Liters (11 Quarts)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Case No. 1 Engine Oil (SAE 15W-40
Hydraulic Reservoir
Refill Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 Liters (18 Gallons)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MS-1209 Hy-Tran Ultra
SPECIAL TORQUES
Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 to 298 Nm (180 to 220 lb-ft)
Engine Drive Shaft Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Radiator Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Counterweight Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693 to 780 Nm (510 to 575 lb-ft)
Counterweight Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955 to 1075 Nm (704 to 793 lb-ft)
Charge Air Tube Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Muffler Front Mounting Bracket Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 to 133 Nm (87 to 98 lb-ft)
Muffler Rear Mounting Bracket Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 39 Nm (25 to 28 lb-ft)
Turbocharger Elbow Clamp at Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 Nm (15 to 18 lb-ft)
Turbocharger Elbow Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 to 5.2 Nm (42.5 to 46 lb-inch)
Air Cleaner Hose Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Air Cleaner Inlet Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 to 4.5 Nm (32.9 to 39.6 lb-inch)
Hood Mounting Bolts at Cooling Frame Pivot Points . . . . . . . . . . . . . . . . . . . . . . . . . 36 to 45 Nm (26.5 to 32.5 lb-ft)
Screen Hinge Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 to 33 Nm (19.8 to 24.4 lb-ft)
Coupler to Flywheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-3
ENGINE
STEP 5
Removal
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.
STEP 2
BD01D141
Using a flat blade screwdriver or other suitable tool,

disengage bottom clip (1) from hood prop (2) and pull
bottom of prop from stud (3). Repeat to remove top of
prop from hood; remove prop then close hood.
STEP 6
BD00M030
Put articulation lock in LOCKED position.
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD01D142
Open screen.
STEP 7
BD01D139
Open and raise hood. Put master disconnect switch

in OFF position.
BD01D143
Remove cotter pin and three washers.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-4
STEP 8
STEP 11
5
6
4
4
BD01D144
BD01D145
Remove four bolts (4) securing hinges of screen to

hood. Disconnect prop bar (5) from screen and
remove screen.
Remove lock nut (6) securing LH spring (7) to hood.

Repeat to remove lock nut securing RH spring to
hood. Disconnect springs from hood; it may be
necessary to raise hood to disconnect springs from
hood.
STEP 9
STEP 12
BD01D255
Connect a lifting strap to the hood handle and

connect lifting equipment to strap. Depress handle
latch and let hood raise.
STEP 10
BD01D258
At front RH side of hood, identify, tag, and disconnect

hood wiring harness connector from rear chassis
wiring harness connector.
STEP 13
Lower hood.
BD01D256
Take up all slack in strap connected to hood handle.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-5
STEP 14
STEP 17
BD01D149
BD01D254
Install two lifting eyes and connect lifting strap to

eyes.
Carefully raise and remove hood from loader. Lower

hood onto suitable platform and disconnect lifting
equipment.
STEP 15
STEP 18
BD01D254
Connect lifting equipment to the lifting straps.
BD01D150
Tag and disconnect engine wiring harness connector

from air filter restriction switch.
STEP 16
STEP 19
BD01D147
Re mo ve tw o nu ts an d bo lts a nd fo ur w ashe rs
securing hood.
BD01D152
Loosen clamp on air cleaner intake hose and remove

hose.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-6
STEP 20
STEP 23
BD01D154
BD01D158
Loosen clamp on turbocharger intake hose and

disconnect hose from turbocharger.
Disconnect battery cable from LH battery negative

post. Put a plastic cap over the negative post.
STEP 21
STEP 24
BD01D155
BD01D161
Remove bolt and washer securing front of battery

cover.
Disconnect battery cable from RH battery positive

post. Put a plastic cap over the positive post.
STEP 22
STEP 25
8
9
BD01D156
BD01D162
Loosen bolt. Slide battery cover forward and remove.

Repeat Steps 21 and 22 to remove RH battery cover.
Support air cleaner assembly (9) and remove two

lock nuts, washers, bolts (8), and washers. Remove
air cleaner and support as an assembly.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-7
STEP 26
STEP 29
11
10
BD01D165
BD01D167
Remove four bolts (10) and washers securing drive

belt guard (11) to master disconnect switch mounting
bracket and belt guard bracket.
Support muffler and brackets and remove three bolts

and washers at rear of engine. Remove muffler and
brackets as an assembly from engine.
STEP 27
STEP 30
BD01D168
BD01D169
Remove clamp securing elbow to muffler.
Loosen clamp and remove tube from turbocharger.
STEP 28
STEP 31
13
12
12
BD01D166
BD01D170
At fron t o f en gin e, re move two b olts (12 ) an d

washers securing wiring harness clamps and muffler
mounting bracket (13).
Loosen two clamps. Remove tube and hose as an

assembly.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-8
STEP 32
STEP 35
14
14
15
16
15
BD01D172
BD01D178
Loosen two clamps. Remove tube and hose as an

assembly.
Remove two nuts (14) and washers and two bolts

(15), washers, and nuts. Remove counterweight (16)
from loader and place on pallet.
STEP 33
STEP 36
BD01D177
Cut, remove, and discard tie strap securing LH rear

combination lamp wire. Identify, tag, and disconnect
r e a r c h a s s i s w i r in g h a r n e s s c o n n e c t o r f r o m
combination lamp connector. Repeat this step for RH
rear combination lamp.
BD01D164
Identify, tag, and disconnect the four connectors.
STEP 37
STEP 34
18
17
BD01D173
BD01D179
Connect lifting equipment to rear counterweight.

Take up all slack in lifting equipment.
Bur 6-42290
Pull rubber boot (17) back from starter B+ terminal

(18). Remove the nut, lock washer, and flat washer
from B+ terminal. Identify, tag, and disconnect the
wires from terminal.
Issued 8-01
Printed in U.S.A.
Copyright
2000-9
STEP 38
STEP 40
BD01D250
BD01D175
Identify and tag wire connected to starter solenoid

terminal. Pull the plastic cap from starter solenoid
termin al. U sin g a Ph illips scre wdriver, lo ose n
terminal screw and disconnect wire from terminal.
Remove nut and washer from engine ground stud.

Disconnect the five ground wires of the rear chassis
wiring harness from the stud.
STEP 41
STEP 39
21
20
22
19
BD01D176
BD01D174
Remove nut (19) and washer. Disconnect ground

cables from engine ground stud. Move ground cables
away from engine. Remove bolt (20), lock washer,
and washer securing harness clamps to engine. Top
harness (21) is rear chassis wiring harness; bottom
harness (22) is engine wiring harness.
BD01D257
Route rear chassis wiring harness to front of engine.

Cut, remove, and discard two tie straps then route
harness to RH side of engine compartment and away
from engine.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-10
STEP 42
STEP 45
23
25
26
24
23
BD00M031
BD01D188
Put a 37.8 liter (10 gallon) container below radiator

drain. Remove cap and drain coolant into container.
Install cap after coolant has drained.
At top of cooling system frame, loosen two hose

clamps (23). Remove hose (24). Remove two nuts
(25) securing U-bolt (26). Remove U-bolt, clamp, and
spacer.
STEP 43
STEP 46
BD01D184
Loosen two hose clamps. Remove bottom hose.
BD01D192
Remove two nuts securing U-bolt holding top coolant

pipe. Remove U-bolt, clamp, and spacer. Remove
top coolant pipe from cooling system frame.
STEP 44
STEP 47
BD01D185
Loosen two hose clamps. Remove upper hose.

BD01D189
Put a 12.7 mm (1/2 inch) drive breaker bar or ratchet

in bracket for automatic belt tensioner. Lift up on
breaker bar or ratchet to release drive belt tension
and remove belt.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-11
STEP 48
STEP 51
28
27
29
BD01D180
BD00M031
If loader is equipped with air conditioning, identify,

tag, and disconnect the engine wiring harness
connectors from air compressor clutch connector
(27) an d high pressure switch connector (28).
Disconnect engine wiring harness connector from
disconnect switch wiring harness connector (29).
Put a 18.9 liter (5 gallon) container below engine oil

d r a in . R e m o ve c a p a n d d r a in e n g in e o il in t o
container. Install cap after oil has drained.
STEP 52
STEP 49
BD01D194
Disconnect hose from fitting installed in engine oil

pan. Install a plug in hose and a cap on fitting.
BD01D193
Support air conditioning compressor and remove four

bolts.
STEP 50
STEP 53
31
30
BD01D200
BD01D218
At front of engine, remove six bolts (30) securing

drive shaft (31) to engine coupling. Use a pry bar to
move drive shaft away from engine coupling.
Install battery cover. Put air conditioning compressor

on battery cover.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-12
STEP 54
STEP 56
32
35
36
33
37
38
34
BD01D208
BD01D210
Disconnect engine wiring harness connector (32)

f r o m t r a n s m i s s i o n w i r in g h a r n e s s b u l k h e a d
connector. Remove clamp (33) securing fuel supply
hose to engin e flywhee l housing. Remove two
clamps (34) securing fuel return hose to engine.
Cut, remove, and discard tie strap (35) securing

ether start tube (36). Move ether start tube away
from engine. Loosen clamp (37). Tag and disconnect
fuel supply hose (38) from primer pump. Plug hose
and cap fitting to prevent intrusion of foreign matter
into fuel system.
STEP 55
STEP 57
40
39
41
42
BD01D209
If equipped, disconnect ether start nozzle from intake

manifold.
Bur 6-42290
BD01D212
Remove nut and washer securing ball joint (39) to

throttle lever (40). Remove two socket head bolts
(41) and washers securing throttle bracket (42) to
engine. Move throttle bracket with throttle cable and
ball joint attached away from engine.
Issued 8-01
Printed in U.S.A.
Copyright
2000-13
STEP 58
STEP 60
44
45
43
BD01D215
BD01D217
Connect a vacuum pump to hydraulic reservoir. If a

vacuum pump is not available, drain the hydraulic oil
(hydraulic reservoir holds 68.5 liters (18 gallons) of
oil). Turn o n va cu um pump (if a va ilable). Tag,
disconnect, and plug hoses connected to brake
pump. Plug hoses securely and cap fittings. Turn off
vacuum pump. Remove clamp securing fuel return
hose to engine.
Remove nut (43), washer, and bolt securing clamp

(44) and engine oil pressure sender (45) to rear
chassis. Remove these parts as an assembly and
secure to engine using suitable means.
STEP 61
STEP 59
BD01D219
Remove two nuts and remove belt guard bracket.
STEP 62
BD01D216
Tag and disconnect fuel return hose. Plug hose and

cap fitting.
BD01D203
If e q u ip p e d , d is c o n n e ct e t h e r s t a r t s o l e n o i d
connector from engine wiring harness connector.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-14
STEP 63
STEP 65
BD01D220
BD01D181
Connect lifting equipment to engine lifting brackets.

At rear of rear chassis, between fuel tank mounting

plate and rear chassis, remove bolt and washer
securing rear of engine to rear chassis.
STEP 64
STEP 66
Slowly raise engine from rear chassis. Be sure all
harness c onnect ions and hoses hav e been
disconnected and out of the way. Remove engine
from machine.
BD01D206
At front of engine, remove nut, bolt, and two washers

securing both sides of engine to rear chassis.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-15
STEP 68
Installation
STEP 67
A
48
56
B
55
47
51
46
52
49
A
50
53
BC01D129
54
46.
47.
48.
49.
B
57
58
BC01D128
51.
52.
53.
54.
55.
RUBBER ISOLATOR
WASHER
RUBBER ISOLATOR
WASHER
WASHER
56.
57.
58.
A.
B.
BOLT
WASHER
NUT
ENGINE
REAR CHASSIS
If engine front rubber isolators require replacement,

remove and discard isolators (51 and 53). Install new
rubber isolator (53), washer (52), then rubber isolator
(51).
RUBBER ISOLATOR
SPACER
RUBBER ISOLATOR
WASHER
50. BOLT
A. ENGINE
B. REAR CHASSIS
If engine rear rubber isolators require replacement,

remove and discard isolators (46 and 48) and spacer
(47). Install new rubber isolators (46 and 48) and
spacer (47) in rear chassis.
STEP 69
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
(54) between front rubber isolator (53) and rear
chassis. Install washer (55), bolt (56), washer (57),
and nut (58) in engine front isolators. Lower engine
into position. Install washer (49) and bolt (50) in rear
isolator.
STEP 70
56
BD01D206
At front of engine, tighten two bolts (56) to a torque of

244 to 298 Nm (180 to 220 lb-ft).
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-16
STEP 71
STEP 74
50
BD01D181
BD01D219

plate and rear chassis, tighten bolt (50) to a torque of
244 to 298 Nm (180 to 220 lb-ft).
Position belt guard bracket on rear chassis and

secure using two nuts.
STEP 75
STEP 72
44
45
43
BD01D217
BD01D220
Disconnect lifting equipment from engine lifting

brackets.
Position engine oil pressure sender (45) and clamp

(44) on tab of rear chassis. Install nut (43), washer,
and bolt to secure clamp and engine oil pressure
sender to rear chassis.
STEP 73
STEP 76
BD01D203
At right side of engine compartment, connect ether

start solenoid connector to engine wiring harness
connector if equipped.
Bur 6-42290
BD01D216
Remove plug from hose and cap from fuel injection

pump fitting. Connect fuel return hose to fuel injection
pump following tag installed during removal. Position
and tighten clamp. Remove and discard tag.
Issued 8-01
Printed in U.S.A.
Copyright
2000-17
STEP 77
STEP 79
BD01D215
BD01D209
Install clamp to secure fuel return hose to engine.

Turn on vacuum pump conne cted to hydraulic
reservoir. Remove caps from fittings and plugs from
hoses. Connect hoses to brake pump following tags
installed during removal. Remove and discard tags.
Turn off and disconnect vacuum pump from hydraulic
reservoir.
If equipped, connect ether start nozzle to intake

manifold.
STEP 80
35
36
STEP 78
37
40
38
39
41
42
BD01D212
Position throttle bracket with throttle cable and ball

joint attached on engine. Install two washers and
socket head bolts (41) to secure throttle bracket (42)
to engine. Connect ball joint (39) to throttle lever (40)
and secure with nut and washer.
BD01D210
Re mo ve c ap fr om fittin g a nd p lug fr om h os e.
Connect fuel supply hose (38) to primer pump
following tag installed during removal. Position and
tighten clamp (37). Remove and discard tag. Install a
new tie strap (35) to secure ether start tube (36).
STEP 81
32
33
34
BD01D208
Position fuel return hose and secure using two

clamps (34). Position fuel supply hose and secure
using clamp (33). Connect engine wiring harness
connector (32) to transmission wiring harness
bulkhead connector.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-18
STEP 82
STEP 85
31
30
27
28
29
BD01D200
BD01D180
At front of engine, position drive shaft (31) on engine

coupling. Install six bolts (30) to secure drive shaft
(31) to engine coupling. Tighten the six bolts to a
torque of 53 to 62 Nm (39 to 46 lb-ft).
C o n n e ct e n g in e w irin g h a r n e ss c o n n e c to r t o
disconnect switch wiring harness connector (29). If
loader is equipped with air conditioning, connect the
engine wiring harness connectors to air compressor
clutch connector (27) and high pressure switch
con necto r (28 ) fo llowing ta gs installe d du rin g
removal. Remove and discard tags.
STEP 83
STEP 86
BD01D194
Remove plug from oil drain hose and cap from fitting
installed in engine oil pan. Connect and tighten hose
to fitting.
BD01D189
Route drive belt on pulleys then put a 12.7 mm (1/2

inch) drive breaker bar or ratchet in bracket for
automatic belt tensioner. Lift up on breaker bar or
ratchet and position drive belt then release belt
tensioner to put tension on drive belt.
STEP 84
BD01D193
If loader is equipped with air conditioning, position

and support air conditioning compressor and install
four bolts.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-19
STEP 87
STEP 90
BD01D192
BD01D184
Insert top coolant pipe in cooling system frame.

Install spacer, clamp, and U-bolt then install two nuts.
Do not tighten nuts at this time.
Install bottom hose. Position and tighten hose

clamps.
STEP 91
STEP 88
25
23
26
24
23
BD01D257
BD01D188
At top of cooling system frame, install spacer, clamp,

and U-bolt (26) and secure using two nuts (25). Do
not tighten nuts at this time. Install hose (24 ).
Position clamps (23) and tighten clamps to a torque
of 10.1 to 11.3 Nm (90 to 100 lb-inch). Tighten four
nuts securing two U-bolts.
STEP 89
BD01D176
Route rear chassis wiring harness around front of

engine to LH side of engine compartment. Install two
new tie straps.
BD01D185
Install upper hose. Position and tighten hose clamps.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-20
STEP 92
STEP 94
BD01D175
BD01D250
Connect the five ground wires of the rear chassis

wiring harness to the stud. Install washer and nut to
secure ground wires to engine ground stud.
Connect wire to starter solenoid terminal following

tag in sta lled du ring re mova l. Using a P hillips
screwdriver, tighten terminal screw. Install plastic cap
in terminal screw recess. Remove and discard tag.
STEP 93
STEP 95
21
20
18
22
19
17
BD01D174
Install bolt (20), lock washer, and washer to secure

harness clamps to engine. Top harness (21) is rear
chassis wiring harness; bottom harness (22) is
engine wiring harness. Connect ground cables to
engine ground stud. Install washer and nut (19) to
secure ground cables.
BD01D173
Connect wires to starter B+ terminal (18) following

tags installed during removal. Install flat washer, lock
washer, and nut to secure wires. Position rubber boot
(17) over starter B+ terminal. Remove and discard
tags from wires.
STEP 96
BD01D164
Connect connectors following tags installed during

Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-21
STEP 97
STEP 99
BD01D179
14
BD01D172
Install tube and hose as shown. Position clamps and

tighten to a torque of 10.1 to 11.3 Nm (90 to 100
lb-inch).
14
STEP 100
15
16
15
BD01D178
Move counterweight into position at rear of loader.

Install two nuts (14) and washers and two bolts (15),
washers, and nuts. Tighten nuts to a torque of 693 to
780 Nm (510 to 575 lb-ft). Tighten bolts to a torque of
955 to 1075 Nm (704 to 793 lb-ft).
BD01D170
Install tube and hose as shown. Position clamps and

lb-inch).
STEP 98
STEP 101
BD01D177
Connect rear chassis wiring harness connector to

combination lamp connector following tag installed
during removal. Install new tie strap to secure LH
rear combination lamp wire. Remove and discard
tags. Repeat this step for RH rear combination lamp.
Bur 6-42290
BD01D169
Position tube on turbocharger. Do not tighten clamp

at this time.
Issued 8-01
Printed in U.S.A.
Copyright
2000-22
STEP 102
STEP 104
BD01D167
BD01D168
Install and support muffler and brackets on engine

while connecting muffler to tube installed in Step 101.
Install three washers and bolts at rear of engine
finger tight.
Position clamp securing elbow to muffler. Tighten

clamp to a torque of 20 to 25 Nm (15 to 18 lb-ft).
Tighten clamp securing opposite end of elbow to
turbocharger to a torque of 4.8 to 5.2 Nm (42.5 to 46
lb-inch).
STEP 103
STEP 105
11
13
12
10
12
BD01D166
At front of engine, position wiring harness clamps on

muffler mounting bracket (13). Secure clamps and
muffler mounting bracket using two washers and
bolts (12). Tighten bolts to a torque of 118 to 133 Nm
(87 to 98 lb-ft). Tighten the three rear bolts installed
in Step 102 to a torque of 34 to 39 Nm (25 to 28 lb-ft).
BD01D165
Position drive belt guard (11) and secure using four

washers and bolts (10) to master disconnect switch
mounting bracket and belt guard bracket.
STEP 106
8
9
BD01D162
Position air cleaner assembly (9) and support as an

assembly. Secure using two bolts (8), four washers,
and two lock nuts.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-23
STEP 107
STEP 110
BD01D161
BD01D155
Remove plastic cap installed over the positive post

during removal. Connect battery cable to RH battery
positive post.
Install bolt and washer to secure front of battery

cover.
STEP 111
STEP 108
BD01D154
BD01D158
Remove plastic cap installed over the negative post

during removal. Connect battery cable to LH battery
negative post.
C o n n e c t h o s e f r o m a ir c l e a n e r a s s e m b ly t o
turbocharger. Position clamp and tighten to a torque
of 10.1 to 11.3 Nm (90 to 100 in-inch).
STEP 112
STEP 109
BD01D152
BD01D156
Install battery cover and slide rearward. Tighten bolt.
Bur 6-42290
Connect air cleaner hose between cooling frame and

air cleaner inlet. Position clamp and tighten to a
torque of 3.6 to 4.5 Nm (32.4 to 39.6 lb-inch).
Issued 8-01
Printed in U.S.A.
Copyright
2000-24
STEP 113
STEP 116
BD01D150
BD01D147
Connect engine wiring harness connector to air filter

restriction switch following tag installed during
removal. Remove and discard tag.
Install two bolts, four washers, and two nuts to

secure hood. Tighten bolts to a torque of 36 to 44 Nm
(26.5 to 32.5 lb-ft).
STEP 114
STEP 117
BD01D254
BD01D242
If removed, install bushings at hood pivot points on

top of cooling frame.
STEP 115
BD01D149
Lower lifting equipment until strap connected to two

lifting eyes can be removed. Remove the two lifting
eyes from hood.
BD01D254
Raise and move hood into position above loader.

Slowly and carefully lower hood into position while
guiding hood pivot points into position with pivot
points on top of cooling frame.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-25
STEP 118
STEP 122
BD01D256
BD01D255
Disconnect lifting strap from hood handle.
STEP 119
STEP 123
5
6
4
4
BD01D145
BD01D144
Connect springs (7) to hood; it may be necessary to

raise hood to connect springs. Install lock nuts (6) to
secure LH and RH springs to hood.
Position screen on hood. Install four bolts (4) to

secure hinges of screen to hood. Tighten bolts to a
torque of 27 to 33 Nm (19.8 to 24.4 lb-ft). Connect
prop bar (5) to screen.
STEP 120
STEP 124
BD01D258
At front RH side of h ood, connect hood wiring

harness connector to rear chassis wiring harness
connector following tag installed during removal.
Remove and discard tag.
BD01D143
Install three washers and cotter pin.
STEP 121
Lower hood.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-26
STEP 125
STEP 129
If hydraulic reservoir was drained, fill reservoir with
68.5 liters (18 gallons) of MS-1209 Hy-Tran Ultra
fluid.
STEP 130
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 34.1 liters (9 gallons). Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
STEP 131
BD01D142
Close screen and open hood.
STEP 126
2
3
1
BD01D140
Put master disconnect switch in ON position.
BD01D141

disengage bottom clip (1) from hood prop (2) and
push bottom of prop onto stud (3). Repeat to install
top of prop to hood.
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 132
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
a n d w a te r. W h e n th e c o o la n t is a t o p e r a ti n g
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
STEP 127
STEP 133
Lower and close hood.
STEP 134
Put articulation lock in OPERATING position.
BD00M031
Check and make sure that drain caps are tight.
STEP 128
Install a new oil filter on engine. Fill engine with 10.5
liters (11 quarts) of Case No. 1 Engine Oil (SAE
15W-40).
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-27
RADIATOR
STEP 140
Removal
STEP 135
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 136
BD01D155
Remove two bolts and washers securing LH fender.

Remove LH fender.
STEP 141
BD00M030
STEP 137
Open and raise hood.
STEP 138
BD00M031

STEP 142
BD01D139
Put master disconnect switch in OFF position.
STEP 139
Remove the hood (Steps 5 through 17).
BD01D221
Loosen two hose clamps (1 and 2). Disconnect two

hoses (3 and 4) from fuel cooler (5). Plug hoses and
cap cooler ports to prevent entry of foreign matter
into fuel system.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-28
STEP 143
STEP 146
9
10
11
12
BD01D222
BD01D223
Support fuel cooler (5); remove two bolts (6) and

washers. Remove fuel cooler.
Remove radiator cap (9) and disconnect overflow

h o se ( 1 0 ) fr o m r a d ia to r. I n st a ll r a d ia to r ca p .
Disconnect connector from coolant level sender (11).
Remove screw (12) and install lifting eye.
STEP 144
STEP 147
7
13
14
8
7
BD01D188

clamps (7). Remove hose (8).
BD01D226
Remove two bolts (13) and lock washers on both

sides of radiator. Remove screw (14) and install
lifting eye.
STEP 145
STEP 148
BD01D229
Loosen two clamps securing radiator bottom hose.

Remove bottom hose.
BD01D227
Connect lifting equipment to lifting eyes. Take up all

slack in lifting equipment.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-29
STEP 149
STEP 152
15
BD01D225
Remove four bolts (15) and lock washers securing

radiator to cooling frame. Carefully and slowly raise
radiator from cooling frame and remove from loader.
BD01D227
Disconnect lifting equipment from lifting eyes.
STEP 153
Installation
13
STEP 150
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.
14
STEP 151
BD01D226
Remove lifting eye and install screw (14). Install two

lock washers and bolts (13) to secure radiator on
both sides.
15
STEP 154
9
10
BD01D225
Install four lock washers and bolts (15) to secure

radiator to cooling frame.
11
12
BD01D223
Remove lifting eye and install screw (12). Connect

connector to coolant level sender (11). Remove
radiator cap (9) and connect overflow hose (10) to
radiator. Install radiator cap.
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-30
STEP 155
STEP 158
BD01D229
BD01D221
At bottom of radiator, install bottom radiator hose.

Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
Remove plugs from hoses (3 and 4) and caps from

fuel cooler ports. Connect hoses to fuel cooler.
Position two hose clamps (1 and 2) and tighten.
STEP 156
STEP 159
7
BD01D188
BD01D155
At top of cooling system frame, install hose (8).

Position hose clamps and tighten to a torque of 10.1
to 11.3 Nm (90 to 100 lb-inch).
Install LH fender. Install two bolts and washers to

secure LH fender.
STEP 160
STEP 157
Install the hood (Steps 114 through 126).
STEP 161
5
BD01D222
Position and support fuel cooler (5) on radiator.

Install two washers and bolts (6) to secure fuel
cooler.
Bur 6-42290
BD00M031
Check that coolant drain cap is tight.
Issued 8-01
Printed in U.S.A.
Copyright
2000-31
STEP 162
STEP 164

the reservoir.
STEP 163

radiator cap.
STEP 165
STEP 166
BD01D140
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
2000-32
NOTES
Bur 6-42290
Issued 8-01
Printed in U.S.A.
Copyright
Section
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
CASE CORPORATION
700 State Street
Bur 6-48920

Printed in U.S.A.
February, 2003
2000
P.I.N. JEE0135501 AND ABOVE
Copyright
2000-2
TABLE OF CONTENTS
ENGINE . . . .
Removal .
Installation
RADIATOR .
Removal .
Installation
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3
3
17
31
31
33
SPECIFICATIONS
Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 Liters (9 Gallons)
Engine Oil
Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Liters (11 Quarts)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Case No. 1 Engine Oil (SAE 15W-40
Hydraulic Reservoir
Refill Capacity with Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 Liters (18 Gallons)
Type of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MS-1209 Hy-Tran Ultra
SPECIAL TORQUES
Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 to 298 Nm (180 to 220 lb-ft)
Engine Drive Shaft Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Radiator Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Counterweight Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 955 to 1075 Nm (704 to 793 lb-ft)
Charge Air Tube Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Muffler Front Mounting Bracket to Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 118 to 133 Nm (87 to 98 lb-ft)
Muffler Rear Mounting Bracket to Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 68 to 77 Nm (50 to 56.5 lb-ft)
Muffler Mounting Brackets to Muffler Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 to 44 Nm (29 to 32 lb-ft)
Turbocharger Elbow Clamp at Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 Nm (15 to 18 lb-ft)
Turbocharger Elbow Clamp at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 to 5.2 Nm (42.5 to 46 lb-inch)
Air Cleaner Hose Clamps at Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 to 11.3 Nm (90 to 100 lb-inch)
Air Cleaner Inlet and Outlet Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 to 4.5 Nm (32.9 to 39.6 lb-inch)
Hood Mounting Bolts at Cooling Frame Pivot Points . . . . . . . . . . . . . . . . . . . . . . . . . 36 to 44 Nm (26.5 to 32.5 lb-ft)
Screen Hinge Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 to 33 Nm (19.8 to 24.4 lb-ft)
Coupler to Flywheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 to 62 Nm (39 to 46 lb-ft)
Air Conditioning Compressor Mounting Bracket Mounting Bolts
M8 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 44 Nm (25 to 32.5 lb-ft)
M10 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 to 87 Nm (49.4 to 64 lb-ft)
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-3
ENGINE
STEP 5
Removal
STEP 1
STEP 2
BD01D141
1. CLIP
2. HOOD PROP
3. STUD

disengage bottom clip (1) from hood prop (2) and pull
bottom of prop from stud (3). Repeat to remove top of
prop from hood; remove prop then close hood.
STEP 6
BD00M030
STEP 3
STEP 4
BD01D142
Open screen.
STEP 7
BD01D139
Open and raise hood. Put master disconnect switch

in OFF position.
BD01D143
Remove cotter pin and three washers.

Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-4
STEP 8
STEP 11
5
6
4
4
BD01D144
BD01D145
Remove four bolts (4) securing hinges of screen to

hood. Disconnect prop bar (5) from screen and
remove screen.
Remove lock nut (6) securing LH spring (7) to hood.

Repeat to remove lock nut securing RH spring to
hood. Disconnect springs from hood; it may be
necessary to raise hood to disconnect springs from
hood.
4. BOLTS
5. PROP BAR
6. LOCK NUT
STEP 9
7. LH SPRING
STEP 12
BD01D255
Connect a lifting strap to the hood handle and

connect lifting equipment to strap. Depress handle
latch and let hood raise.
STEP 10
BD01D258
At front RH side of hood, identify, tag, and disconnect

hood harness connector from rear chassis harness
connector.
STEP 13
Lower hood.
BD01D256
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-5
STEP 14
STEP 17
BD01D149
BD01D254
Install two lifting eyes and connect lifting strap to

eyes.
Carefully raise and remove hood from loader. Lower

hood onto suitable platform and disconnect lifting
equipment.
STEP 15
STEP 18
BD01D254
Connect lifting equipment to the lifting straps.
BD01D150
Tag and disconnect engine wiring harness connector

from air filter restriction switch.
STEP 16
BD01D147
Re mo ve tw o nu ts an d bo lts a nd fo ur w ashe rs
securing hood.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-6
STEP 19
STEP 22
8
13
14
8
10
15
11
10
11
BD01D161
Disconnect battery cable from RH battery positive

post. Put a plastic cap over the positive post.
12
11
11
12
STEP 23
BS02J037
8. BOLT
11. WASHER
9. BATTERY COVER 12. BOLT
10. LOCK NUT
13. BOLT
16
14. WASHER
15. BATTERY COVER
19
18
At LH battery cover, remove two bolts (8) and battery

cover (9). Remove two lock nuts (10), bolts (12), four
washers (11), bolt (13), and washer (14). Remove
battery cover (15).
17
16
20 21 20
27
STEP 20
22
Repeat Step 19 to remove RH battery covers.
STEP 21
18
23
24
25
25
26
BD01D158
Disconnect battery cable from LH battery negative

post. Put a plastic cap over the negative post.
BS02J036
16.
17.
18.
19.
20.
21.
CLAMP
INTAKE HOSE
CLAMP
HOSE
CLAMP
HOSE
22.
23.
24.
25.
26.
27.
TUBE
HOSE
LOCK NUT
WASHER
BOLT
AIR CLEANER
Loosen clamp (16) on air cleaner intake hose (17)

and remove intake hose.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-7
STEP 24
STEP 27
Loosen clamps (18 and 20) on crankcase hose (21)

and turbocharger intake hose (23). Disconnect hose
(21) from breather pipe. Disconnect hose (23) with
tube (22) attached from turbocharger.
38
40
STEP 25
31
Support air cleaner assembly (27) and remove two

lock nuts (24), bolts (26), four washers (25), and one
clamp holding battery B+ cable routed to relay plate.
Remove air cleaner (27) and associated parts as an
assembly.
36
39
STEP 26
28
38
32
33
29
37
30
34
35
29
28
BS02J046
BS02J049
28. BOLT
29. WASHER
30. DRIVE BELT GUARD
Remove four bolts (28) and washers (29) securing

drive belt guard (30) to master disconnect switch
mounting bracket and belt guard bracket.
31.
32.
33.
34.
35.
CLAMP
BOLT
WASHER
BOLT
WASHER
36.
37.
38.
39.
40.
FRONT BRACKET
REAR BRACKET
MUFFLER
CLAMP
EXHAUST TUBE ELBOW
Remove clamp (31) securing exhaust tube elbow

(40) to muffler (38).
STEP 28
At fron t o f en gine, re move two b olts (32 ) an d
washers (33) securing muffler front mounting bracket
(36).
STEP 29
Support muffler (38) and brackets (36 and 37) and
remove two bolts (34) and washers (35) at rear of
e n g in e . R e m o v e m u ff le r a n d b r a c k e t s a s a n
assembly from engine.
STEP 30
Loosen clamp (39) and remove exhaust tube elbow
(40) from turbocharger.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-8
STEP 31
STEP 34
45
41
42
44
46
BD01D179
Connect lifting equipment to rear counterweight.

43
41
STEP 35
45
55
50
48
49
47
50
BS02J048
41.
42.
43.
44.
CLAMP
TUBE
HOSE
CLAMP
45.
46.
47.
48.
49
50
CLAMP
TUBE
HOSE
CLAMP
49
52
50
Loosen two clamps (41). Remove tube (42) and hose

(43) as an assembly.
STEP 32
Loosen two clamps (45). Remove tube (46) and hose
(47) as an assembly.
54
51
54
53
53
49
52
51
STEP 33
BS02J047
49.
50.
51.
52.
NUT
WASHER
BOLT
WASHER
53. BOLT
54. WASHER
55. COUNTERWEIGHT
Remove four nuts (49) and washers (50) and two

bolts (51), washers (52), bolts (53), and washers
(54). Remove counterweight (55) from loader and
place on pallet.
BD01D177
Cut, remove, and discard tie strap securing LH rear

combination lamp wire. Identify, tag, and disconnect
r e a r c h a s s i s w i r in g h a r n e s s c o n n e c t o r f r o m
combination lamp connector. Repeat this step for RH
rear combination lamp.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-9
STEP 36
STEP 39
Remove nut and washer securing cables to starter
B+ stud (65). Identify, tag, and disconnect both
cables.
59
60
STEP 40
66
BS02J055
56
57
58
66. STARTER SOLENOID WIRE

BS02J057
56. NUT
57. GROUND CABLE
58. GROUND CABLE
59. BOLT
60. CABLE CLAMP
Remove nut (56) and washer from stud installed in

engine block. Tag and disconnect two ground cables
(57 and 58) and one ground wire of rear chassis
harness from stud.
Identify and tag rear chassis harness wire (66)

connected to starter solenoid terminal. Disconnect
rear chassis harness wire from terminal.
STEP 41
67
STEP 37
Remove bolt (59) and washer securing cable clamp
(60) to engine.
STEP 38
65
BS02J054
67. CONNECTOR
64
Identify, tag, and disconnect rear chassis harness

connector (67) from grid heater temperature switch.
Move rear chassis harness away from engine.
63
62 61
BS02J056
61. ACORN NUT

62. NUT
63. WASHER
64. COVER
65. B+ STUD
Remove acorn nut (61), nut (62), and washer (63)

securing cover (64) to starter. Remove cover.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-10
STEP 42
STEP 47
82
70
79
71
72
80
80
78
81
69
73 68
75
74
83
BS02J059
68.
69.
70.
71.
CONNECTOR
CONNECTOR
BOOT
WIRE
72.
73.
74.
75.
CONNECTOR
BOLT
NUT
STUD
Id e nt ify, ta g , a n d d isc o n ne c t e n g ine h ar n es s

connector (68) from disconnect harness connector
(69).
76
77
BS02J058
76.
77.
78.
79.
BOLT
WASHER
NUT
BOLT
80.
81.
82.
83.
WASHER
CLAMP
FLYWHEEL HOUSING COVER
CONNECTOR
STEP 43
Remove bolt (76) and washer (77) securing clamps

of engine harness and rear chassis harness to
engine block. Top harness is rear chassis harness;
bottom harness is engine harness.
Pull boot (70) away from alternator stud. Identify, tag,

and disconnect engine harness wire (71) from stud.
STEP 48
Identify, tag, and disconnect two connectors (72).
Remove two nuts (78) and bolts (79 ) and four

washers (80) securing two clamps (81) to flywheel
housing cover (82).
STEP 45
STEP 49
Remove bolt (73) and washer securing engine

harness clamp to engine.
Route engine harness and rear chassis harness to

front of engine and away from flywheel housing
cover. Remove any hardware securing harness
clamps to engine as necessary.
STEP 44
STEP 46
Remove nut (74) and washer securing five ground
wires of rear chassis harness and three ground wires
of engine harness to stud (75). Identify, tag, and
disconnect ground wires from stud.
Bur 6-48920
STEP 50
Identify, tag, and disconnect four connectors (83).
Issued 2-03
Printed in U.S.A.
Copyright
2000-11
89
85
91
92
84
90
88
86
87
BS02J060
84. CONNECTOR
85. BOLT
86. CONNECTOR
87. CONNECTOR
88. WIRE
89. WIRE
90. CONNECTOR
91. CONNECTOR
92. WIRE
A. ENGINE HARNESS
B. ALTERNATOR
C. GRID HEATER
STEP 51
STEP 56
Identify, tag, and disconnect connector (84) from

engine coolant temperature sender.
Identify, tag, and disconnect connector (90) from fuel

filter heater.
STEP 52
STEP 57
Remove bolt (85) and washer securing engine

harness clamp.
Identify, tag, and disconnect connector (91) from fuel

filter temperature switch.
STEP 53
STEP 58
If wheel loader is equipped with air conditioning,

identify, tag, and disconnect connector (86) from air
conditioner compressor clutch. Identify. tag, and
disconnect connector (87) from air conditioning high
pressure switch.
Identify and tag wire (92). Locate connector on end

of wire (92) and disconnect from fuel injection pump
fuel solenoid.
STEP 54
STEP 59
Ro u te en gin e ha rn e ss a w ay fro m e n gin e a n d
towards front of engine compartment.
Identify, tag, and disconnect wire (88) from engine oil

pressure switch.
STEP 55
If equipped, identify, tag, and disconnect wire (89)
from grid heater.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-12
STEP 60
STEP 62
100
99
Insta ll b atte ry co vers on RH side. Suppo rt a ir

conditioning compressor (104) and remove bolt
(103), three washers, and nut securing compressor.
Remove compressor and place on RH battery cover.
STEP 63
98
96
95
97
94
93
BS02J066
93.
94.
95.
96.
BOLT
WASHER
BOLT
WASHER
97. BRACKET
98. CLAMP
99. HOSE
100.HOSE
BD00M031

Remove two bolts (93 and 95) and washers (94 and
96) securing bracket (97). Let bracket (97) with
clamp (98) and hoses (99 and 100) hang down from
air conditioning compressor.
STEP 64
STEP 61
102
105
104
101
106
105
BS02J069
103
BS02J067
101.BOLT
102.DRIVE BELT
103.BOLT
104.AC COMPRESSOR
105.CLAMP
106.HOSE
Loosen two clamps (105). Disconnect and remove

bottom hose (106).
Loosen bolts (101 and 103). Move air conditioning

compressor (104) to put slack in drive belt (102) then
remove drive belt. Remove bolt (101), washers,
spacer, and nut.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-13
STEP 65
STEP 68
107
109
117
114
112
113
111
110
113
115
116
108
BS02J065
110
115.HOSE
116.ELBOW
117.ENGINE OIL PAN
107
Disconnect hose (115) from elbow (116) installed in

engine oil pan (117). Put a plug in hose and a cap on
fitting.
STEP 69
BS02J068
107.CLAMP
108.BLEED LINE HOSE
109.CLAMP
110.CLAMP
111.HOSE
112.PIPE
113.TIE STRAP
114.HOSE
121
Loosen two clamps (107) securing bleed line hose

(108). Disconnect bleed line hose (108) from fittings.
127
STEP 66
Loosen clamps (109 and 110). Disconnect and
remove hose (111) from engine and pipe (112).
Disconnect and remove pipe (112) with bleed line
hose (108) attached from hose (114). If necessary,
cut, remove, and discard tie straps (113) to separate
bleed line hose (108) from pipe (112).
120
124
126
125
119
118
123
122
STEP 67
BS02J070
118.NUT
119.WASHER
120.BALL JOINT
121.THROTTLE LEVER
122.NUT
123.WASHER
124.U-BOLT
125.CLAMP
126.THROTTLE CABLE
127.SUPPORT BRACKET
Remove nut (118) and washer (119) securing ball

joint (120) to throttle lever (121).
STEP 70
BD00M031
Put a 18.9 liter (5 gallon) container below engine oil

d r a in . R e m o ve c a p a n d d r a in e n g in e o il in t o
container. Install cap after oil has drained.
Bur 6-48920
Remove two nuts (122) and washers (123), U-bolt

(124), and clamp (125) securing throttle cable (126)
to support bracket (127). Position throttle cable away
from engine.
Issued 2-03
Printed in U.S.A.
Copyright
2000-14
STEP 71
STEP 72
139
131
130
138
137
128
137
136
129
136
BS02J072
128.BOLT
129.CLAMP
130.FUEL SUPPLY HOSE

131.FUEL RETURN HOSE
Remove bolt (128) and washer securing clamp (129)

holding in-line fuel filter to engine block. Tag and
disconnect fuel supply hose (130) from priming
pump. Plug hose and cap fitting. Tag and disconnect
fuel return hose (131) from fuel injection pump. Plug
hose and cap fitting.
135
134
135
132
133
BS02J071
132.BOLT
133.WASHER
134.CLAMP
135.BOLT
136.WASHER
137.WASHER
138.HOSE BRACKET
139.FLYWHEEL HOUSING COVER
Remove bolt (132) and washer (133) securing fuel

return hose clamp (134) to flywheel housing cover
(139). Remove two bolts (135), washers (136 and
137) holding hose bracket (138) to flywheel housing
cover. (Throttle cable and associated clamp and (if
used) air conditioning hoses and associated clamp
are also secured to hose bracket.)
STEP 73
Connect a vacuum pump to hydraulic reservoir. If a
vacuum pump is not available, drain the hydraulic oil
(hydraulic reservoir holds 68.5 liters (18 gallons) of
oil). Turn on vacuum pump (if available). At RH side,
front of engine, tag, disconnect, and plug hoses
connected to brake pump. Plug hoses securely and
cap fittings. Turn off vacuum pump.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-15
STEP 74
STEP 77
140
141
BD01D200
140.BOLT
BD01D181
141.DRIVE SHAFT
At front of engine, remove six bolts (140) securing

drive shaft (141) to engine coupling. Use a pry bar to
move drive shaft away from engine coupling.
156
STEP 75
Connect lifting equipment to engine lifting brackets.
155
STEP 76
154
144
145
153
147
150
153
149
153
152
147
151
148
146
BS02J064
151.BOLT
152.WASHER
153.ENGINE MOUNT
142
154.BOLT
155.WASHER
156.ENGINE SUPPORT

plate and rear chassis, remove bolt (151) and washer
(152) securing rear of engine to rear chassis.
143
BS02J073
142.NUT
143.WASHER
144.BOLT
145.WASHER
146.WASHER
147.ENGINE MOUNT
148.BOLT
149.WASHER
150.MOUNTING BRACKET
At front of engine, remove nut (142), washer (143),

bolt (144), and washer (145) securing engine and
mounting brackets to rear chassis.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-16
STEP 78
STEP 80
Slowly raise engine from rear chassis. Check and be

sure all harness connections, hoses, and throttle
cable have been disconnected and are positioned
out of the way. Remove engine from machine.
Remove engine mounts (147 and 153) from engine

mounting brackets (150) and engine support (156).
STEP 79
Remove washers (146) from rear chassis where
engine was secured.
Bur 6-48920
STEP 81
If engine mounting brackets (150) require removal,
remove four bolts (148) and washers (149) then
remove mounting brackets. If engine support (156)
requires removal, remove four bolts (154) and
washers (155). Remove engine support (156).
Issued 2-03
Printed in U.S.A.
Copyright
2000-17
STEP 83
Installation
144
STEP 82
145
156
147
150
149
155
154
147
148
146
153
153
153
142
143
152
151
BS02J064
151.BOLT
152.WASHER
153.ENGINE MOUNT
154.BOLT
155.WASHER
156.ENGINE SUPPORT
If engine support (156) was removed, connect

suitable lifting equipment to engine support and
move into position on engine. Install four bolts (154)
an d wa sh e rs (1 55 ). Tigh te n b o lt s se cu re ly. If
necessary, install new engine mount (153) in engine
mounting hole in rear chassis.
BS02J073
142.NUT
143.WASHER
144.BOLT
145.WASHER
146.WASHER
147.ENGINE MOUNT
148.BOLT
149.WASHER
150.MOUNTING BRACKET
If engine mounting brackets (150) were removed,

position bracket on engine and secure using four
b olts ( 14 8 ) an d w a sh e rs (1 4 9 ). Tig ht en b o lts
securely. If necessary, install new engine mount
(147) in mounting bracket. Repeat this step to install
remaining engine mounting bracket and engine
mount as necessary.
STEP 84
Connect suitable lifting equipment to engine lifting
brackets. 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 (146) between front engine mount (147) and
rear chassis. Install washer (145), bolt (144), washer
(143), and nut (142) in engine front mounts. Lower
engine into position. Install washer (152) and bolt
(151) in rear engine mount (153).
STEP 85
At front of engine, tighten two bolts (144) to a torque
of 244 to 298 Nm (180 to 220 lb-ft).
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-18
STEP 86
STEP 90
139
151
138
137
137
136
BD01D181
151.BOLT
136

plate and rear chassis, tighten bolt (151) to a torque
of 244 to 298 Nm (180 to 220 lb-ft).
135
134
135
STEP 87
Disconnect lifting equipment from engine lifting
brackets.
140
133
BS02J071
132.BOLT
133.WASHER
134.CLAMP
135.BOLT
STEP 88
141
132
136.WASHER
137.WASHER
138.HOSE BRACKET
139.FLYWHEEL HOUSING COVER
Position and support hose bracket (138) with throttle

ca b le a n d a sso c iat ed cla mp a n d , if u se d , a ir
conditioning hoses and associated clamp on flywheel
housing cover (139). Install four washers (137 and
136) and two bolts (135) to secure hose bracket.
Positio n fue l re tu rn h ose with cla mp (13 4) o n
flywheel housing cover and secure using washer
(133) and bolt (132).
BD01D200
140.DRIVE SHAFT
141.BOLTS
At front of engine, position drive shaft (140) on

engine coupling. Put Loctite 242 on threads of six
bolts (141). Install six bolts (141) and tighten to a
torque of 53 to 62 Nm (39 to 46 lb-ft).
STEP 89
Turn on vacuum pump conne cted to hydraulic
reservoir. Remove caps from brake pump fittings and
plugs from brake pump hoses. Connect hoses to
brake pump following tags installed during removal.
Remove and discard tags. Turn off and disconnect
vacuum pump from hydraulic reservoir.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-19
STEP 91
STEP 93
Install ball joint (120) on throttle lever (121) and
secure using washer (119) and nut (118).
STEP 94
131
130
117
128
129
115
116
BS02J072
128.BOLT
129.CLAMP
130.FUEL SUPPLY HOSE

131.FUEL RETURN HOSE
BS02J065
Remove plug from fuel return hose (131) and cap

from fuel injection pump fitting. Connect fuel return
hose to fuel injection pump. Remove plug from fuel
supply hose (130) and cap from priming pump fitting.
Connect fuel supply hose to priming pump. Position
clamp (129) holding in-line fuel filter and secure to
engine block using washer and bolt (128).
115.HOSE
116.ELBOW
117.ENGINE OIL PAN
Remove plug from oil drain hose (115) and cap from
fitting (116) installed in engine oil pan (117). Connect
hose to fitting and tighten.
STEP 92
121
127
120
124
126
125
119
118
123
122
BS02J070
118.NUT
119.WASHER
120.BALL JOINT
121.THROTTLE LEVER
122.NUT
123.WASHER
124.U-BOLT
125.CLAMP
126.THROTTLE CABLE
127.SUPPORT BRACKET
Route throttle cable (126) up and over towards fuel

injection pump. Put clamp (125), throttle cable (126),
and U-bolt (124) on support bracket (127) and secure
using two washers (123) and nuts (122).
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-20
STEP 95
STEP 97
107
109
114
112
105
113
113
106
111
110
108
105
110
107
BS02J069
105.CLAMP
106.HOSE
BS02J068
107.CLAMP
108.BLEED LINE HOSE
109.CLAMP
110.CLAMP
111.HOSE
112.PIPE
113.TIE STRAP
114.HOSE
Put clamp (109) on hose (114). Connect pipe (112) to

hose (114). Position clamp (109) and tighten to a
torque of 10.1 to 11.3 Nm (90 to 100 lb-inch). Put
clamps (110) on hose (111). Connect hose (111) to
pipe (112) and engine coolant outlet. Position clamps
(110) and tighten to a torque of 10.1 to 11.3 Nm (90
to 100 lb-inch).
Put clamps (105) on hose (106). Connect hose (106)

between bottom pipe and engine coolant inlet.
Position clamps and tighten to a torque of 10.1 to
11.3 Nm (90 to 100 lb-inch).
STEP 98
102
104
101
STEP 96
Put hose clamps (107) on bleed line hose (108) and
connect hose to fittings. Position clamps (107) and
lb-inch). Install three tie straps (113) to secure bleed
line hose (108) to pipe (112).
103
BS02J067
101.BOLT
102.DRIVE BELT
103.BOLT
104.AC COMPRESSOR
Position and support air conditioning compressor

(104) on mounting bracket. Secure using bolt (103),
three washers, and nut. Install bo lt (101), two
washers, spacer, and nut.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-21
STEP 99
STEP 103
Install drive belt (102). Take up slack in drive belt and

tighten bolts (101 and 103).
Connect connector (91) to fuel filter temperature

switch following tag ins ta lled du rin g re mova l.
STEP 100
STEP 104
100
99
98
96
95
97
94
BOLT
WASHER
BOLT
WASHER
STEP 105
If equipped, connect wire (89) to grid heater following
tag installed during removal. Remove and discard
tag.
STEP 106
Connect wire (88) to engine oil pressure switch
following tag installed during removal. Remove and
discard tag.
STEP 107
93
BS02J066
93.
94.
95.
96.
Connect connector (90) to fuel filter heater following

tag installed during removal. Remove and discard
tag.
97. BRACKET
98. CLAMP
99. HOSE
100.HOSE
Position and support bracket (97) with clamp (98)

and hoses (99 and 100) on engine block. Secure
bracket (97) using two bolts (93 and 95) and washers
(94 and 96).
STEP 101
R o u t e e n g in e h a rn e s s b r a n c h c o n t a in i n g a ir
conditioning compressor connectors and engine
coolant temperature sender connector from front of
engine compartment to RH side of engine towards
rear of engine compartment.
If wheel loader is equipped with air conditioning,

connect con necto r (86) to a ir co nditioni ng
compressor clutch following tag installed during
removal. Connect connector (87) to air conditioning
high pressure switch following tag installed during
STEP 108
Position engine harness clamp on engine and secure
using bolt (85) and washer.
STEP 109
Connect connector (84) to engine coolant
temperature sender following tag installed during
STEP 102
Locate connector on end of wire (92) and connect to
fuel injection pump fuel solenoid followin g tag
installed during removal. Remove and discard tag.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-22
89
85
91
92
84
90
88
86
87
BS02J060
84. CONNECTOR
85. BOLT
86. CONNECTOR
87. CONNECTOR
88. WIRE
89. WIRE
STEP 110
90. CONNECTOR
91. CONNECTOR
92. WIRE
A. ENGINE HARNESS
B. ALTERNATOR
C. GRID HEATER
STEP 111
Position clamp (81) holding engine harness and rear
chassis harness on flywheel housing cover (82).
Bottom harness is engine harness; top harness is
rear chassis harness. Install nut (78) and bolt (79)
and two washers (80) to secure clamp. Repeat this
step to install remaining clamp (81) on other side of
flywheel housing cover (82).
82
79
80
80
78
81
STEP 112
Route engine harness and rear chassis harness to
rear of engine.
STEP 113
83
76
77
BS02J058
76.
77.
78.
79.
BOLT
WASHER
NUT
BOLT
80.
81.
82.
83.
P o s i t io n c la m p s o f e n g in e a n d r e a r c h a s s i s
harnesses on engine block. Top harness is rear
chassis harness; bottom harness is engine harness.
Install bolt (76) and washer (77) to secure clamps.
WASHER
CLAMP
FLYWHEEL HOUSING COVER
CONNECTOR
Connect four connectors (83) following tags installed

during removal. Remove and discard tags.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-23
STEP 114
STEP 119
70
67
71
72
69
73 68
75
BS02J054
74
67. CONNECTOR
BS02J059
68.
69.
70.
71.
CONNECTOR
CONNECTOR
BOOT
WIRE
72.
73.
74.
75.
CONNECTOR
BOLT
NUT
STUD
Connect five ground wires of rear chassis harness

and three ground wires of engine harness to stud
(75) following tags installed during removal. Install
nut (74) and washer to secure ground wires. Remove
and discard tags.
STEP 115
Connect rear chassis harness connector (67) to grid

heater temperature switch following tag installed
during removal. Remove and discard tag.
STEP 120
66
Position engine harness clamp on engine block.

Secure using bolt (73) and washer.
STEP 116
Connect two connectors (72) following tags installed
BS02J055
STEP 117
Connect engine harness wire (71) to alternator stud
discard tag. Push boot (70) on alternator stud.
Connect rear chassis harness wire (66) to starter

solenoid terminal following tag installed during
STEP 118
Connect engine harness connector (68) to
disconnect harness connector (69) following tags
installed during removal. Remove and discard tags.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-24
STEP 121
STEP 124
Connect ground wire of rear chassis harness and two
ground cables (57 and 58) to stud following tags
installed during removal. Install nut (56) to secure
cables and wire. Remove and discard tags.
65
STEP 125
64
55
63
62 61
BS02J056
61. ACORN NUT

62. NUT
63. WASHER
64. COVER
65. B+ STUD
BD01D179
55
Connect cables to starter B+ stud (65) following tags

installed during removal. Install nut and washer to
secure cables. Remove and discard ta gs from
cables.
50
49
50
50
49
STEP 122
Put cover (64) on starter. Install washer (63), nut
(62), and acorn nut (61) to secure cover (64).
49
52
50
STEP 123
54
59
51
54
53
53
60
49
52
51
BS02J047
49.
50.
51.
52.
NUT
WASHER
BOLT
WASHER
53. BOLT
54. WASHER
55. COUNTERWEIGHT
Move counterweight into position at rear of loader.

Install two washers (54), bolts (53), washers (52),
bolts (51), and four washers (50), and nuts (49).
Tighten bolts to a torque of 955 to 1075 Nm (704 to
7 9 3 lb - ft) . D isc o n n e ct lif tin g e q u ip me n t f ro m
counterweight.
56
57
58
BS02J057
56. NUT
57. GROUND CABLE
58. GROUND CABLE
59. BOLT
60. CABLE CLAMP
Install cable clamp (60) and secure with bolt (59) and
washer.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-25
STEP 126
STEP 129
38
40
31
36
39
BD01D177
Connect rear chassis wiring harness connector to

combination lamp connector following tag installed
during removal. Install new tie strap to secure LH
rear combination lamp wire. Remove and discard
tags. Repeat this step for RH rear combination lamp.
38
32
33
37
34
STEP 127
35
45
41
BS02J046
31.
32.
33.
34.
35.
42
44
46
41
Install and support muffler (38) and brackets (36 and

37) on engine while connecting muffler to exhaust
tube elbow (40). Install two washers (35) and bolts
(34) finger tight.
48
47
BS02J048
45.
46.
47.
48.
CLAMP
TUBE
HOSE
CLAMP
Install tube (46) and hose (47) as an assembly.

Tighten two clamps (45) to a torque of 10.1 to 11.3
Nm (90 to 100 lbs-inch).
STEP 128
Install tube (42) and hose (43) as an assembly.
Tighten two clamps (41) to a torque of 10.1 to 11.3
Nm (90 to 100 lbs-inch).
Bur 6-48920
FRONT BRACKET
REAR BRACKET
MUFFLER
CLAMP
EXHAUST TUBE ELBOW
STEP 130
45
CLAMP
TUBE
HOSE
CLAMP
36.
37.
38.
39.
40.
Put clamp (39) on exhaust tube elbow (40). Install

exhaust tube elbow and clamp on turbocharger. Do
not tighten clamp at this time.
43
41.
42.
43.
44.
CLAMP
BOLT
WASHER
BOLT
WASHER
STEP 131
At front of engine, install two washers (33) and bolts
(32) to secure muffler front mounting bracket (36).
Tighten bolts (32) to a torque of 118 to 133 Nm (87 to
98 lb-ft). Tighten bolts (34) to a torque of 68 to 77 Nm
(50 to 56 lb-ft).
STEP 132
Install clamp (31). Tighten clamp (31) to a torque of
20 to 25 Nm (15 to 18 lb-ft). Tighten clamp (39) to a
torque of 4.8 to 5.2 Nm (42.5 to 46 lb-ft).
Issued 2-03
Printed in U.S.A.
Copyright
2000-26
STEP 133
STEP 134
28
16
29
19
18
30
29
17
16
20 21 20
27
22
28
18
23
BS02J049
28. BOLT
29. WASHER
30. DRIVE BELT GUARD
24
25
Position drive belt guard (30) and secure using four

washers (29) and bolts (28) to master disconnect
switch mounting bracket and belt guard bracket.
25
26
BS02J036
16.
17.
18.
19.
20.
21.
CLAMP
INTAKE HOSE
CLAMP
HOSE
CLAMP
HOSE
22.
23.
24.
25.
26.
27.
TUBE
HOSE
LOCK NUT
WASHER
BOLT
AIR CLEANER
Position air cleaner assembly (27) and support as an

assembly. Secure using two washers (25) and bolts
(26). Put clamp holding battery B+ cable routed to
relay plate on rear bolt then install two washers (25)
and lock nuts (24).
STEP 135
Connect turbocharger intake hose (23) attached to
tube (22) to turbocharger and crankcase hose (21) to
breather pipe. Position clamps (18 and 20) and
tighten. Tighten clamps (18) to a torque of 10.1 to
11.3 Nm (90 to 100 lb-inch).
STEP 136
Connect a ir clea ner intake hose (17) betwe en
cooling frame and air cleaner inlet. Position clamp
(16) and tighten to a torque of 3.6 to 4.5 Nm (32.4 to
39.6 lb-inch).
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-27
STEP 137
STEP 139
8
13
14
8
10
15
11
BD01D161
Remove plastic cap installed over the positive post

during removal. Connect battery cable to RH battery
positive post.
10
11
12
11
11
12
STEP 138
BS02J037
8. BOLT
11. WASHER
9. BATTERY COVER 12. BOLT
10. LOCK NUT
13. BOLT
14. WASHER
15. BATTERY COVER
At LH battery, position battery cover (15). Install

wash er (14) and bolt (13), two bolts (12), four
washers (11), and two lock nuts (10). Install battery
cover (9) and secure using two bolts (8).
STEP 140
BD01D158
Remove plastic cap installed over the negative post

during removal. Connect battery cable to LH battery
negative post.
BD01D150
Connect engine wiring harness connector to air filter

restriction switch following tag installed during
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-28
STEP 141
STEP 144
BD01D242
BD01D254
If removed, install bushings at hood pivot points on

top of cooling frame.
STEP 142
BD01D149
Lower lifting equipment until strap connected to two

lifting eyes can be removed. Remove the two lifting
eyes from hood.
BD01D254
Raise and move hood into position above loader.

Slowly and carefully lower hood into position while
guiding hood pivot points into position with pivot
points on top of cooling frame.
STEP 145
STEP 143
BD01D256
BD01D147
Install two bolts, four washers, and two nuts to

secure hood. Tighten bolts to a torque of 36 to 44 Nm
(26.5 to 32.5 lb-ft).
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-29
STEP 146
STEP 149
6
7
BD01D145
6. LOCK NUT
BD01D255
Disconnect lifting strap from hood handle.
7. SPRING
Connect springs (7) to hood; it may be necessary to

raise hood to connect springs. Install lock nuts (6) to
secure LH and RH springs to hood.
STEP 150
5
STEP 147
4
4
BD01D144
4. BOLT
BD01D258
At front RH side of h ood, connect hood wiring

harness connector to rear chassis wiring harness
connector following tag installed during removal.
5. PROP BAR
Position screen on hood. Install four bolts (4) to

secure hinges of screen to hood. Tighten bolts to a
torque of 27 to 33 Nm (19.8 to 24.4 lb-ft). Connect
prop bar (5) to screen.
STEP 151
STEP 148
Lower hood.
BD01D143
Install three washers and cotter pin.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-30
STEP 152
STEP 155
Install a new oil filter on engine. Fill engine with 10.5
liters (11 quarts) of Case No. 1 Engine Oil (SAE
15W-40).
STEP 156
If hydraulic reservoir was drained, fill reservoir with
68.5 liters (18 gallons) of MS-1209 Hy-Tran Ultra
fluid.
STEP 157
BD01D142
Close screen and open hood.
STEP 153

the reservoir.
STEP 158
2
3
BD01D141
1. CLIP
2. HOOD PROP
3. STUD
BD01D140

disengage bottom clip (1) from hood prop (2) and
push bottom of prop onto stud (3). Repeat to install
top of prop to hood.
STEP 154

radiator cap.
STEP 159
STEP 160
STEP 161
BD00M031
Check and make sure that drain caps are tight.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-31
RADIATOR
STEP 167
Removal
STEP 162
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 163
BD01D155
Remove two bolts and washers securing LH fender.

Remove LH fender.
STEP 168
BD00M030
STEP 164
Open and raise hood.
STEP 165
BD00M031

STEP 169
BD01D139
STEP 166
Remove the hood (Steps 5 through 17).
1
BD01D188
1. HOSE CLAMP
2. HOSE

clamps (1). Remove hose (2).
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-32
STEP 170
STEP 173
BD01D229
BD01D227
Loosen two clamps securing radiator bottom hose.

Remove bottom hose.
Connect lifting equipment to lifting eyes. Take up all

slack in lifting equipment.
STEP 171
STEP 174
3
4
9
5
6
BD01D223
3. RADIATOR CAP
4. OVERFLOW HOSE
5. COOLANT LEVEL SENDER

6. SCREW
Remove radiator cap (3) and disconnect overflow

h o s e ( 4 ) f r o m r a d i a t o r. I n s t a l l r a d i a t o r c a p .
Disconnect connector from coolant level sender (5).
Remove screw (6) and install lifting eye.
BD01D225
9. BOLT
Remove four bolts (9) and lock washers securing

radiator to cooling frame. Carefully and slowly raise
radiator from cooling frame and remove from loader.
STEP 172
7
BD01D226
7. BOLTS
8. SCREW
Remove two bolts (7) and lock washers on sides of

radiator. Remove screw (8) and install lifting eye.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-33
STEP 178
Installation
STEP 175
Move radiator into position above cooling frame.

Carefully lower radiator while guiding it into position
in cooling frame.
STEP 176
BD01D226
7. BOLT
8. SCREW
Remove lifting eye and install screw (8). Install two

lock washers and bolts (7) to secure radiator on both
sides.
STEP 179
BD01D225
9. BOLTS
Install four lock washers and bolts (9) to secure

radiator to cooling frame.
STEP 177
5
6
BD01D223
3. RADIATOR CAP
4. OVERFLOW HOSE
BD01D227
5. COOLANT LEVEL SENDER

6. SCREW
Remove lifting eye and install screw (6). Connect

connector to coolant level sender (5). Remove
radiator cap (3) and connect overflow hose (4) to
radiator. Install radiator cap.
Disconnect lifting equipment from lifting eyes.
Bur 6-48920
Issued 2-03
Printed in U.S.A.
Copyright
2000-34
STEP 180
STEP 184
BD01D229
At bottom of radiator, install bottom radiator hose.

Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
BD00M031
Check that coolant drain cap is tight.
STEP 185
the reservoir.
STEP 181
STEP 186
1
BD01D188
1. HOSE CLAMP
2. HOSE
At top of cooling system frame, install hose (2).

Position hose clamps (1) and tighten to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
BD01D140
STEP 182
STEP 187
BD01D155

radiator cap.
Install LH fender. Install two bolts and washers to

secure LH fender.
STEP 188
STEP 183
Lower a nd close hood. Put articulation lock in

OPERATING position.
Install the hood (Steps 141 through 153).

Bur 6-48920
Issued 2-03
Printed in U.S.A.
2002
Copyright
Section
2002
STALL TESTS
CASE CORPORATION
700 State Street
Bur 6-40770

Printed in U.S.A.
March, 2001
Copyright
2002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure to Heat the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-40770
Issued 3-01
3
3
3
3
3
4
4
4
4
4
Printed in U.S.A.
Copyright
2002-3
SPECIFICATIONS
Low idle ..........................................................................................................................................1020 to 1080 rpm
Full throttle (no load)........................................................................................................................2220 to 2280 rpm
Temperature of the torque converter oil.......................................................................82 to 104 C (180 to 220 F)
Temperature of the hydraulic oil....................................................................................... 51 to 79C (125 to 175F)
Stall Speeds
Torque converter..............................................................................................................................1930 to 2090 rpm
Hydraulic system .............................................................................................................................1945 to 2255 rpm
Torque converter and hydraulic system together.............................................................................1395 to 1705 rpm
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
Procedure to Heat the Oil

Torque Converter
1. Sit in the seat.
Hydraulic System
1. Apply the parking brake.
2. Start the engine and run at full throttle.
2. Start the engine and run the engine at low idle.
3. Hold the bucket control lever in the ROLLBACK

position.
3. To measure the oil temperature with the

instrument cluster:
4. Place the lift control lever in FLOAT and hold.
A. Press the program switch.

B. Press the up count switch to function 007.
C. Return the program switch to the OFF (center)
position.
5. View the oil temperature by pressing the program

switch, then press the up count switch to function
008. Return the program switch to the center
(OFF) position.
6. Repeat step 3 until the temperature of the
hydraulic oil is 51 to 79C (125 to 175F).
4. Place the declutch switch in the OFF position.

5. Place the automatic switch in the manual mode
position.
Test No. 1 - Torque Converter and

Hydraulic Stall Together
6. Release the parking brake.
1. Sit in the seat.
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 until the instrument
cluster shows a temperature of 115C (239F).
4. Make sure the parking brake is released (OFF).
9. Decrease the engine speed to low idle and move

the transmission control lever to the Neutral
position.
10. Wait and allow the converter temperature to cool
to 90C (194F).
11. Repeat steps 4 through 9 (approximately three
times) until the temperature of the torque
converter oil is 82 to 104C (180 to 220F).
Bur 6-40770
3. Press the brake pedal, and shift into Forward.
5. Run engine at low idle. Push the clutch cutout

switch to OFF. Put the transmission in manual
mode. Push down and hold the brake pedal for
the remainder of this procedure.
6. Make sure that the transmission is in Forward
and turn the transmission control lever to third
gear.
7. Increase the engine speed to full throttle.
position.
Issued 3-01
Printed in U.S.A.
Copyright
2002-4
9. Repeatedly raise and lower the lift arms.
10. Check the engine speed by pressing the program
switch, left side of the program/reset switch.
Press the up count switch until the display reads
(OFF) position.
NOTE: The engine speed must be checked while the
bucket is rolled back and the lift arms are moving.
11. Release the bucket control lever.
12. Decrease the engine speed to low idle.
13. Stop the engine.
Understanding the Results of Test

No. 1

No. 2
1. If the engine speed was as specified, the engine,
torque converter and transmission are probably
good.
2. If the engine speed was more than specified, the
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
troubleshooting information.
3. If the engine speed was less than specified, do
Test No. 3.
Test No. 3 - Hydraulic Stall

1. Start the engine and run at 1500 rpm.
1. If the engine speed was as specified, the engine,

torque converter, transmission and hydraulic
system are probably good.
2. If the engine speed was not as specified, do Test

No. 2 and 3.
4. Repeatedly raise and lower the lift arms.
Test No. 2 - Torque Converter Stall

1. Sit in the seat.
3. Press the brake pedal, and shift into Forward.
4. Make sure the parking brake is released (OFF).
5. Run the engine at low idle.
6. Push down and hold the brake pedal for the
remainder of this test.
7. Make sure that the transmission is in Forward
and turn the transmission control lever to third
gear.

position.

(OFF) position.
NOTE: The engine speed must be checked while the
bucket is rolled back and the lift arms are moving.
6. Release the bucket control lever.
8. Stop the engine.

No. 3
1. If the engine speed was as specified, the engine

and hydraulic system are good.

(OFF) position.
2. If the engine speed was more than specified, a

component in the hydraulic system is probably
the cause. See Section 8002 for troubleshooting
information.
3. If the engine speed was less than specified in all

tests, the engine is probably the cause.
Bur 6-40770
Issued 3-01
Printed in U.S.A.
Copyright
SECTION INDEX
FUEL SYSTEM
Section Title
Section Number
FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL
CASE CORPORATION
700 State Street
Bur 6-42300

Printed in U.S.A.
August, 2001
Copyright
Copyright
SECTION INDEX
ELECTRICAL
Section Title
Section Number
Removal and Installation of Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001

Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Electrical Specifications and Troubleshooting P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Information and Diagnostic Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005
Alternator - 65 Ampere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4007
Alternator - 45 Ampere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4008
CASE CORPORATION
700 State Street
Bur 6-42311

Printed in U.S.A.
Copyright
4001
Copyright
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND
ALTERNATOR
CASE CORPORATION
700 State Street
Bur 6-42321

Printed in U.S.A.
Copyright
4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
P.I.N. JEE0135501 AND ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
P.I.N. JEE0135501 AND ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bur 6-42321
Revised 2-03
Printed in U.S.A.
Copyright
4001-3
STARTER
P.I.N. JEE0135500 AND BELOW
Removal
Installation
NOTE: The starter is located on the left side of the

engine, mounted on the engine flywheel housing.
STEP 8
Position and support starter (3) on engine. Install

washers (7) and bolts (6) to secure starter. Tighten
bolts (6) to a torque of 41 to 74 Nm (30 to 54 lb-ft).
STEP 2
STEP 9
Remove air cleaner and air cleaner bracket.
Connect positive cables to starter following tags

installed during removal. Install nut (2) and tighten to
a torque of 22.5 to 29.4 Nm (17 to 22 lb-ft). Push boot
over nut.
STEP 1
STEP 3
Move boo t to ga in a ccess to nu t (2 ). Refe r to
illustration below.
STEP 10
STEP 4
Conn ect so leno id wire to starter followin g ta g

installed during removal. Secure using screw (4).
Tighten screw to a torque of 2.6 to 4.6 Nm (2 to 3.4
lb-ft).
Remove nut (2) and tag and disconnect all positive

cables from starter (3).
STEP 5
STEP 11
Move cover to gain access to screw (4).
Push cover over screw (4).
STEP 6
STEP 12
Remove screw (4) and tag and disconnect solenoid

wire from starter (3).
Install air cleaner bracket and air cleaner.
STEP 7
STEP 13
Remove bolts (6) and washers (7). Remove starter

(3).
1
7
6
2
7
6
5
BS01C137
1. POSITIVE BATTERY CABLE

CONNECTION
2. NUT
3. STARTER
4.
5.
6.
7.
SCREW
SOLENOID WIRE CONNECTION
BOLT
WASHER
STARTER REMOVAL AND INSTALLATION - P.I.N. JEE0135500 AND BELOW

Bur 6-42321
Revised 2-03
Printed in U.S.A.
Copyright
4001-4
STARTER
Removal
STEP 17
NOTE: The starter is located on the left side of the

engine, mounted on the engine flywheel housing.
Remove nut and washer securing cables to starter

B+ stud (5). Identify, tag, and disconnect the two
cables from B+ stud.
STEP 14
STEP 18
STEP 15
Remove air cleaner and air cleaner bracket.
STEP 16
5
BS02J055
Id entify and tag rear chassis harness wire (6)

connected to starter solenoid terminal. Disconnect
wire from terminal.
STEP 19
2
1
BS02J056
1. ACORN NUT
2. NUT
3. WASHER
Support starter and remove bolts and washers

securing starter to engine. Remove starter.
4. COVER
5. B+ STUD
Remove acorn nut (1), nut (2), and washer (3)

securing cover (4) to starter. Remove cover.
Bur 6-42321
Revised 2-03
Printed in U.S.A.
Copyright
4001-5
Installation
STEP 23
STEP 20
Put cover (4) on starter. Install washer (3), nut (2),

and acorn nut (1) to secure cover.
Position and support starter on engine. Install

washers and bolts to secure starter. Tighten bolts to
a torque of 44 to 54 Nm (32 to 40 lb-ft).
STEP 24
STEP 21
STEP 25
Install air cleaner bracket and air cleaner.
BS02J055
Connect rear chassis harness wire (6) to starter

solenoid terminal following tag installed during
STEP 22
5
1
BS02J056
1. ACORN NUT
2. NUT
3. WASHER
4. COVER
5. B+ STUD
Connect two cables to starter B+ stud (5) following

tags installed during removal. Install nut and washer
to secure cable terminals to B+ stud. Remove and
discard tags from cables.
Bur 6-42321
Revised 2-03
Printed in U.S.A.
Copyright
4001-6
ALTERNATOR
Removal
Installation
STEP 26
STEP 33
Put master disconnect switch in OFF position and

remove drive belt guard.
Install alternator (4), shield (3), washer (19) and bolt

(18) on machine. Tighten bolt (18) to a torque of 60 to
104 Nm (42.5 to 76 lb-ft). Refer to illustration on
following page.
STEP 27
Use a wrench to move belt tensioner (2) and loosen
tension on belt (1). Refer to illustration on following
page.
STEP 34
Install washer (16), nut (14) and bolt (13). Tighten
bolt (13) to a torque of 60 to 104 Nm (42.5 to 76 lb-ft).
STEP 28
Remove belt (1).
STEP 35
STEP 29
Use a wrench to move belt tensioner (2) until belt (1)

can be installed.
Remove boots (5 and 8), nuts (6 and 9), and lock

washers (7 and 10). Tag and disconnect wires (11
and 12) from alternator (4).
STEP 36
STEP 30
STEP 37
Remove bolt (13), nut (14), and washer (16) from

support bracket (17) and alternator (4).
Install wire (12), lock washer (7) and nut (6) on

alternator D+ terminal. Tighten nut (6) to a torque of
3.5 to 3.9 Nm (2.6 to 2.9 lb-ft).
Install belt (1).
STEP 31
Loosen and remove bolt (18) and washer (19).
STEP 38
Install boot (5).
STEP 32
Remove alternator (4) and shield (3) from machine.
STEP 39
Install wire (11), lock washer (10) and nut (9) on
alternator B+ terminal. Tighten nut (9) to a torque of
15 to 27 Nm (11 to 20 lb-ft).
STEP 40
Install boot (8).
STEP 41
Install drive belt guard and put master disconnect
switch in ON position.
Bur 6-42321
Revised 2-03
Printed in U.S.A.
Copyright
4001-7
10
12
11
17
14
16
2
4
13
18
19
3
20
15
21
1
BS01C136
1.
2.
3.
4.
5.
6.
7.
FAN BELT
BELT TENSIONER
SHIELD
ALTERNATOR
BOOT (NOT SHOWN)
NUT
LOCK WASHER
8.
9.
10.
11.
12.
13.
14.
BOOT
NUT
LOCK WASHER
B+ WIRE
D+ WIRE
BOLT
NUT
15.
16.
17.
18.
19.
20.
21.
BRACE
WASHER
SUPPORT
BOLT
WASHER
PULLEY
BOLT
ALTERNATOR REMOVAL AND INSTALLATION ILLUSTRATION - P.I.N. JEE0135500 AND BELOW
Bur 6-42321
Revised 2-03
Printed in U.S.A.
Copyright
4001-8
BS01E102
ALTERNATOR WITH AIR CONDITIONING DRIVE BELT INSTALLATION - P.I.N. JEE0135500 AND BELOW
Bur 6-42321
Revised 2-03
Printed in U.S.A.
Copyright
4001-9
ALTERNATOR
Removal
STEP 45
STEP 42
5
STEP 43
1
2
7
BS02J059
5. BOOT
6. WIRE
7. CONNECTOR
Pull boot (5) away from alternator stud. Identify, tag,

an d d is co nn e ct e ng ine h a rn ess w ir e (6 ) fr om
alternator stud.
STEP 46
Identify, tag, and disconnect two connectors (7).
STEP 47
BS02J049
1. BOLT
2. WASHER
3. DRIVE BELT GUARD
Remove four bolts (1) and washers (2) securing drive

belt guard to master disconnect switch mounting
bracket and belt guard bracket.
STEP 44
10
4
BS02K146
11
A
10
BS02K147
4. DRIVE BELT

(A) in bracket for automatic belt tensioner. Push
down on breaker bar or ratchet to release drive belt
tension and remove drive belt (4) from alternator
pulley.
Bur 6-42321
BS02K145
A. BREAKER BAR
8. BOLT
9. BRACE
10. BOLT
11. ALTERNATOR
Remove bolt (8 ) securing bra ce (9) to engine.

Loosen bolt (10) and move alternator then remove
b o lt ( 1 0 ) a n d a s s o c ia te d h a r d w a r e . R e m o v e
alternator.
Revised 2-03
Printed in U.S.A.
Copyright
4001-10
Installation
STEP 50
STEP 48
Connect engine harness wire (6) to alternator stud

following tag installed during removal. Push boot (5)
over alternator terminal. Remove and discard tag.
11
STEP 51
4
10
A
BS02K145
9
8
BS02K147
4. DRIVE BELT
A. BREAKER BAR

(A) in bracket for automatic belt tensioner. Push
down on breaker bar or ratchet then position drive
belt (4) on alternator pulley. Release breaker bar or
ratchet to put tension on drive belt.
10
BS02K146
8. BOLT
9. BRACE
STEP 52
10. BOLT
11. ALTERNATOR
Position and support alternator (11) on alternator

mounting bracket. Install bolt (10) and associated
hardware. Reposition alternator and install bolt (8) to
secure brace (9) to engine. Tighten bolt (10) to a
torque of 37 to 49 Nm (27 to 36 lb-ft). Tighten bolt (8)
to a torque of 20 to 28 Nm (15 to 21 lb-ft).
1
2
3
STEP 49
5
6
BS02J049
1. BOLT
2. WASHER
3. DRIVE BELT GUARD
7
BS02J059
5. BOOT
6. WIRE
7. CONNECTOR
Connect two connectors (7) following tags installed

Put belt guard bracket in position between master

disconnect switch mounting bracket and belt guard
bracket. Secure using four bolts (1) and washers (2).
STEP 53
Bur 6-42321
Revised 2-03
Printed in U.S.A.
4002
Copyright
Section
4002
ELECTRICAL SPECIFICATIONS AND
TROUBLESHOOTING
CASE CORPORATION
700 State Street
Bur 6-40782

Printed in U.S.A.
March, 2001 (Revised June, 2002)
Copyright
NOTES
Copyright
4002-3
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING, ALTERNATOR, ETHER START,
IGNITION SWITCH AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ether Start Temperature Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Ether Start Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ether Start Relay No. 6 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ether Start Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Neutral Start Relay No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ignition Relay No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Relay No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessory Relay No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltmeter Relay No. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
42
42
42
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE,

SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Kick-down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FNR Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Alarm Relay No. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
45
45
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM/RESET SWITCH, PARK BRAKE

SWITCH, INSTRUMENT CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH . . . 46
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-4
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program/Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument Cluster (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Up/down Count Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
48
48
48
49
49
49
50
51
52
52
TROUBLESHOOTING ENGINE OIL PRESSURE SWITCH, PILOT CONTROL, PARKING BRAKE, AND
REDUNDANT BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Control Relay No. 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Relay No. 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Brake Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Socket No. 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
54
54
54
55
55
55
56
56
56
TROUBLESHOOTING BUCKET CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Detent Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bucket Control Valve Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Float Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Float Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
57
58
58
59
59
59
60
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL . . . . . . . . . . . . . . .

Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Relay No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
62
62
63
63
64
64
65
65
65
TROUBLESHOOTING WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
67
68
68
69
69
69
TROUBLESHOOTING HORN, BLOWER, AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horn Relay No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Low Pressure Switch (In Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
70
71
71
71
72
72
72
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-5
A/C High Pressure Switch (In Rear Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Clutch Lockout Relay No. 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
73
73
73
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET,

RADIOS AND SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Radio or 24 Volt Radio (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radio Power Converter (24 volts to 12 volts) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
74
75
75
75
75
76
76
76
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD SWITCH, TURN SIGNAL/HI/LOW BEAM/
HORN SWITCH, AND FLASHER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Beacon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Brake Lamps Relay No. 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Turn Signal, Hi/Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH, AND CAB LIGHTS . .
LH Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Five Position Rotary Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High/Low Beam Relay No. 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
82
83
84
85
85
86
86
86
87
87
88
88
88
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-6
NOTES
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage............................................................................................................................................... 24 volts
Batteries
Specifications are the same for production battery and replacement battery.
Production Battery Case P/N ................................................................................................................... A176482
Replacement Battery Case P/N ............................................................................................................... A180406
Group Size .......................................................................................................................................................... 31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17C (0F) for 60 Seconds At 6.0 Volts .................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Plates per Cell ..................................................................................................................................................... 17
Approximate weight with electrolyte ..................................................................................... 25.9 kg (57.1 pounds)
Nonspill caps ............................................................................................................................................ Standard
Alternator ..................................................................................................................................... 24 volt, 45 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20C (68F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20C (68F) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20C (68F) .......................................... 3521 ohms
Coolant and Hydraulic Temperature Sender (Yellow Line) 105C (221F) ................................................. 154 ohms
Coolant and Hydraulic Temperature Sender (Red Line) 110 C (230F) .................................................. 133.9 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Setpoint ............................................................................................................................. 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Setpoint ............................................... 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Setpoint .................................. -6.4 kPa (Gauge) (-0.928 psig)
Brake Warning Pressure Switch (Normally Closed) Opening Setpoint ...................................... 117.2 Bar (1700 psi)
A/C High Pressure Switch (Normally Open) Closing Setpoint..................... 27.6 Bar (400 psi) (increasing pressure)
A/C Low Pressure Switch (Normally Closed) Opening Setpoint .................... 1.4 Bar (20 psi) (decreasing pressure)
Thermostat Switch
Contacts 2 to 3 close at initial turn of the switch. Contacts 1 to 2 close with thermal setting.
Engine Oil Pressure Switch (Normally Closed) Opening Setpoint ................................................... 0.69 Bar (10 psi)
Fuel Solenoid Resistance (pull in) At 20C (68F) (Nominal) ..................................................................... 1.1 ohms
Fuel Solenoid Resistance (hold in) At 20C (68F) (Nominal) ................................................................... 41.5 ohms
Brake Declutch Pressure Switch (Normally Closed) Opening Setpoint............................................. 24 Bar (350 psi)
Redundant Brake Pressure Switches (Normally Open) Closing Setpoint ......................................... 62 Bar (900 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Setpoint....................................................... 4.1 Bar (60 psi)
Float Pressure Switch (Normally Open) Closing Setpoint ................................................................. 19 Bar (275 psi)
Secondary Steering Pressure Switch (Form C) Closing Setpoint ...................................................... 2.4 Bar (35 psi)
Ether Start Temperature Switch
Opens.................................................................................................................................. 13 3C (55.4 5.4F)
Closes ............................................................................................................................. 1.5 4.5C (34.7 8.1F)
Ether Start Solenoid DC Resistance At 25 C (77F) (Nominal)................................................................... 2.2 ohms
Parking Brake Solenoid DC Resistance At 20C (68F) (Nominal) ........................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20C (68F) (Nominal) ........................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20C (68F) (Nominal) ...................................... 27.4 ohms
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-8
Ride Control Solenoid DC Resistance At 20C (68F) (Nominal) .............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20C (68F) (Nominal) ............................................................... 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20C (68F) (Nominal) .................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20C (68F) (Nominal)........................................................... 39.3 ohms
Float Solenoid DC Resistance At 20C (68F) (Nominal) .......................................................................... 39.7 ohms
Rollback Pressure Switch (Normally Closed) Opening Setpoint ........................................................ 6.2 Bar (90 psi)
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-9
ELECTRICAL WIRE IDENTIFICATION

Wire Identification Codes
21C Bk - 1.0
Wire Size (mm 2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
Circuit
5.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Alternator B+
R-13.0-SXL
153 Alternator B+
149 Starter Power
14
Alternator D+
Or-1.0-SXL
94M Engine Trans
154 Alternator D+
44
Brake Lt Input Signal
T-1.0-SXL
159 Brake Lt Press Sw
21M Rear Cab
29
52
Fan Reverse Sol
W-1.0-SXL
158 Fan Rev Sol Opt
21M Rear Cab
27
57
Pin Engage Sol Pwr
W-1.0-SXL
1 Cab-Frnt Chas
107M Pin Engage Opt
58
Ride Cntrl Sol Pwr
W-1.0-SXL
1 Cab-Frnt Chas
SPL_A7 Ride Cntrl Sol Pwr
64
Horn
Or-1.0-SXL
1 Cab-Frnt Chas
147 Horn Pwr
0_A
Ground
Bk-1.0-SXL
125 LH Rear Comb Lt
SPL_E4 SPL_E4
0_AA
Height-RTT Grnd
Bk-1.0-SXL
10 Height Cntrl-RTT
SPL_A2 Splice A2
SPL_A2
0_AB
Pin Engage Grnd
Bk-1.0-SXL
107M Pin Engage Opt
SPL_A1 Splice A1
SPL_A1
0_AC
Ride Cntrl Grnd
Bk-1.0-SXL
5F Ride Control Opt
SPL_A1 Splice A1
SPL_A1
0_AD
Horn Grnd
Bk-1.0-SXL
146 Horn Grnd
SPL_A1 Splice A1
SPL_A1
0_AF
RTD Grnd
Bk-1.0-SXL
12F RTD
SPL_A2 Splice A2
SPL_A2
0_AG
Lights Grnd RH
Bk-1.0-SXL
8 Lights RH
SPL_A1 Splice A1
SPL_A1
0_AH
Grnd Frnt Chas
Bk-5.0-SXL
144 Grnd Rear Chas
143 Grnd Frnt Chas
0_AJ
Grnd Cab
Bk-2.0-SXL
145 Grnd Cab
SPL_A1 Splice A1
SPL_A1
0_AK
Grnd Cab
Bk-1.0-SXL
145 Grnd Cab
SPL_A2 Splice A2
SPL_A2
0_AL
Lights Grnd LH
Bk-1.0-SXL
6 Lights LH
SPL_A1 Splice A1
SPL_A1
0_AM
RTD Grnd
Bk-1.0-SXL
12M RTD
200 RTD
0_AN
Sec Str Signal Grd
Bk-1.0-SXL
131F Sec Str Pres Sw Opt
180F Sec Str Mod Opt
0_AP
Splice
Bk-1.0-SXL
SPL_A6 SPL_A6
0_AQ
Ground
Bk-1.0-SXL
229M Diode Module
0_AR
Splice
Bk-1.0-SXL
SPL_A2 Splice A2
0_BA
Signal Grnd
Bk-1.0-SXL
150 Signal Grnd
SPL_B1
0_BB
Ether Fuel Sol Grnd
Bk-2.0-SXL
134 Fuel Solenoid
151 Solenoid Grnd
0_BC
Ether Fuel Sol Grnd
Bk-1.0-SXL
97 Ether Temp Sw
151 Solenoid Grnd
0_BD
Air Filter Rest Sw Grnd
Bk-1.0-SXL
117 Air Filter Res Sw
SPL_B1
0_BE
Eng Cool Temp Ground
Bk-1.0-SXL
138 Eng Cool Temp
SPL_B1
Bur 6-40782
SPL_A6 179F Float Solenoid

C
SPL_A7
SPL_A6 SPL_A6
SPL_A6
SPL_A2 SPL_A6 SPL_A6
SPL_A6
Revised 6-02
Printed in U.S.A.
Copyright
4002-10
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_BF
Signal Ground
Bk-1.0-SXL
94M Engine Trans
SPL_B1
0_BG
Analog Ground
Bk-1.0-SXL
94M Engine Trans
15
152 Analog Grnd
0_BH
Signal Ground
Bk-1.0-SXL
94M Engine Trans
11
SPL_B1
0_BJ
Ground
Bk-1.0-SXL
268 AC Diode Ground
265F Diode Module
0_C
Ground
Bk-1.0-SXL
127 RH Rear Comb Lt
SPL_E4 SPL_E4
0_CA
Sec Str Signal Grd
Bk-1.0-SXL
90M Sec Str Mod
11
SPL_C1
0_CB
Sec Str Signal Grd
Bk-1.0-SXL
90M Sec Str Mod
12
SPL_C1
0_CC
Sec Str Signal Grd
Bk-1.0-SXL
180M Sec Str Mod Frnt Harn
SPL_C1
0_CD
Sec Str Signal Grd
Bk-1.0-SXL
177 Sec Str Mod Sig Grnd
SPL_C1
0_CE
Sec Str Chassis Grnd
Bk-1.0-SXL
90M Sec Str Mod
176 Sec Str Mod Chas Grnd
0_CF
Sec Str Grnd
Bk-1.0-SXL
264M Sec Str Sol Opt
SPL_C1
0_D
Hood Ground
Bk-2.0-SXL
164 Engine Grounds
SPL_E4 SPL_E4
0_DA
AC Brk Lt Time Del Horn Grnd
Bk-0.8-SXL
204F Relay Brake Lights
85
220F Ground Cab
0_DAB Signal Ground
Bk-0.8-SXL
22F Cab Transmission
15
13F Cab-Pedestal
38
0_DAC Relay Grnd
Bk-0.8-SXL
13F Cab Pedestal
53
222F Ground Cab
0-DAD
Bk-1.0-SXL
222F Ground Cab
SPL_D13 Ground
0_DAE Ground
Bk-1.0-SXL
199F Trans Enable Sw
SPL_D13 Ground
0_DAF Switch Grnd
Bk-1.0-SXL
210F Fan Reverser Sw
40F Pin Engage Sw
0_DAG Switch Grnd
Bk-1.0-SXL
39F Return To Travel Sw
SPL_D13 Ground
0_DAH Switch Grnd
Bk-1.0-SXL
0_DAJ
Switch Grnd
Bk-1.0-SXL
36F Detent Switch
0_DAK Switch Grnd
Bk-1.0-SXL
36F Detent Switch
38F Declutch Switch
0_DAL
Switch Grnd
Bk-1.0-SXL
40F Pin Engage Sw
44F Ride Control Sw
0_DAM Switch Grnd
Bk-1.0-SXL
44F Ride Control Sw
41F Trans Auto Sw
0_DAN Flasher Module Grnd
Bk-0.8-SXL
62M Flasher Module
SPL_D14 Module Grnds
0_DAP Ground
Bk-1.0-SXL
42F Beacon Sw
0_DAQ Flasher Module Grnd
Bk-0.8-SXL
62M Flasher Module
0_DAR Blwr Wiper Seat Grnd
Bk-1.0-SXL
35F Wiper and Washer Sw
218F Ground Cab
0_DAS Time Delay Mod Grnd
Bk-0.8-SXL
63M Time Delay Module
0_DAT Brk Lt Time Del Horn Grnd
Bk-0.8-SXL
220F Ground Cab
Relay Grnd
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-11
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_DAU Analog Ground
Bk-0.8-SXL
30
13F Cab-Pedestal
0_DAV Diag TECM Grnd
Bk-0.8-SXL
108F Diagnostic Connector
221F Ground Cab
0_DAW Ground
Bk-1.0-SXL
42F Beacon Sw
118F Back-up Alarm Dis Sw
0_DAX Beacon Wiper Diode Grnd
Bk-0.8-SXL
206F Cab Floor Weld Stud
140M Diode Module
0_DAY Switch Grnd
Bk-1.0-SXL
SPL_D13 Ground
0_DB
Can Pilot Sol Grnd
Bk-0.8-SXL
89M Pilot Pres Sol
219F Ground Cab
0_DC
Relay Grnd
Bk-0.8-SXL
52F Ether Start Relay
85
49F Accessory Relay
85
0_DD
Ride Cntrl Relay Sink
Bk-0.8-SXL
19F TECM
57
50F Ride Control Relay
85
0_DE
Relay Grnd
Bk-0.8-SXL
48F Ignition Relay #2
85
85
0_DF
Relay Grnd
Bk-0.8-SXL
49F Accessory Relay
85
85
0_DG
Relay Grnd
Bk-0.8-SXL
85
58F Volt Meter Relay
85
0_DH
Relay Grnd
Bk-0.8-SXL
85
54F Neutral Start Relay
85
0_DJ
Relay Grnd
Bk-0.8-SXL
85
222F Ground Cab
0_DK
Bk-0.8-SXL
203F Relay AC
85
85
0_DL
Signal Ground
Bk-0.8-SXL
22F Cab-Transmission
23
13F Cab-Pedestal
39
0_DM
Speed Sensor Grounds
Bk-0.8-SXL
19F TECM
11
0_DN
Out Speed Sensor Grnd
Bk-0.8-SXL
19F TECM
28
0_DP
Diag TECM Grnd
Bk-0.8-SXL
19F TECM
221F Ground Cab
0_DQ
Diag TECM Grnd
Bk-0.8-SXL
19F TECM
221F Ground Cab
0_DR
Dome Court Work Lt Grnd
Bk-1.0-SXL
24M Cab Roof
223F Ground Cab
0_DS
Bk-1.0-SXL
24M Cab Roof
223F Ground Cab
0_DT
Bk-1.0-SXL
23F Cab Roof
223F Ground Cab
0_DU
Beacon Wiper Diode Grnd
Bk-1.0-SXL
23F Cab Roof
0_DV
Bk-0.8-SXL
13F Cab-Pedestal
61
0_DW
Ground
Bk-0.8-SXL
45F Rear Wiper Sw
0_DX
Horn Ground
Bk-0.8-SXL
13F Cab-Pedestal
41
220F Ground Cab
0_DY
Blwr Wiper Seat Grnd
Bk-1.0-SXL
28M Seat Comp Motor
218F Ground Cab
0_DZ
Bk-2.0-SXL
29M Blower Motor
218F Ground Cab
0_E
Fuel Redundant Br Cool Grnd
Bk-1.0-SXL
160 Engine Grounds
171 Fuel Sender Grnd
0_F
Frt Rear Wash Hot Grnd
Bk-1.0-SXL
162 Engine Ground
3 Rear Washer
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-12
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_G
Bk-1.0-SXL
2 Front Washer
162 Engine Ground
0_GA
Relay Ground
Bk-2.0-SXL
93M Relay Box
SPL_G1 Splice G1
0_GB
Starter Relay Ground
Bk-2.0-SXL
132 Starter Relay
SPL_G1 Splice G1
0_GC
Fuel Relay Ground
Bk-2.0-SXL
173 Fuel Relay
SPL_G1 Splice G1
0_HA
Signal Ground
Bk-1.0-SXL
22M Cab Transmission
23
94F Eng-Trans
0_HB
Signal Ground
Bk-1.0-SXL
15
94F Eng-Trans
11
0_HC
Analog Ground
Bk-1.0-SXL
30
94F Eng-Trans
15
0_HD
Speed Sense Grnd
Bk-1.0-SXL
11
SPL_H2 Splice H2
0_HE
Out Speed Grnd
Bk-1.0-SXL
28
100 Out Speed Sens
0_HF
Eng Speed Grnd
Bk-0.8-BLD
101 Eng Speed Sense
SPL_H2 Splice H2
Splice
0_HG
Int Speed Sig
Bk-0.8-BLD
95 Int Speed Sense
SPL_H2 Splice H2
Splice
0_HH
Turb Speed Grnd
Bk-0.8-BLD
96 Turb Speed Sense
SPL_H2 Splice H2
Splice
0_J
Hood Ground
Bk-1.0-SXL
164 Engine Grounds
128F Rear-Hood
0_JA
Hood Ground
Bk-1.0-SXL
128M Lic/Backup Alarm
SPL_J1 SPL_J1
0_JB
Backup Alarm Grnd
Bk-1.0-SXL
174 Backup Alarm Grnd
SPL_J1 SPL_J1
0_JC
Lic Plate Lt Grnd
Bk-1.0-SXL
168 Lic Plate Light
SPL_J1 SPL_J1
0_KD
Signal Grnd
Bk-0.8-SXL
76 Instrument Cluster
39
13M Pedestal-Cab
39
0_KE
Signal Grnd
Bk-0.8-SXL
38
SPL_K1 SPL_K1
0_KF
Horn High Low Beam Grnd
Bk-0.8-SXL
187 High Low Beam
185 Horn Switch
0_KG
Bk-0.8-SXL
13M Pedestal-Cab
41
185 Horn Switch
0_KH
Pilot Light Grnd
Bk-0.8-SXL
71 Hazard Switch
37 Pilot Control Switch
0_KJ
Pilot Light Grnd
Bk-0.8-SXL
72 Parking Brake Switch
0_KK
Pilot Light Grnd
Bk-0.8-SXL
74 Up Down Count Switch
0_KL
Pilot Light Grnd
Bk-0.8-SXL
75 Program Reset Switch
0_KM
Pilot Light Grnd
Bk-0.8-SXL
13M Pedestal-Cab
53
0_KN
Front Wiper Grnd
Bk-0.8-SXL
13M Pedestal-Cab
61
60 Front-Wiper Motor
0_KP
Analog Grnd
Bk-0.8-SXL
13M Pedestal-Cab
0_KQ
Signal Grnd
Bk-0.8-SXL
37
SPL_K1 SPL_K1
0_KR
Signal Grnd
Bk-0.8-SXL
13M Pedestal-Cab
38
SPL_K1 SPL_K1
Ground
Bk-1.0-SXL
157 Redundant Brake Sw
SPL_E9 SPL_E9
0_L
Bur 6-40782
Revised 6-02
Splice
1
Printed in U.S.A.
Copyright
4002-13
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_M
Ground
Bk-1.0-SXL
SPL_E9 SPL_E9
0_MA
Rear Wiper Mtr Grnd
Bk-1.0-SXL
82M Rear Wiper Mtr
SPL_M6 Rear Wip Beacon Grnd
0_MB
Dome Lt Grnd
Bk-0.8-SXL
84F Dome Light
SPL_M5 Dome Courtesy Lt Grnd
0_MC
Beacon Light Ground
Bk-1.0-SXL
85F Beacon Light
0_MD
Beacon-Rear Wiper Grnd
Bk-1.0-SXL
23M Roof-Cab
0_ME
LH Rear Work Lt Grnd
Bk-1.0-SXL
83F LH Rear Work Lt
SPL_M3 Rear Work Lts Grnd
0_MF
RH Rear Work Lt Grnd
Bk-1.0-SXL
80F RH Rear Work Lt
0_MG
Rear Work Light Grnd
Bk-1.0-SXL
23M Roof-Cab
0_MH
LH Frnt Work Lt Grnd
Bk-1.0-SXL
79F LH Front Work Lt
SPL_M2 Frnt Work Lt Grnd
0_MJ
RH Frnt Work Lt Grnd
Bk-1.0-SXL
78F RH Front Work Lt
0_MK
Frnt Work Lt Grnd
Bk-1.0-SXL
24F Roof-Cab
0_ML
Courtesy Lt Grnd
Bk-0.8-SXL
77F Courtesy Lt
0_MM
Dome Lt Grnd
Bk-0.8-SXL
84F Dome Light
84F Dome Light
0_MN
Dome Courtesy Lt Grnd
Bk-0.8-SXL
24F Roof-Cab
0_N
Brk Warn Pr Sw
Bk-1.0-SXL
88 Brk Warn Pr Sw
SPL_E9 SPL_E9
0_NA
Chas Grnd Blck Grnd
Bk-62.0-SGR
232F Chas Grnd Blck Grnd
0_NB
Discon-Blck Grnd
Bk-62.0-SGR
235F Discon-Blck Grnd
0_NC
Disconect Battery
Bk-62.0-SGR
237F Disconect Battery
236F Disconect Battery
0_ND
Chas Grnd-Sec Strg Mtr
Bk-62.0-SGT
242F Chas Grnd-Sec Strg Mtr
0_P
Bk-1.0-SXL
160 Engine Grounds
SPL_E9 SPL_E9
0_PA
Left Spkr Ground
Bk-0.8-SXL
114F
112M
0_PB
Right Spkr Ground
Bk-0.8-SXL
114F
111M
0_PC
Radio Ground
Bk-0.8-SXL
114F
110F 24/12V Converter
0_PD
Radio Ground
Bk-1.0-SXL
247F Radio Ground
109M 24/12V Converter
0_Q
Park Str Fuel Relay Grnd
Bk-1.0-SXL
87 Parking Brk Sol
165 Engine Ground
0_QA
Left Spkr Ground
Bk-0.8-SXL
114M
113 Radio
0_QB
Right Spkr Ground
Bk-0.8-SXL
114M
113 Radio
0_QC
Radio Ground
Bk-0.8-SXL
114M
113 Radio
0_RA
Converter Ground
Bk-5.0-SXL
251F Converter Ground
0_RB
Outlet Ground
Bk-3.0-SXL
252F Outlet Ground
253F Power Outlet
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-14
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_S
Cigar Lighter Grnd
Bk-3.0-SXL
261F Cigar Lighter Grnd
259F Cigar Lighter
0_U
Bk-2.0-SXL
93F Rear-Fuel Str Rel
165 Engine Ground
0_V
Bk-1.0-SXL
104 Cool Level Sensor
160 Engine Grounds
0_VA
Y-0.8-SOLID
274F Cool Jmpr Rear Chsis
275M Coolant Jmpr Coolant Sndr
0_W
Bk-1.0-SXL
136 Hyd Oil Temp Send
162 Engine Ground
0_X
Fan Rev Sol Grd
Bk-1.0-SXL
158 Fan Rev Sol Opt
163 Engine Ground
0_Y
Engine Cab Grd
Bk-13.0-SXL
161 Engine Ground
167 Engine Cab Grnd
12K_A
Acc Power
Or-1.0-SXL
49F Accessory Relay
86
18F Fuse Block
M1
12K_B
Acc Power
Or-0.8-SXL
49F Accessory Relay
86
13F Cab-Pedestal
63
12K_C
Ign Sw Acc Pwr
Or-0.8-SXL
13M Pedestal-Cab
63
69 Ignition Switch
12P_A
Acc Relay
Or-1.0-SXL
49F Accessory Relay
87
18F Fuse Block
L1
12P_B
Acc Relay
Or-1.0-SXL
18F Fuse Block
N1
18F Fuse Block
L1
12V_A
12V Pwr To Outlet
R-3.0-SXL
257F 12V Pwr To Outlet
253F Power Outlet
12V_B
12V Pwr To Fuse Blck
R-5.0-SXL
258F 12V Pwr To Fuse Blck
18F Fuse Block
13C
Fuel Sol
Or-1.0-SXL
94M Engine Trans
139F Disc Harness
13C_A
Fuel Sol
Or-1.0-SXL
94F Eng-Trans
22M Cab-Transmission
13C_B
Fuel Sol Pwr
Or-0.8-SXL
57F Engine Shutdown Relay
87
217M Engine Shutdown Jumper
13C_C
Fuel Sol Pwr
Or-0.8-SXL
87
140M Diode Module
13C_D
Fuel Sol Pwr
Or-0.8-SXL
87
13C_E
Fuel Sol Pwr
Or-1.0-SXL
139M Disconnect-Engine
231F Fuel Sol Disconnect
13D
Delay Pwr (2 Way)
Or-1.0-SXL
18F Fuse Block
S1
13K
Ignition Switch Pwr
Or-0.8-SXL
13M Pedestal-Cab
56
69 Ignition Switch
13K_A
Ignition Switch Pwr
Or-1.0-SXL
86
86
13K_B
Ignition Switch Pwr
Or-1.0-SXL
86
30
13K_C
Ignition Switch Pwr
Or-1.0-SXL
86
30
13K_D
Ignition Switch Pwr
Or-0.8-SXL
30
217F Engine Shutdown Jumper
13K_E
Ignition Switch Pwr
Or-0.8-SXL
86
SPL_D22 Ignition Switch
13K_F
Ignition Switch Pwr
Or-0.8-SXL
13K_G Ignition Switch Pwr
Or-0.8-SXL
13F Cab-Pedestal
56
Or-1.0-SXL
139F Disc Harness
134 Fuel Solenoid
13M
Fuel Sol Hold In
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-15
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
13M_A Fuel Sol Hold In
Or-1.0-SXL
13P_A
Ign Rel 1 Out
Or-1.0-SXL
87
18F Fuse Block
A1
13P_B
Ign Rel 1 Out
Or-1.0-SXL
87
18F Fuse Block
P1
13R
Ign Rel 2 Out (5 Way)
Or-1.0-SXL
87
18F Fuse Block
F1
13V
Voltmeter Relay Out
Or-1.0-SXL
87
18F Fuse Block
V1
14
Alternator D+
LG-1.0-SXL
154 Alternator
94M Eng-Trans
14_A
Alternator D+
LG-1.0-SXL
94F Eng-Trans
14_B
Alternator D+
LG-0.8-SXL
215F Alternator Resistor
18A
Rear Fld Lts Fuse Pwr
Or-2.0-SXL
32F Light Switch
18F Fuse Block
18B
High Beam LH
Or-1.0-SXL
1 Cab-Frnt Chas
6 Lights LH
18B_A
High Beam LH
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
18C
High Beam RH
Or-1.0-SXL
1 Cab-Frnt Chas
8 Lights RH
18C_A
High Beam Fused Pwr
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
C2
18C_B
High Beam Fused Pwr
Or-0.8-SXL
13F Cab-Pedestal
15
18F Fuse Block
C2
18C_C
High Beam Telltale
Or-0.8-SXL
15
13M Pedestal-Cab
15
18D
Low Beam LH
Or-1.0-SXL
1 Cab-Frnt Chas
6 Lights LH
18D_A
Low Beam LH
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
18E
Low Beam RH
Or-1.0-SXL
1 Cab-Frnt Chas
8 Lights RH
18E_A
Low Beam RH
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
Position LH
Or-1.0-SXL
1 Cab-Frnt Chas
6 Lights LH
18F_A
Left Tail
Or-1.0-SXL
125 LH Rear Comb Lt
21M Rear-Cab
18F_D
Left Tail Pos
Or-0.8-SXL
21F Cab-Rear
18F Fuse Block
F2
18F_E
Left Tail Pos
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
F2
18G
Position RH
Or-1.0-SXL
1 Cab-Frnt Chas
8 Lights RH
18G_A Right Tail
Or-1.0-SXL
127 RH Rear Comb Lt
SPL_E8 SPL_E8
18G_C Lic Plate Light
Or-1.0-SXL
128F Rear-Hood
SPL_E8 SPL_E8
18G_D RH Tail Lic Lts
Or-1.0-SXL
21M Rear-Cab
SPL_E8 SPL_E8
18G_E Lic Plate Light
Or-1.0-SXL
168 Lic Plate Light
18G_F
Or-0.8-SXL
21F Cab-Rear
18F Fuse Block
G2
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
G2
18F
RH Tail Lic Lts
18G_G Position RH
Bur 6-40782
Revised 6-02
A2
3
B2
3
D2
2
E2
Printed in U.S.A.
Copyright
4002-16
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
18_H
Radio Power
Or-0.8-SXL
113 Radio
269 Radio Fuse Holder
19A
Out Speed Power
Or-1.0-SXL
29
100 Out Speed Sens
19A_A
Declutch Switch
Or-1.0-SXL
4 Dec Press Sw
21M Rear-Cab
30
19A_B
FNR Switched Pwr
Or-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
19A_C
Trans Ena Sw Pwr
Or-0.8-SXL
197F Main Cab FNR
10
19A_D
Trans Ena Sw Pwr
Or-0.8-SXL
SPL_D15
19A_E
Trans Ena Sw Pwr
Or-0.8-SXL
10
19A_F
FNR Switched Pwr
Or-0.8-SXL
198 FNR Switch
198 FNR Switch
19A_G Trans Control Pwr
Or-0.8-SXL
13M Pedestal-Cab
43
19A_H
Trans Control Pwr
Or-0.8-SXL
70 Transmission Shifter
19A_K
Cab Switched Pwr
Or-0.8-SXL
19F TECM
45
SPL_D15
19A_L
Cab Switched Pwr
Or-0.8-SXL
SPL_D15
19A_M Cab Switched Pwr
Or-0.8-SXL
29
SPL_D15
19A_N
Cab Switched Pwr
Or-0.8-SXL
18F Fuse Block
A2
SPL_D15
19A_P
Cab Switched Pwr
Or-0.8-SXL
53F Backup Alarm Relay
86
18F Fuse Block
A2
19A_Q Cab Switched Pwr
Or-0.8-SXL
41F Trans Auto Sw
SPL_D15
19A_R
Cab Switched Pwr
Or-0.8-SXL
38F Declutch Switch
SPL_D15
19A_S
Cab Switched Pwr
Or-0.8-SXL
13F Cab-Pedestal
43
SPL_D15
19A_T
Cab Switched Pwr
Or-0.8-SXL
21F Cab-Rear
30
SPL_D15
19A_U
Cab Switched Pwr
Or-0.8-SXL
20M Trans Kick-Down
SPL_D15
19B
Turn Signal Power
Or-0.8-SXL
13M Pedestal-Cab
66
67 Turn Signal Switch
19B_A
Turn Signal Power
Or-0.8-SXL
13F Cab-Pedestal
66
18F Fuse Block
B2
19C
Pilot Control Signal
Or-0.8-SXL
13M Pedestal-Cab
68
19C_A
Pilot Ride Cntrl Fused Pwr
Or-1.0-SXL
18F Fuse Block
C2
SPL_D24 Ride Cntrl Fuse Pwr
19C_B
Ride Ctrl Fused Pwr
Or-1.0-SXL
44F Ride Control Sw
19C_C
Ride Ctrl Fused Pwr
Or-0.8-SXL
13F Cab-Pedestal
68
19C_D
Or-1.0-SXL
56F Pilot Control Relay
30
18F Fuse Block
C2
19C_E
Or-1.0-SXL
30
86
19D_A
Parking Brake Rel Fused Pwr
Or-1.0-SXL
55F Brake Lights Relay
30
18F Fuse Block
D2
19D_B
Or-1.0-SXL
30
86
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-17
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
19E
Ether Start Rel Fused Pwr
Or-1.0-SXL
30
18F Fuse Block
E2
19F
Eng Shtdwn Rel Fused Pwr
Or-1.0-SXL
86
18F Fuse Block
F2
19G
Blower Switch Fused Pwr
Or-2.0-SXL
30F Blower Switch
18F Fuse Block
G2
19H
Backup Alarm Rel Fuse Pwr
Or-1.0-SXL
30
18F Fuse Block
H2
19J
Frt Wip Wash Fused Pwr
Or-0.8-SXL
13M Pedestal-Cab
60
19J_A
Or-1.0-SXL
18F Fuse Block
J2
19J_B
Or-0.8-SXL
13F Cab-Pedestal
60
19K_A
Rear Wip Wash Fused Pwr
Or-1.0-SXL
18F Fuse Block
K2
SPL_D23 Rear Wiper Pwr
19K_B
Or-1.0-SXL
23F Cab-Roof
19K_C
Or-1.0-SXL
45F Rear Wiper Sw
19K_D
Or-0.8-SXL
45F Rear Wiper Sw
19K_E
Rear Wip Wshr Fused Pwr
Or-1.0-SXL
23M Roof-Cab
81M Rear Wiper Mtr
19L
Access To Fuse L (3 Way)
Or-1.0-SXL
18F Fuse Block
L2
18F Fuse Block
19L_A
Radio Power
Or-1.0-SXL
246M Radio Power
19L_B
Converter Pwr Ign
Or-1.0-SXL
249M Converter Pwr Ign
256F Converter Pwr Ign
19M_A Sec Str Accessory
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
M2
19M_B Sec Str Accessory
Or-1.0-SXL
1 Cab-Frnt Chas
19M_C Sec Str Accessory
Or-1.0-SXL
90M Sec Str Mod
180M Sec Str Mod-Frnt Harn
19N_A
Access Seat Fused Pwr (3 Way) Or-1.0-SXL
28M Seat Comp Motor
18F Fuse Block
N2
19N_B
18F Fuse Block
N2
18F Fuse Block
19P_A
Fan Rev Pin Eng Fused Pwr
Or-1.0-SXL
40F Pin Engage Sw
18F Fuse Block
P2
19P_B
Or-1.0-SXL
40F Pin Engage Sw
19R_A
Sec Str Ignition
Or-0.8-SXL
1F Cab-Frnt Chas
SPL_D25 SPL_D25
Splice
19R_B
Sec Str Ignition
Or-1.0-SXL
1 Cab-Frnt Chas
19R_C
Sec Str Ignition
Or-1.0-SXL
90M Sec Str Mod
19R_D
Sec Strg Ignition
Or-0.8-SXL
SPL_D25 SPL_D25
Splice
262F Diode Module
19R_E
Cab Switched Pwr
Or-0.8-SXL
SPL_D25 SPL_D25
Splice
19R_F
Sec Strg Ignition
Or-0.8-SXL
262F Diode Module
18F Fuse Block
R2
19S
Instr Cluster Fused Del Pwr
Or-0.8-SXL
13F Cab-Pedestal
18F Fuse Block
S2
19S_A
Or-0.8-SXL
13M Pedestal-Cab
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-18
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
19S_B
Or-0.8-SXL
19T_A
Time Delay Fused Pwr
Or-0.8-SXL
19F TECM
23
18F Fuse Block
T2
19T_B
Or-0.8-SXL
19F TECM
68
18F Fuse Block
T2
19U_A
Dome Lt Horn Fused Pwr
Or-1.0-SXL
23F Cab-Roof
18F Fuse Block
U2
19U_B
Or-1.0-SXL
51F Horn Relay
30
18F Fuse Block
U2
19U_C
Or-0.8-SXL
51F Horn Relay
86
51F Horn Relay
30
19U_D
Dome Lt Fused Pwr
Or-1.0-SXL
23M Roof-Cab
84F Dome Light
Cluster Main Fused Power
Or-0.8-SXL
13F Cab-Pedestal
18F Fuse Block
V2
Cluster Main Fused Pwr
Or-0.8-SXL
13M Pedestal-Cab
Cigarette Lighter Fused Pwr
Or-1.0-SXL
18F Fuse Block
18F Fuse Block
16
Or-3.0-SXL
259F Cigar Lighter
260M Cigar Lighter Pwr
19V
19V_A
19W
19W_A Cigar Lighter Pwr
W2
19X
Beacon Sw Fused Pwr
Or-1.0-SXL
42F Beacon Sw
18F Fuse Block
X2
19Z
Frnt Flood Illum Fused Pwr
Or-1.0-SXL
34F Light Switch
18F Fuse Block
Z2
1A_A
Ign Prog Reset Sw Pwr
R-0.8-SXL
13M Pedestal-Cab
62
69 Ignition Switch
1A_B
R-0.8-SXL
69 Ignition Switch
1A_C
Ignition Switch Power
R-0.8-SXL
13F Cab-Pedestal
62
SPL_D21 CB A Load
1A_D
CB A Load
R-0.8-SXL
214F Ign Sw Cir Brkr
SPL_D21 CB A Load
1A_E
Time Delay Pwr
R-0.8-SXL
SPL_D21 CB A Load
Hazard Switch Pwr
R-0.8-SXL
13M Pedestal-Cab
65
71 Hazard Switch
1B_A
Brake Lt Sw Pwr
R-1.0-SXL
159 Brake Lt Pres Sw
21M Rear-Cab
28
1B_B
Flasher Module Pwr
R-0.8-SXL
62M Flasher Module
SPL_D19 CB B Load
1B_C
Hazard Switch Power
R-0.8-SXL
13F Cab-Pedestal
65
SPL_D19 CB B Load
1B_D
CB B Load
R-0.8-SXL
212F Flasher Cir Brkr
21F Cab-Rear
28
1B_E
Brake Lt Relay Pwr
R-0.8-SXL
30
SPL_D19 CB B Load
1B_F
CB B Load
R-0.8-SXL
SPL_D19 CB B Load
1_A
B+
R-1.0-SXL
21M Rear-Cab
21
156 Fuel Str Rel B+
1_B
B+
R-13.0-SXL
156 Fuel Str Rel B+
155 Cab Power B+
1_C
Starter Fuel Relay Pwr
R-8.0-SXL
190 Jblock Relay
191 Jblock-Relay
1_D
Starter Fuel Relay Pwr
R-2.0-SXL
190 Jblock Relay
192 Jblock-Relay
1_E
Power
R-19.0-SGT
195 Jblock Pwr
196 Jblock Pwr
1B
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-19
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
1_F
Starter Sol Pwr
R-8.0-GPT
193 Starter Relay
194 Starter Signal
1_G
Acc Relay Pwr
R-3.0-SXL
49F Accessory Relay
30
SPL_D16 B+ Power
1_H
High Beam Signal (2 Way)
R-3.0-SXL
59F High/Low Beam
SPL_D16 B+ Power
1_J
B+ Pwr
R-3.0-SXL
228F Power Cab
SPL_D17 B+ Power
1_K
B+ Pwr
R-3.0-SXL
226F Power Cab
SPL_D16 B+ Power
1_L
CB A Power
R-3.0-SXL
SPL_D17 B+ Power
1_M
CB B Power
R-3.0-SXL
SPL_D17 B+ Power
1_N
Light Sw Power
R-3.0-SXL
33F Light Switch
224F Power Cab
1_NA
Battery Crossover
R-62.0-SGR
239 Discon-Blck Grnd
238F Battery Crossover
1_NB
Starter-Battery
R-62.0-SGR
240F Starter-Battery
1_NC
Starter-Sec Strg Mtr
R-62.0-SGR
245F Starter-Sec Strg Mtr
1_P
Voltmeter Rel Pwr
R-0.8-SXL
30
21F Cab-Rear
21
1_Q
Dome Lt Horn Pwr
R-1.0-SXL
18F Fuse Block
U1
SPL_D16 B+ Power
1_R
Cigar Lighter Pwr
R-3.0-SXL
18F Fuse Block
W1
227F Power Cab
1_S
Ign Relay #1 Pwr
R-3.0-SXL
30
SPL_D17 B+ Power
1_T
Ign Relay #2 Pwr
R-3.0-SXL
30
SPL_D17 B+ Power
1_U
B+ Power (4 Way)
R-3.0-SXL
18F Fuse Block
Z1
225F Power Cab
1_V
Converter 24V Pwr
R-5.0-SXL
250F Converter 24V Pwr
1_W
Sec Strg Mtr B+
R-1.0-SXL
263F Sec Str Mtr
90M Sec Str Mod
1_X
Radio Memory Power
R-1.0-SXL
270F Radio Memory Power
21C_A
Fuel Relay Signal
W-1.0-SXL
172 Fuel Relay
SPL_G2 Splice G2
21C_B
Starter Relay Signal
W-1.0-SXL
135 Starter Relay
SPL_G2 Splice G2
21C_C
Starter Fuel Relay Signal
W-1.0-SXL
93M Relay Box
SPL_G2 Splice G2
21C_D
W-1.0-SXL
93F Rear-Fuel Str Rel
21M Rear-Cab
11
21C_E
W-0.8-SXL
87
21F Cab-Rear
11
21C_F
W-0.8-SXL
87
140M Diode Module
21K
Ign Sw Start Signal
W-0.8-SXL
13M Pedestal-Cab
64
69 Ignition Switch
21K_A
Ign Sw Start Signal
W-0.8-SXL
30
13F Cab-Pedestal
64
23C
Engine Shutdown Signal
W-0.8-SXL
23
13M Pedestal-Cab
23
23C_A
W-0.8-SXL
85
13F Cab-Pedestal
23
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-20
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
23F
Fuel Sol Pull In
W-2.0-SXL
134 Fuel Solenoid
133M Fuel Relay
23F_A
Fuel Sol Pull In
W-2.0-SXL
137 Fuel Relay
133F Fuel Solenoid
25A
Eng Speed Sig
W-0.8-BLD
101 Eng Speed Sens
25A_A
Eng Speed Sig
LU-0.8-SXL
19F TECM
19
25B
Turb Speed Sig
W-0.8-BLD
96 Turb Speed Sens
25B_A
Turb Speed Sig
LU-0.8-SXL
19F TECM
41
25C
Int Speed Sig
W-0.8-BLD
95 Int Speed Sens
25C_A
Int Speed Sig
LU-0.8-SXL
19F TECM
42
25D
Output Speed Sig
LU-1.0-SXL
10
100 Out Speed Sens
25D_A
Output Speed Sig
LU-0.8-SXL
19F TECM
62
10
25F
Forward Signal
LU-0.8-SXL
13M Pedestal-Cab
44
25F_A
Forward Signal
LU-0.8-SXL
19F TECM
43
13F Cab-Pedestal
44
25G
Declutch Switch
LU-1.0-SXL
4 Declutch Press Sw
21M Rear-Cab
31
25G_A Declutch Switch
LU-0.8-SXL
38F Declutch Switch
21F Cab-Rear
31
25G_B Declutch Switch
LU-0.8-SXL
19F TECM
66
38F Declutch Switch
25H
Trans Auto Signal
LU-0.8-SXL
19F TECM
29
41F Trans Auto Sw
25J
Trans Sol Valve Y6
LU-0.8-TXL
21
102 Trans Control
25J_A
Trans Sol Valve Y6
LU-0.8-SXL
19F TECM
51
21
25K
Trans Sol Valve Y1
LU-0.8-TXL
16
102 Trans Control
25K_A
Trans Sol Valve Y1
LU-0.8-SXL
19F TECM
56
16
25L
Trans Sol Valve Y2
LU-0.8-TXL
17
102 Trans Control
25L_A
Trans Sol Valve Y2
LU-0.8-SXL
19F TECM
10
17
25M
Trans Sol Valve Y3
LU-0.8-TXL
18
102 Trans Control
25M_A Trans Sol Valve Y3
LU-0.8-SXL
19F TECM
32
18
25N
Trans Sol Valve Y4
LU-0.8-TXL
19
102 Trans Control
25N_A
Trans Sol Valve Y4
LU-0.8-SXL
19F TECM
55
19
25P
Trans Sol Valve Y5
LU-0.8-TXL
20
102 Trans Control
25P_A
Trans Sol Valve Y5
LU-0.8-SXL
19F TECM
20
25R
Reverse Signal
LU-0.8-SXL
13M Pedestal-Cab
45
25R_A
Reverse Signal
LU-0.8-SXL
19F TECM
64
13F Cab-Pedestal
45
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-21
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
25S
Output Sw Power VPS1
LU-0.8-TXL
22
102 Trans Control
25S_A
LU-0.8-SXL
22
SPL_D12 Common Power
25S_B
LU-0.8-SXL
19F TECM
12
25S_C
LU-0.8-SXL
19F TECM
13
25T_A
Neutral Signal
LU-0.8-SXL
92 Ether Switch
25T_B
Neutral Signal
LU-0.8-SXL
13M Pedestal-Cab
46
92 Ether Switch
25T_C
Neutral Signal
LU-0.8-SXL
13F Cab-Pedestal
46
SPL_D18 Neutral Signal
25T_D
Neutral Signal
LU-0.8-SXL
19F TECM
67
25T_E
Neutral Signal
LU-0.8-SXL
86
3rd And 4th Gear Signal
LU-0.8-SXL
13M Pedestal-Cab
48
25W_A 3rd And 4th Gear Signal
LU-0.8-SXL
19F TECM
65
13F Cab-Pedestal
48
25W
25Y
Trans Kickdown Signal
LU-0.8-SXL
13M Pedestal-Cab
50
25Y_A
LU-0.8-SXL
13F Cab-Pedestal
50
SPL_D11 Trans Kick Down Signal
25Y_B
Trans Kickdown Sig
LU-0.8-SXL
19F TECM
22
25Y_C
LU-0.8-SXL
20M Trans Kick-Down
25Z
1st And 4th Gear Signal
LU-0.8-SXL
13M Pedestal-Cab
49
25Z_A
LU-0.8-SXL
19F TECM
63
13F Cab-Pedestal
49
26E
Trans Enable Signal
LU-0.8-SXL
19F TECM
31
26F_A
FNR Forward Signal
LU-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
26F_B
FNR Forward Signal
LU-0.8-SXL
19F TECM
20
197F Main Cab FNR
26J
FNR Switch Jumper
LU-0.8-SXL
198 FNR Switch
198 FNR Switch
26N_A
FNR Neutral Signal
LU-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
26N_B
FNR Neutral Signal
LU-0.8-SXL
19F TECM
44
197F Main Cab FNR
26R_A
FNR Reverse Signal
LU-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
26R_B
FNR Reverse Signal
LU-0.8-SXL
19F TECM
30
197F Main Cab FNR
28C
Ether Start Control
W-0.8-SXL
13M Pedestal-Cab
52
182 Ether Switch
28C_A
Ether Start Control
W-0.8-SXL
86
13F Cab-Pedestal
52
28P
Ether Sol
W-1.0-SXL
103 Ether Sol Opt
21M Rear-Cab
28P_A
Ether Sol
W-0.8-SXL
87
21F Cab-Rear
Ether Start Temp Sw
W-1.0-SXL
97 Ether Temp Sw
65M Eng-Rear (Ether Start)
28T
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-22
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
To Connector
Wire
Circuit
28T_A
Ether Start Temp Sw
W-1.0-SXL
103 Ether Sol Opt
65F Rear-Eng (Ether Start)
31D
Coolant Level Signal
Y-1.0-SXL
21M Rear-Cab
31D_A
Y-0.8-SXL
21F Cab-Rear
13F Cab-Pedestal
31D_B
Y-0.8-SXL
13M Pedestal-Cab
31D_C
Y-0.8-SOLID
274F Coolant Jmpr Rear Chs
275M Coolalnt Jmpr Coolant Sndr
31F
Air Filter Rest Sw Signal
Y-1.0-SXL
94M Engine Trans
31F_A
Y-1.0-SXL
94F Eng-Trans
31F_B
Y-0.8-SXL
13F Cab-Pedestal
31F_C
Y-0.8-SXL
13M Pedestal-Cab
Hyd Oil Filter Rest Sw Signal
Y-1.0-SXL
21M Rear-Cab
14
170 Hyd Oil Filter Res Sw
31H_A
Hyd Filter Rest Sw Signal
Y-0.8-SXL
21F Cab-Rear
14
13F Cab-Pedestal
31H_B
Y-0.8-SXL
13M Pedestal-Cab
31L
Pilot Lockout Signal
Y-0.8-SXL
29
32F
Trans Filter Maint Sw
Y-1.0-SXL
31
31 Filter Maint Sw
32F_A
Y-0.8-SXL
19F TECM
17
31
32J_A
FNR Lt Signal
Y-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
32J_B
Trans Enable Lt Sig
Y-0.8-SXL
197F Main Cab FNR
32J_C
Trans Enable Lt Sig
Y-0.8-SXL
19F TECM
33P
Low Brake Pres Warning
Y-1.0-SXL
88 Brk Warn Pr Sw
21M Rear-Cab
33P_A
Y-0.8-SXL
21F Cab-Rear
13F Cab-Pedestal
33P_B
Y-0.8-SXL
13M Pedestal-Cab
33R_A
Redundant Brake Sw Signal
Y-1.0-SXL
SPL_E10 SPL_E10
33R_B
Y-1.0-SXL
SPL_E10 SPL_E10
33R_C
Y-1.0-SXL
21M Rear-Cab
15
SPL_E10 SPL_E10
33R_D
Y-0.8-SXL
21F Cab-Rear
15
13F Cab-Pedestal
28
33R_E
Y-0.8-SXL
28
13M Pedestal-Cab
28
Parking Brake Signal
Y-0.8-SXL
35A_A
Left Reverse
K-1.0-SXL
125 LH Rear Comb Lt
SPL_E2 SPL_E2
35A_B
Right Reverse
K-1.0-SXL
127 RH Rear Comb Lt
SPL_E2 SPL_E2
35A_C
Reverse Lights
K-1.0-SXL
21M Rear-Cab
SPL_E2 SPL_E2
31H
33U
Bur 6-40782
Connector
K = Pink
U = Blue
Y = Yellow
Cavity
Connector
Revised 6-02
Cavity
Printed in U.S.A.
Copyright
4002-23
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
35A_D
Backup Alarm Relay Out
Y-0.8-SXL
87
21F Cab-Rear
35A_E
Y-0.8-SXL
118F Backup Alarm Dis Sw
87
35A_F
Y-0.8-SXL
209M Backup Alarm Disa Jmp
35C
Backup Alarm Pull-Dwn
Y-0.8-SXL
19F TECM
85
35R_A
Backup Alarm Sw
Y-1.0-SXL
175 Backup Alarm
35R_B
Backup Alarm Sw
Y-1.0-SXL
21M Rear-Cab
128F Rear-Hood
35R_C
Backup Alarm Sw
Y-0.8-SXL
21F Cab-Rear
35R_D
Backup Alarm Sw
Y-0.8-SXL
209F Backup Alarm Disa Jmp
35X_A
Sec Str Low Pres Sig
Y-1.0-SXL
SPL_A4 SPL_A4
SPL_A4
35X_B
Y-1.0-SXL
1 Cab-Frnt Chas
SPL_A4 SPL_A4
SPL_A4
35X_C
Y-1.0-SXL
SPL_A4 SPL_A4
SPL_A4
35X_D
Y-1.0-SXL
90M Sec Str Mod
35X_E
Y-0.8-SXL
13F Cab-Pedestal
1 Cab-Frnt Chas
35X_F
Y-0.8-SXL
13M Pedestal-Cab
36C
Eng Cool Temp Signal
P-1.0-SXL
94M Engine Trans
13
138 Eng Cool Temp
36C_A
P-1.0-SXL
94F Eng-Trans
13
36C_B
P-0.8-SXL
13F Cab-Pedestal
18
36C_C
P-0.8-SXL
18
13M Pedestal-Cab
18
36F
Fuel Level Signal
P-1.0-SXL
141 Fuel Sender
21M Rear-Cab
16
36F_A
Fuel Level Signal
P-0.8-SXL
21F Cab-Rear
16
13F Cab-Pedestal
19
36F_B
Fuel Level Signal
P-0.8-SXL
19
13M Pedestal-Cab
19
Torque Conv Outpt Temp Signal
P-1.0-SXL
13
142 Torque Conv Temp Sender
36G_A Torque Conv Outpt Temp Signal
P-1.0-SXL
19F TECM
49
13
36G
36H
Hot Signal
P-1.0-SXL
21M Rear-Cab
13
36H_A
Hot Signal
P-0.8-SXL
13F Cab-Pedestal
20
21F Cab-Rear
13
36H_B
Hot Signal
P-0.8-SXL
20
13M Pedestal-Cab
20
36P
Engine Oil Pressure Signal
P-1.0-SXL
94M Engine Trans
148 Engine Oil Pressure Switch
36P_A
P-1.0-SXL
94F Engine Trans
36P_B
P-0.8-SXL
13F Cab-Pedestal
22
36P_C
P-0.8-SXL
22
13M Pedestal-Cab
22
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-24
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
36R_A
Valve Body Temp Ret
P-1.0-SXL
12
SPL_H1 Splice H1
Splice
36R_B
Valve Body Temp Ret
P-1.0-SXL
31 Filter Maint Sw
SPL_H1 Splice H1
Splice
36R_C
Valve Body Temp Ret
P-0.8-SXL
102 Trans Control
SPL_H1 Splice H1
Splice
36R_D
Valve Body Temp Ret
P-1.0-SXL
142 Trq Conv Temp Sender
SPL_H1 Splice H1
Splice
36R_E
Valve Body Temp Ret
P-0.8-SXL
19F TECM
46
12
36T
Valve Body Temp Sig
P-0.8-SXL
102 Trans Control
36T_A
Valve Body Temp Sig
P-0.8-SXL
19F TECM
39
Down Count Signal
P-0.8-SXL
27
37D_A
Diagnostic Signal
P-0.8-SXL
19F TECM
15
37E
Diagnostic Signal
P-0.8-SXL
19F TECM
18
37P
Program Signal
P-0.8-SXL
24
37R_A
Reset Signal
P-0.8-SXL
13M Pedestal-Cab
25
37R_B
Reset Signal
P-0.8-SXL
25
37R_C
Reset Signal
P-0.8-SXL
13F Cab-Pedestal
25
37U
Up Count Signal
P-0.8-SXL
26
41H
High/Low Beam Relay Pwr
K-2.0-SXL
59F High/Low Beam
18F Fuse Block
41J_A
Driving Light Sig
K-2.0-SXL
33F Light Switch
59F High/Low Beam
41J_B
Driving Light Sig
K-2.0-SXL
25F Light Switch
33F Light Switch
41L_A
Low Beam Power
K-2.0-SXL
59F High/Low Beam
18F Fuse Block
E1
41T_A
Tail Lt Switched Pwr
K-1.0-SXL
32F Light Switch
18F Fuse Block
G1
41T_B
K-1.0-SXL
33F Light Switch
32F Light Switch
42C_A
Front Flood Lts
DU-1.0-SXL
24M Cab-Roof
34F Light Switch
42C_B
LH Frnt Work Lt Pwr
DU-1.0-SXL
SPL_M1 Frnt Work Lt Pwr
42C_C
RH Frnt Work Lt Pwr
DU-1.0-SXL
42C_D
Front Work Lts Pwr
DU-1.0-SXL
24F Roof-Cab
42R_A
Work Light Telltale Sig
Y-0.8-SXL
12
13M Pedestal-Cab
12
42R_B
Rear Work Light Pwr
DU-0.8-SXL
23F Cab-Roof
32F Light Switch
42R_C
Rear Work Light Pwr
DU-0.8-SXL
13F Cab-Pedestal
12
32F Light Switch
42R_D
LH Rear Work Lt Pwr
DU-1.0-SXL
83F LH Rear Work Lt
SPL_M4 Rear Work Lt Pwr
42R_E
RH Rear Work Lt Pwr
DU-1.0-SXL
80F RH Rear Work Lt
37D
Bur 6-40782
Revised 6-02
C1
Printed in U.S.A.
Copyright
4002-25
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
To Connector
Wire
Circuit
42R_F
Rear Work Light Pwr
DU-1.0-SXL
23M Roof-Cab
44A_B
T-0.8-SXL
86
21F Cab-Rear
29
44_A
Brake Light Signal
T-1.0-SXL
125 LH Rear Comb Lt
SPL_E1 SPL_E1
44_B
Brake Light Signal
T-1.0-SXL
127 RH Rear Comb Lt
SPL_E1 SPL_E1
44_C
Brake Light Signal
T-1.0-SXL
21M Rear-Cab
SPL_E1 SPL_E1
44_D
Brake Light Signal
T-0.8-SXL
21F Cab-Rear
SPL_D9 Brake Lt Signal
44_E
Brake Lt Relay Signal
T-0.8-SXL
87
44_F
Brake Light Signal
T-0.8-SXL
13F Cab-Pedestal
35
44_G
Brake Light Signal
T-0.8-SXL
35
13M Pedestal-Cab
35
45A
Left Turn Switch Power
N-0.8-SXL
13M Pedestal-Cab
69
45A_A
N-0.8-SXL
62M Flasher Module
10
13F Cab-Pedestal
69
45B
Right Turn Switch Power
N-0.8-SXL
13M Pedestal-Cab
70
45B_A
N-0.8-SXL
62M Flasher Module
13F Cab-Pedestal
70
45H
Hazard Switch Power
N-0.8-SXL
13M Pedestal-Cab
67
71 Hazard Switch
45H_A
Hazard Switch Power
N-0.8-SXL
62M Flasher Module
11
13F Cab-Pedestal
67
45L
Left Turn Signal
N-1.0-SXL
1 Cab-Frnt Chas
6 Lights LH
45L_A
Left Turn Signal
N-1.0-SXL
125 LH Rear Comb Lt
21M Rear-Cab
10
45L_B
Left Turn Signal
N-0.8-SXL
21F Cab-Rear
10
SPL_D10 Left Turn Signal
45L_C
Left Turn Signal
N-0.8-SXL
1F Cab-Frnt Chas
45L_D
Left Turn Signal
N-0.8-SXL
62M Flasher Module
45L_E
Left Turn Signal
N-0.8-SXL
13F Cab-Pedestal
16
45L_F
Left Turn Signal
N-0.8-SXL
16
13M Pedestal-Cab
16
45N_A
Flasher Opp Side Cntrl
N-0.8-SXL
64F Flasher Connector
62M Flasher Module
45N_B
N-0.8-SXL
64M Flasher Connector
62M Flasher Module
12
45R
Right Turn Signal
N-1.0-SXL
1 Cab-Frnt Chas
8 Lights RH
45R_A
Right Turn Signal
N-1.0-SXL
127 RH Rear Comb Lt
21M Rear-Cab
12
45R_B
Right Turn Signal
N-0.8-SXL
21F Cab-Rear
12
SPL_D20 Rt Turn Signal
45R_C
Right Turn Signal
N-0.8-SXL
13F Cab-Pedestal
17
45R_D
Right Turn Signal
N-0.8-SXL
1F Cab-Frnt Chas
45R_E
Right Turn Signal
N-0.8-SXL
62M Flasher Module
Bur 6-40782
Connector
K = Pink
U = Blue
Y = Yellow
Cavity
Connector
Revised 6-02
Cavity
Printed in U.S.A.
Copyright
4002-26
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
45R_F
Right Turn Signal
N-0.8-SXL
17
13M Pedestal-Cab
17
46_A
Beacon Switched Pwr
K-0.8-SXL
23F Cab-Roof
13F Cab-Pedestal
13
46_B
Beacon Telltale
K-0.8-SXL
13
13M Pedestal-Cab
13
46_C
Beacon Switched Pwr
K-1.0-SXL
23F Cab-Roof
42F Beacon Sw
46_D
Beacon Switched Power
K-1.0-SXL
23M Roof-Cab
85F Beacon Light
49_A
Pilot Light
S-0.8-SXL
13M Pedestal-Cab
51
71 Hazard Switch
49_B
Pilot Light
S-0.8-SXL
71 Hazard Switch
49_C
Pilot Light
S-0.8-SXL
49_D
Pilot Light
S-0.8-SXL
49_E
Pilot Light
S-0.8-SXL
49_F
Pilot Light Pwr
S-0.8-SXL
13F Cab-Pedestal
51
SPL_D8 Pilot Lights
49_G
Pilot Light
S-0.8-SXL
SPL_D8 Pilot Lights
49_H
Pilot Light
S-0.8-SXL
40F Pin Engage Sw
10
49_J
Pilot Light
S-0.8-SXL
34F Light Switch
SPL_D8 Pilot Lights
49_K
Pilot Light
S-1.0-SXL
34F Light Switch
49_L
Pilot Light
S-0.8-SXL
45F Rear Wiper Sw
49_M
Pilot Light
S-1.0-SXL
36F Detent Switch
49_N
Pilot Light
S-1.0-SXL
36F Detent Switch
38F Declutch Switch
49_P
Pilot Light
S-1.0-SXL
40F Pin Engage Sw
10
44F Ride Control Sw
49_Q
Pilot Light
S-1.0-SXL
44F Ride Control Sw
41F Trans Auto Sw
49_R
Pilot Light
S-1.0-SXL
42F Beacon Sw
49_S
Courtesy Pilot Lt
S-1.0-SXL
24M Cab-Roof
SPL_D8 Pilot Lights
49_T
Pilot Light
S-1.0-SXL
42F Beacon Sw
49_U
Pilot Light
S-0.8-SXL
SPL_D8 Pilot Lights
49_V
Courtesy Pilot Lt
S-0.8-SXL
24F Roof-Cab
77F Courtesy Lt
50G_A Can Ground
Bk-0.8-SXL
13M Pedestal-Cab
34
SPL_K2 SPL_K2
50G_B Can Ground
Bk-0_5-SXL
SPL_K3 SPL_K3
SPL_K2 SPL_K2
50G_C Can Ground
R-0_5-SXL
SPL_K2 SPL_K2
SPL_K3 SPL_K3
50G_D Can Ground
Bk-0.8-SXL
13F Cab-Pedestal
34
SPL_D6 Can Ground
50G_E Can Ground
Bk-0_5-SXL
SPL_D7 Can Ground
SPL_D6 Can Ground
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-27
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
50G_F
Circuit
Can Ground
50G_G Can Pilot Sol Grnd
5.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
R-0_5-SXL
SPL_D7 Can Ground
SPL_D6 Can Ground
Bk-0.8-SXL
219F Ground Cab
SPL_D7 Can Ground
50H
Can H
Y-0_5-SXL
32
13M Pedestal-Cab
32
50H_A
Can H
Y-0_5-SXL
19F TECM
25
13F Cab-Pedestal
32
50L
Can L
G-0_5-SXL
31
13M Pedestal-Cab
31
50L_A
Can L
G-0_5-SXL
13F Cab-Pedestal
31
SPL_D5 Can L
50L_B
Can L
G-0_5-SXL
19F TECM
26
SPL_D5 Can L
50L_C
Can L
G-0_5-SXL
19F TECM
27
SPL_D5 Can L
50T
Can T
Bk-0.8-SXL
21
33
51P_A
Sec Str High Pres
W-1.0-SXL
90M Sec Str Mod
51P_B
Sec Str High Pres
W-1.0-SXL
51_A
Sec Str Mtr Rel
W-1.0-SXL
90M Sec Str Mod
SPL_C2
51_B
SPL_C2
W-1.0-SXL
SPL_C2
181 Sec Str Mtr Relay
51_C
Sec Strg Sol Pwr
W-1.0-SXL
264M Sec Strg Sol Opt
SPL_C2
52C
W-0.8-SXL
30
13M Pedestal-Cab
30
52C_A
W-0.8-SXL
85
13F Cab-Pedestal
30
52P
Parking Brk Relay Out
W-1.0-SXL
87 Parking Brk Sol
21M Rear-Cab
18
52P_A
W-0.8-SXL
19F TECM
21
87
52P_B
W-0.8-SXL
87
21F Cab-Rear
18
52_A
Fan Reverse Sol
W-0.8-SXL
21F Cab-Rear
27
53B
RTD Signal
W-1.0-SXL
1 Cab-Frnt Chas
12F RTD
53B_A
RTD Signal
W-1.0-SXL
12M RTD
200 RTD
53B_B
RTD Signal
W-0.8-SXL
1F Cab-Frnt Chas
17M RTD Height Cont RTT
53C
W-0.8-SXL
36
13M Pedestal-Cab
36
53C_A
W-0.8-SXL
85
13F Cab-Pedestal
36
53P_A
W-0.8-SXL
87
89M Pilot Pres Sol
53P_B
W-0.8-SXL
36F Detent Switch
87
53P_C
W-0.8-SXL
87
1F Cab-Frnt Chas
53P_D
Float Sol Power
W-1.0-SXL
178M Float Switch
1 Cab-Frnt Chas
53S_A
Float Sol Signal
W-1.0-SXL
178M Float Switch
SPL_A5 SPL_A5
SPL_A5
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-28
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
Circuit
5.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
53S_B
Float Sol Signal
W-1.0-SXL
179F Float Solenoid
SPL_A5 SPL_A5
SPL_A5
53S_C
Float Sw Signal
W-1.0-SXL
202F Diode Module
SPL_A5 SPL_A5
SPL_A5
53S_D
Float Sol Signal
W-1.0-SXL
229M Diode Module
SPL_A5 SPL_A5
SPL_A5
53S_E
Float Switch Signal
W-1.0-SXL
273F Rollbck Jmpr Diode Mdl
271M Frt Chassis Rollbck Jmpr
54B
Height-RTT Signal
W-1.0-SXL
1 Cab-Frnt Chas
10 Height Cntrl-RTT
54B_A
Height-RTT Signal
W-0.8-SXL
1F Cab-Frnt Chas
SPL_D2 Height Cntrl-RTT Signal
54B_B
RTT-Float Sw Load
W-0.8-SXL
54B_C
Height Cont Elec Mag
W-0.8-SXL
55A
RTT-Float Sw
W-0.8-SXL
56_A
Height-RTT Pwr
W-1.0-SXL
10 Height Cntrl-RTT
SPL_A3 Splice A3
SPL_A3
56_B
RTD Pwr
W-1.0-SXL
12F RTD
SPL_A3 Splice A3
SPL_A3
56_C
Prox Switch Pwr
W-1.0-SXL
1 Cab-Frnt Chas
SPL_A3 Splice A3
SPL_A3
56_D
RTD Pwr
W-1.0-SXL
12M RTD
200 RTD
56_E
Detent Switched Pwr
W-0.8-SXL
SPL_D4 Detent Switched Pwr
56_F
Detent Switched Pwr
W-0.8-SXL
56_G
Detent Switched Pwr
W-0.8-SXL
56_H
Detent Switched Pwr
W-0.8-SXL
36F Detent Switch
56_J
Prox Switch Pwr
W-0.8-SXL
1F Cab-Frnt Chas
57_A
Pin Engage Sol Pwr
W-0.8-SXL
40F Pin Engage Sw
1F Cab-Frnt Chas
58A_A
Float Switch Signal
W-1.0-SXL
272F Rollbck Jmpr Press Sw
273F Rollbck Jmpr Diode Module
58H_B
Ride Cntl Signal
W-0.8-SXL
19F TECM
86
58S
Ride Cntl Relay Pwr
W-0.8-SXL
30
44F Ride Control Sw
58_A
Ride Cntrl Sol Pwr
W-0.8-SXL
87
1F Cab-Frnt Chas
58_B
Ride Cntrl Sol Pwr
W-0.8-SXL
87
44F Ride Control Sw
58_C
Ride Cntrl Sol Pwr
W-1.0-SXL
SPL_A7 5F Ride Control Opt
58_D
Ride Cntrl Sol Pwr
W-1.0-SXL
202F Diode Module
SPL_A7
58_E
Ride Cntrl Sol Pwr
W-1.0-SXL
229M Diode Module
SPL_A7
58_F
Float Switch Signal
W-1.0-SXL
271M Frt Chs Rollbck Jmpr
61A
AC High Pres Sw
Or-1.0-SXL
94M Engine Trans
98 AC High Pres Sw
61A_A
AC High Pres Sw
Or-1.0-SXL
26
94F Eng-Trans
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-29
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
61A_B
AC Relay Pwr
Or-0.8-SXL
203F Relay AC
30
26
61A_C
AC Relay Pwr
Or-0.8-SXL
203F Relay AC
30
SPL_D3 AC Power
61A_D
AC Thermostat
Or-0.8-SXL
208F Thermostat Switch
SPL_D3 AC Power
61A_E
AC Low Pres Sw
Or-0.8-SXL
27M AC Low Pres Sw
SPL_D3 AC Power
61C
AC Comp Clutch
Or-1.0-SXL
94M Engine Trans
99 AC Comp Clutch
61C_A
AC Comp Clutch
Or-1.0-SXL
25
94F Eng-Trans
61C_B
AC Comp Clutch
Or-0.8-SXL
203F Relay AC
87a
25
61C_C
Splice
Or-1.0-SXL
SPL_N1 Splice
265F Diode Module
61C_D
AC Compressor Clutch
Or-1.0-SXL
267F AC Compressor Clutch
SPL_N1 Splice
61C_E
Or-1.0-SXL
266M AC Compressor Clutch
SPL_N1 Splice
61R
AC High Pres Sw
Or-1.0-SXL
94M Engine Trans
98 AC High Pres Sw
61R_A
AC High Pres Sw
Or-1.0-SXL
27
94F Eng-Trans
61R_B
AC Relay Signal
Or-0.8-SXL
203F Relay AC
87
27
61R_C
AC Relay Signal
Or-0.8-SXL
203F Relay AC
87
203F Relay AC
86
61R_D
AC Relay Signal
Or-0.8-SXL
203F Relay AC
87
SPL_D1
61R_E
AC Low Pres Sw
Or-0.8-SXL
27M AC Low Pres Sw
SPL_D1
61R_F
AC Telltale
Or-0.8-SXL
13F Cab-Pedestal
10
SPL_D1
61R_G AC Telltale
Or-0.8-SXL
10
13M Pedestal-Cab
10
61T
AC Thermostat Pwr
Or-1.0-SXL
30F Blower Switch
62H
Blower High Speed
Or-2.0-SXL
29M Blower Motor
30F Blower Switch
62L
Blower Low Speed
Or-1.0-SXL
29M Blower Motor
30F Blower Switch
62M
Blower Medium Speed
Or-2.0-SXL
29M Blower Motor
30F Blower Switch
63C
Front Wiper Park
Or-0.8-SXL
13M Pedestal-Cab
59
63C_A
Front Wiper Park
Or-0.8-SXL
13F Cab-Pedestal
59
63H
Front Wiper High Speed
Or-0.8-SXL
13M Pedestal-Cab
57
63H_A
Or-0.8-SXL
13F Cab-Pedestal
57
63H_B
Or-0.8-SXL
140M Diode Module
63L
Front Wiper Low Speed
Or-0.8-SXL
13M Pedestal-Cab
58
63L_A
Or-0.8-SXL
13F Cab-Pedestal
58
63L_B
Or-0.8-SXL
140M Diode Module
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-30
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Wire
Circuit
Cavity
Connector
Cavity
63W
Front Washer Pump
Or-1.0-SXL
2 Front Washer
21M Rear-Cab
25
63W_A Front Washer Pump
Or-0.8-SXL
21F Cab-Rear
25
64C
Horn Control
Or-0.8-SXL
13M Pedestal-Cab
42
184 Horn Switch
64C_A
Horn Control
Or-0.8-SXL
51F Horn Relay
85
13F Cab-Pedestal
42
High/Low Beam Signal
Or-0.8-SXL
13M Pedestal-Cab
55
186 High Low Beam
Low Beam Signal (2 Way)
Or-0.8-SXL
59F High/Low Beam
13F Cab-Pedestal
55
64A
Horn
Or-0.8-SXL
51F Horn Relay
87
1F Cab-Frnt Chas
65C
Radio Power
Or-0.8-SXL
114F
65C_B
Radio Power
Or-0.8-SXL
114M
113 Radio Power
14
65L
Left Spkr Signal
Or-0.8-SXL
114F
112M
65L_A
Left Spkr Signal
Or-0.8-SXL
114M
113 Radio
11
65R
Right Spkr Signal
Or-0.8-SXL
114F
111M
65R_A
Right Spkr Signal
Or-0.8-SXL
114M
113 Radio
68C_A
Rear Wiper Park
Or-1.0-SXL
23F Cab-Roof
45F Rear Wiper Sw
68C_B
Rear Wiper Park
Or-1.0-SXL
23M Roof-Cab
81M Rear Wiper Mtr
68L_A
Rear Wiper Low Speed
Or-1.0-SXL
23F Cab-Roof
45F Rear Wiper Sw
68L_B
Or-0.8-SXL
45F Rear Wiper Sw
140M Diode Module
68L_C
Or-1.0-SXL
23M Roof-Cab
81M Rear Wiper Mtr
Rear Washer Pump
Or-1.0-SXL
3 Rear Washer
21M Rear-Cab
24
68W_A Rear Washer Pump
Or-1.0-SXL
45F Rear Wiper Sw
21F Cab-Rear
24
64D
64D_A
68W
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-31
UNDERSTANDING THE TROUBLESHOOTING TABLES

1 Alternator
Check Points
Reading
Check the 10 ampere fuse at

location 3 and 4C in the fuse block.
Terminal for wire 1A to ground
Good
Possible Cause of Bad Reading
12 volts
Bad fuse.
Check wire 1A between the starter terminal (21) and the

alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter.
5
6
1.
2.
3.
4.
5.
6.
This title is the number and component name on the Electrical Schematic.
This column shows the location of the check point.
This column shows the indication of the check.
This column shows the possible cause of a bad test indication.
The numbers in the parentheses show the number of the component on the Electrical Schematic.
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.
Co mpo ne nts can b e loc ate d o n th e Ele ctrica l
Schematic posters (rear pocket) by item number
using the key at the bottom of the posters. Use the
following index to find the sheet a component is
located on.
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
12 Volt Radio (Option)
95
Accessory Relay No. 3
16
Air Conditioning High Pressure Switch
87
Air Conditioning Low Pressure Switch
86
Air Filter Restriction Switch
44
Alternator
Back-up Alarm
37
Back-up Alarm Disable Switch
36
Back-up Alarm Relay No. 7
35
Batteries
Beacon Switch
99
Blower Motor
85
Blower Motor Speed Resistors with Thermal Fuse
84
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-32
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
Blower Switch
83
Brake Declutch Pressure Switch
32
Brake Lamp Pressure Switch
101
Brake Lamps Relay No. 15
102
Brake Warning Pressure Switch
38
Bucket Control Valves Electromagnetic Detents
60
Cigar Lighter (Option)
91
Compressor Clutch
90
Compressor Clutch Lockout Relay No. 14
89
Coolant Level Sender
39
Courtesy Lamp
118
Declutch Switch
31
Detent Switch
59
Diagnostic Connector
28
Dome Lamp
117
Engine Coolant Temperature Sender
43
Engine Oil Pressure Switch
50
Engine Speed Sensor
20
Ether Start Relay No. 6
10
Ether Start Solenoid
Ether Start Switch
11
FNR Switch
34
Fan Reverser Switch
55
Fan Reversing Solenoid
56
Filter Maintenance Switch
23
Five Position Rotary Lamp Switch
114
Flasher Module
105
Float Pressure Switch
64
Float Solenoid
65
Front Washer Pump Motor
76
Front Wiper Motor
74
Front Wiper and Washer Switch
75
Fuel Level Sender
40
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-33
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
Fuel Relay
Fuel Shutoff Solenoid
Hazard Switch
103
Height Control/Return-To-Travel Proximity Switch
63
High/Low Beam Relay No. 13
115
Horn
81
Horn Relay No. 5
80
Hydraulic Filter Restriction Switch
42
Hydraulic Oil Temperature Sender
41
Ignition Relay No. 1
14
15
Ignition Switch
13
Instrument Cluster
47
Intermediate Speed Sensor
21
LH Front Combination Lamp
108
LH Front Work Lamp
112
LH Rear Combination Lamp
106
LH Rear Work Lamp
110
Left Speaker (Option
97
License Plate Lamp
116
Master Disconnect Switch
Neutral Start Relay No. 8
12
Output Speed Sensor
19
Parking Brake Relay No. 9
52
Parking Brake Solenoid
53
Parking Brake Switch
46
Pilot Control Relay No. 10
51
Pilot Control Switch
48
Pilot Pressure Solenoid
54
Pin Engage Solenoid (Option)
70
Pin Engage Switch (Option)
69
Power Converter (24 Volts to 12 Volts) (Option)
92
Power Outlet (Option)
93
Program/Reset Switch
45
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-34
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
Relay Socket No. 11
58
RH Front Combination Lamp
109
RH Front Work Lamp
113
RH Rear Combination Lamp
107
RH Rear Work Lamp
111
Radio Power Converter (24 Volts to 12 Volts) (Option)
96
Rear Washer Pump Motor
78
Rear Wiper and Washer Switch
77
Rear Wiper Motor
79
Redundant Brake Pressure Switches
57
Remote Radio or 24 Volt Radio (Option)
94
Return-To-Dig Proximity Switch
62
Return-To-Travel/Float Switch
61
Ride Control Relay No. 4
72
Ride Control Solenoid
73
Ride Control Switch
71
Right Speaker (Option)
98
Rotating Beacon
100
Seat Compressor and Switch
82
Secondary Steering Module (Option)
66
Secondary Steering Motor (Option)
68
Secondary Steering Pressure Switch (Option)
67
68A
Starter Motor
Starting Relay
Thermostat Switch
88
Time Delay Module
18
Torque Converter Output Temperature Sensor
24
Transmission Auto Switch
30
Transmission Electronic Control Module
26
Transmission Enable Switch
33
Transmission Kick-Down Switch
29
Transmission Shifter
27
Transmission Solenoid Valve and Temperature Sender
25
Secondary Steering Solenoid (Option)
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-35
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
Turbine Speed Sensor
22
Turn Signal, High/Low Beam, and Horn Switch
104
Up/Down Count Switch
49
Voltmeter Relay No. 12
17
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-36
TROUBLESHOOTING BATTERIES, FUEL SHUTOFF, CHARGING, STARTING,

ALTERNATOR, ETHER START, IGNITION SWITCH AND RELAYS
11
13
7
6
4
2
10
12
14
1
8
5
9
BC00N140
1.
2.
3.
4.
5.
BATTERIES
MASTER DISCONNECT SWITCH
FUEL SHUTOFF SOLENOID
ALTERNATOR
STARTER MOTOR
6.
7.
8.
9.
10.
STARTER RELAY
FUEL RELAY
ETHER START TEMPERATURE SWITCH
ETHER START SOLENOID
ETHER START RELAY NO. 6
11.
12.
13.
14.
ETHER START SWITCH

NEUTRAL START RELAY NO. 8
IGNITION SWITCH
IGNITION RELAY NO. 1
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.
1 Batteries
NOTE: See Section 4003 and check the batteries.
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-37
2 Master Disconnect Switch

Check Points
Reading
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
Between terminals of master
disconnect switch
Continuity
If there is no continuity, the master disconnect switch (2) is bad.
NOTE: Put the master disconnect switch in the OFF position.

disconnect switch
Open Circuit
If there is continuity, the master disconnect switch is bad.
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
3 Fuel Shutoff Solenoid

Check Points
Reading
NOTE: Disconnect connector 134 from fuel shutoff solenoid (3).

Terminal for wire 0_BB to ground
Continuity
Between terminals A and C of fuel

shutoff solenoid
40 to 44 ohms
Bad fuel shutoff solenoid.
Between terminals B and C of fuel

shutoff solenoid
1 to 2 ohms
Bad fuel shutoff solenoid.
Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the ON position.
Terminal for wire 13M to ground
24 volts
Check wire 13M and circuits 13C and 13K, also check circuit to
batteries. Bad master disconnect switch (2) or ignition switch.
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 23F to ground
24 volts
Check circuit 23F. Bad fuel relay (7), neutral start relay (12), or
no neutral signal from transmission.
NOTE: If the readings are good, replace the fuel shutoff solenoid (3).
4 Alternator
Check Points
Between housing of alternator and
ground
Reading
Continuity

Bad ground connection.
NOTE: Put the master disconnect switch in the ON position.

Between the positive terminal of
alternator and ground
24 volts
Check circuit to positive post of left battery.
NOTE: Put the ignition switch in the ON position.

Between the positive terminal of
24 volts
Terminal for wire 14 to ground
20 volts
Check circuit 14, 75 ohm resistor, and diode module. Bad fuse
R. Check ignition relay No. 1, and 10 ampere circuit breaker A.
NOTE: If the readings are good, see Section 4007 to repair the alternator (4).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-38
5 Starter Motor
Check Points
Between housing of starter and
ground
Reading
Continuity


Starter battery terminal 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 S to ground
24 volts
Bad starter relay (6). Also check wire 1_F between starter (5)
and starter relay (6).
NOTE: If the readings are good, see Section 4004 and repair the starter (5).
6 Starter Relay
Check Points
Terminal for wire 0_GB to ground
Reading
Continuity

Bad ground circuit.

Terminal for wire 1_C to ground
24 volts
Terminal for wire 21C_B to ground
24 volts
Check neutral start relay (12), also check circuit 21C.
Terminal for wire 1_F to ground
24 volts
Bad starter relay (6).
7 Fuel Relay
Check Points
Terminal for wire 0_GC to ground
Reading
Continuity

Bad ground circuit.

Terminal for wire 1_D to ground
24 volts
Check wires 1_D and 1_E, also check circuit to batteries.
Terminal for wire 21C_A to ground
24 volts
Terminal for wire 23F_A to ground
24 volts
Bad fuel relay (7).
8 Ether Start Temperature Switch (Option)

Check Points
Reading
NOTE: The ether start temperature switch opens at 13 3 C (55 5 F).

Terminal for wire 0_BC to ground
Continuity
Bad ground circuit.
NOTE: Disconnect the wires from the ether start temperature switch (8). Make sure the engine temperature is
below -3 C (27 F).
Between terminals A and B
Bur 6-40782
Continuity
Bad ether start temperature switch (8).

Revised 6-02
Printed in U.S.A.
Copyright
4002-39
9 Ether Start Solenoid (Option)

Check Points
Terminal for wire 28T_A to ether
start temperature switch
Reading
Continuity

Bad 28T_A circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Have another person push in
and hold the ether start switch (11). Make sure the engine temperature is below -3 C (27 F).
Terminal for wire 28P to ground
24 volts
Check the ether start relay (10). Also check circuit 28P.
NOTE: If the readings are good, replace the ether start solenoid (9).
10 Ether Start Relay No. 6 (Option)

Check Points
Terminal for wire 0_DC to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 19E to ground
24 volts
Bad 10 ampere fuse E or bad ignition relay No. 1. Check wires

19E and 13P_A.
NOTE: Have an assistant depress and hold ether start switch (11). Make sure engine temperature is below -3 C
(27 F) and transmission is in neutral.
24 volts
Bad ether start switch (11), also check circuit 28C.
Terminal for wire 28P_A to ground
24 volts
Bad ether start relay (10).
11 Ether Start Switch (Option)

Check Points
Reading
NOTE: Disconnect the wires from the ether start switch (11).
Between terminals of switch
Open Circuit
Bad ether start switch (11).
NOTE: Have an assistant depress and hold ether start switch (11).
Between terminals of switch
Continuity
Bad ether start switch (11).
NOTE: Put the master disconnect switch and the ignition switch in the ON position and transmission in neutral.
Terminal for wire 25T_B to ground
Bur 6-40782
24 volts
Check circuit 25T.
Revised 6-02
Printed in U.S.A.
Copyright
4002-40
12 Neutral Start Relay No. 8

Check Points
Terminal for wire 0_DJ to ground
Reading
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_E to ground
24 volts
Check circuit 25T.
Terminal for wire 21K_A to ground
24 volts
Check circuit 21K_A and ignition switch.
Terminal for wire 21C_E to ground
24 volts
Bad neutral start relay (12).
13 Ignition Switch
Check Points
Reading

24 volts
Check circuit 1A to 10 ampere circuit breaker A.
NOTE: Disconnect the connector from the ignition switch (13). Turn the switch to ON.
Between Bat and Ign
Continuity
Bad ignition switch (13).
Between Bat and Acc
Continuity
NOTE: Hold the ignition switch (13) in the START position.

Between Bat and Starter
Continuity
Between Bat and Ign
Continuity
NOTE: Put the switch in the Acc position.

Between Bat and Acc
Continuity
14 Ignition Relay No. 1

Check Points
Terminal for wire 0_DE to ground
Reading
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 1_S to ground
24 volts
Check circuit 1 to B+ stud.
24 volts
Check circuit 13K and ignition switch.
24 volts
Bad ignition relay No. 1 (14)
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-41
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER

RELAY, AND TIME DELAY MODULE
18
15
16
17
BC00N140
15. IGNITION RELAY NO. 2

16. ACCESSORY RELAY NO. 3
17. VOLTMETER RELAY NO. 12

18. TIME DELAY MODULE

Check Points
Reading
Continuity

Bad ground circuit.
Terminal for wire 1_T to ground
24 volts
Terminal for wire 13K to ground
24 volts
Terminal for wire 13R to ground
24 volts
Bad ignition relay No. 2 (15).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-42
16 Accessory Relay No. 3

Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position.
Terminal for wire 1_G to ground
24 volts
24 volts
24 volts
Bad accessory relay (16).
17 Voltmeter Relay No. 12

Check Points
Reading
Continuity

Bad ground circuit.

Terminal for wire 1_P to ground
24 volts
Check circuit 1 to starter motor B+ stud.
NOTE: Turn ignition switch to the ON position.

24 volts
Terminal for wire 13V to ground
24 volts
Bad voltmeter relay (17).
18 Time Delay Module

Check Points
Terminal for wire 0_DAS to ground
Reading
Continuity

Bad ground circuit.

Terminal for wire 1A_E to ground
24 volts
Bad 10 ampere circuit breaker A. Check wire 1_l to SPL_D17

and wire 1_J to B+ stud.
NOTE: Put the ignition switch in the ON position. Have another person press and hold the program/reset switch
(45) in RESET position.
Terminal for wire 37R_C to ground
24 volts
Bad program/reset switch (45), also check circuit 37R.
Terminal for wire 13K_F to ground
24 volts
Bad ignition switch (13), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 10 seconds time
delay an audible click will be heard.
Within 10 seconds of putting the
ignition switch in the OFF position,
check terminal for wire 13D to
ground
24 volts
Key OFF
0 volt after 10
seconds
Bad time delay module (18).
After 10 seconds of turning ignition

switch to the OFF position, check
terminal for wire 13D to ground
0 volt
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-43
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND

SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR,
AND BACK-UP ALARM
,
27
32
25
24
37
23
20
21
22
26
30
28
35
31
36
29
33
34
19
BC00N140
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
OUTPUT SPEED SENSOR

ENGINE SPEED SENSOR
INTERMEDIATE SPEED SENSOR
TURBINE SPEED SENSOR
FILTER MAINTENANCE SWITCH
TORQUE CONVERTER OUTPUT TEMPERATURE SENDER
TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS
TRANSMISSION ELECTRONIC CONTROL MODULE
TRANSMISSION SHIFTER
DIAGNOSTIC CONNECTOR
Bur 6-40782
29.
30.
31.
32.
33.
34.
35.
36.
37.
TRANSMISSION KICK-DOWN SWITCH

TRANSMISSION AUTO SWITCH
DECLUTCH SWITCH
BRAKE DECLUTCH PRESSURE SWITCH
TRANSMISSION ENABLE SWITCH
FNR SWITCH
BACK-UP ALARM RELAY NO. 7
BACK-UP ALARM DISABLE SWITCH
BACK-UP ALARM
Revised 6-02
Printed in U.S.A.
Copyright
4002-44
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 19 through 34.
19 Output Speed Sensor

20 Engine Speed Sensor
21 Intermediate Speed Sensor
22 Turbine Speed Sensor
23 Filter Maintenance Switch
24 Torque Converter Output Temperature Sender
25 Transmission Solenoid Valve and Temperature Sensors
26 Transmission Electronic Control Module
28 Diagnostic Connector
29 Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick
Option; Next to Hydraulic Levers for Single Axis Controls)
30 Transmission Auto Switch
31 Declutch Switch
32 Brake Declutch Pressure Switch
33 Transmission Enable Switch
34 FNR Switch
35 Back-up Alarm Relay No. 7
Check Points
Reading
NOTE: Disconnect the transmission electronic control module (26) quick disconnect connector.
Terminal for wire 35C to terminal 7 of
quick disconnect connector
Continuity
Bad wire 35C.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19A_P to ground
24 volts
Bad fuse A, also check wires 19A_P, 13P_A, and ignition relay
No. 1 (14).
Terminal for wire 19H to ground
24 volts
Bad fuse H, also check wires 19H and 13R and ignition relay
No. 2 (15).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A_D to ground
Bur 6-40782
24 volts
Bad back-up alarm relay (35).
Revised 6-02
Printed in U.S.A.
Copyright
4002-45
36 Back-up Alarm Disable Switch

Check Points
Reading
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.
24 volts
Bad back-up alarm relay (35), also check circuit 35A_E.
NOTE: Wires 35A_F and 35R_D are connected together and switch is removed in North American models. The
wires are disconnected and the switch is installed in TUV road approved (Germany) models.
24 volts
Bad back-up alarm disable switch (36). If machine is not a TUV

model, check wires 35A_F and 35R_D.
Reading
37 Back-up Alarm
Check Points
Continuity
Bad ground circuit.
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
24 volts
Bad back-up alarm disable switch (36), also check wires

35R_C and 35R_B. If machine is not a TUV model, check wires
35R_C and 35R_B.
NOTE: If the readings are good, replace the back-up alarm (37).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-46
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS,

PROGRAM/RESET SWITCH, PARK BRAKE SWITCH, INSTRUMENT
CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH
44
39
43
45
38
42
41
46
47
48
49
40
BC00N140
38.
39.
40.
41.
42.
43.
Bur 6-40782
BRAKE WARNING PRESSURE SWITCH

COOLANT LEVEL SENDER
FUEL LEVEL SENDER
HYDRAULIC OIL TEMPERATURE SENDER
HYDRAULIC FILTER RESTRICTION SWITCH
ENGINE COOLANT TEMPERATURE SENDER
44.
45.
46.
47.
48.
49.
AIR FILTER RESTRICTION SWITCH

PROGRAM/RESET SWITCH
PARKING BRAKE SWITCH
INSTRUMENT CLUSTER
PILOT CONTROL SWITCH
UP/DOWN COUNT SWITCH
Revised 6-02
Printed in U.S.A.
Copyright
4002-47
38 Brake Warning Pressure Switch

Check Points
Reading
NOTE: Brake warning pressure switch opens at 117.2 bar (1700 psi).
Continuity
Bad ground circuit.
Approximately
11.5 volts
Check circuit 33P.
Terminal B for wire 0 to ground

Terminal A for wire 33P to ground
NOTE: Disconnect the wires from the brake warning pressure switch (38).
Between terminals A and B of the
switch
Continuity
Bad brake warning pressure switch (38).
NOTE: Start and run the engine at idle.

switch
Open Circuit
Bad brake warning pressure switch (38) or brake pressure is

below 117.2 bar (1700 psi). Refer to Section 7002 to check
brake pressure.
39 Coolant Level Sender

Check Points
Reading
Continuity

Bad ground circuit.
Terminal A for wire 31D to ground
Approximately
1.6 volts AC
Check circuit 31D, also check the instrument cluster (47).
NOTE: If the readings are correct replace the coolant level sender (39).
40 Fuel Level Sender

Check Points
Reading
Continuity

Bad ground circuit.
Terminal A for wire 36F to ground
Approximately
5 volts
Check the instrument cluster (47).
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
sender
Bur 6-40782
33 to 240
ohms
Bad fuel level sender (40).
Revised 6-02
Printed in U.S.A.
Copyright
4002-48
41 Hydraulic Oil Temperature Sender

Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect the connector from the hydraulic oil temperature sender.
Between terminals of hydraulic oil
temperature sender
130 to 9500
ohms
Replace hydraulic oil temperature sender (41).
Terminal A for wire 36H to ground
Approximately
5 volts
42 Hydraulic Filter Restriction Switch

Check Points
Reading
NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi).
Check between the housing of the
hydraulic filter restriction switch (42)
and ground
Continuity
Bad ground connection between the hydraulic filter restriction

switch (42) and ground.
Terminal A for wire 31H to ground.
Approximately
11.5 volts
NOTE: If the readings are correct replace the hydraulic filter restriction switch (42).
43 Engine Coolant Temperature Sender

Check Points
Terminal for wire 0_BE to ground
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect the connector from the engine coolant temperature sender.
Between terminals of engine coolant
temperature sender
130 to 9500
ohms
Replace engine coolant temperature sender.
Terminal A for wire 36C to ground
Bur 6-40782
Approximately
5 volts
Revised 6-02
Printed in U.S.A.
Copyright
4002-49
44 Air Filter Restriction Switch

Check Points
Reading
NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig).
Terminal for wire 0_BD to ground
Continuity
Bad ground circuit.
Approximately
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch (44).
45 Program/Reset Switch
Check Points
Terminal for wire 0_KM to ground
Reading
Continuity

Bad ground circuit.
24 volts
Terminal for wire 1A_B to ground
Check 10 ampere circuit breaker A. Also check circuit 1A.
NOTE: Press and hold the program/reset switch in the reset position.
24 volts
Bad program/rest switch.
NOTE: Put the program/reset switch (45) in the program position.

24 volts
Bad program/reset switch.
NOTE: Put the five position rotary lamp switch (114) in position 3, 4, or 5.
24 volts
Terminal for wire 49_E to ground
Bad rotary lamp switch. Also check fuse Z and circuit 49 and
19Z.
NOTE: If 24 volts between wire 49 and ground and program/reset switch is not illuminated, replace program/reset
switch.

Check Points
Terminal for wire 0_KJ to ground
Reading
Continuity

Bad ground circuit.
24 volts
Check fuse A, also check circuit 19A.
24 volts
Bad parking brake switch (46).
NOTE: Apply parking brake switch (46).

Terminal for wire 33U to ground
24 volts
Bad rotary lamp switch. Also check fuse Z and circuits 49 and
19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-50
Check Points
Reading
NOTE: Disconnect the connector from the instrument cluster.

Connector terminal 3 to ground
Continuity
Bad brake warning pressure switch (38). Also check circuit 33P
and ground circuit at brake warning pressure switch.
Continuity
Bad coolant level sender (39). Also check circuit 31D and
ground circuit at coolant level sender.
Continuity
Bad secondary steering pressure switch (67). Also check

circuit 35X and ground circuit at pressure switch.
Open Circuit
Bad air filter restriction switch (44). Also check circuit 31F.
Open Circuit
Bad hydraulic filter restriction switch. Also check circuit 31H.
Continuity
130 to 9500
ohms
Bad engine coolant temperature sender (43). Also check circuit

circuit 36C and ground circuit at sender.
33 to 240 ohms
Bad fuel level sender (40). Also check circuit 36F and ground
circuit at sender.
130 to 9500
ohms
Bad hydraulic oil temperature sender (41). Also check circuit

36H and ground circuit at sender.
Bad ground circuit. Check wires 0_KP, 0_DAV, 0_HC, and

0_BG.
Connector terminal 21 to connector

terminal 33
Continuity
Bad wire 50T.
237 to 243
ohms
Bad engine oil pressure switch (50). Also check circuit 36P and
ground circuit.
Open Circuit
Bad redundant brake switche(s) (57). Also check circuit 33R.
Connector terminal 31 to terminals

26 and 27 on the transmission
electronic control module (26)
Continuity
Bad circuit 50L.
Connector terminal 32 to terminal 25

on the transmission electronic
control module (26)
Continuity
Bad circuit 50H.
Continuity
Check LH and RH stop lamps and circuit 44. Also check ground
circuit at lamps.
Continuity
Bad ground circuit.
Continuity
Bad ground circuit.
Continuity
Bad ground circuit.
24 volts
Bad fuse V. Also check circuit 19V.
24 volts
Bad fuse S. Also check circuit 19S.
NOTE: Put the parking brake switch in the ON position.

Bur 6-40782
24 volts
Bad parking brake switch. Also check fuse A and circuit 19A.
Revised 6-02
Printed in U.S.A.
Copyright
4002-51
47 Instrument Cluster (Continued)

NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
24 volts
Check fuse G, blower switch, thermostat switch, and A/C low

pressure switch. Also check circuits 61R, 61A, and 61T.
NOTE: Put the five position rotary lamp switch in position four or five.
24 volts
Check lamp switch and fuse A. Also check circuits18A and

42R.
NOTE: Put the rotating beacon switch in the ON position.

24 volts
Check rotating beacon switch and fuse X. Also check circuit 46.
NOTE: Put the five position rotary lamp switch in position four or five. Put the high/low beam switch in HIGH
BEAM position.
24 volts
Check high/low beam switch, high/low beam relay, five position

rotary lamp switch, and fuse C. Also check circuits 18C and
64D and wires 41H and 41J_A.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and
off every 1-2
seconds
Check fuse B, turn signal switch, and flasher module. Also

check wire 19B, circuit 45A to flasher module, and circuit 45L
from flasher module to instrument cluster.
NOTE: Put the turn signal switch in the RIGHT TURN position.
24 volts on and
off every 1-2
seconds

check wire 19B, circuit 45B to flasher module, and circuit 45R
NOTE: Put the program/reset switch in the PROGRAM position.

24 volts
Bad program/reset switch. Also check wire 37P and wire 1A_B
to ignition switch.
NOTE: Press and hold the program/reset switch in the RESET position.
24 volts
Bad program/reset switch. Also check wire 37R_B and wire

1A_B to ignition switch.
NOTE: Press and hold up/down count switch in UP position.
24 volts
Fuse S, or up/down count switch, or time delay module bad.

Also check wires 37U and wire 13D from time delay module to
fuse S, and circuit 19S.
NOTE: Press and hold up/down count switch in DOWN position.
Bur 6-40782
24 volts

Also check wire 37D and wire 13D from time delay module to
Revised 6-02
Printed in U.S.A.
Copyright
4002-52

NOTE: Press pilot control switch to turn ON switch LED.
24 volts
Bad pilot control switch or fuse C. Also check wire 31L and
circuit 19C.
24 volts
Bad parking brake relay or fuse D. Also check circuits 52C and
19D.
24 volts
Bad pilot control relay or fuse C. Also check circuits 53C and
19C.

Check Points
Reading
Continuity

Bad ground circuit.
Terminal for wire 19C to ground
24 volts
Bad fuse C, also check circuit 19C.

Terminal for wire 31L to ground
24 volts
Bad pilot control switch (48).
NOTE: Put the five position rotary lamp switch (114) in position 3 or higher.
24 volts
Check five position rotary lamp switch (114) and fuse Z. Also
check circuit 49.
NOTE: If the readings are correct replace the pilot control switch (48).
49 Up/down Count Switch

Check Points
Reading
Continuity

Bad ground circuit.
Terminal for wire 19S to ground
24 volts
Check fuse S and time delay module. Also check circuits 19S
and 13D from time delay module to fuse S.
NOTE: Press and hold the up/down switch in the DOWN COUNT position.
Terminal for wire 37D to ground
24 volts
Bad up/down count switch.
NOTE: Press and hold the up/down switch in the UP COUNT position.
24 volts
Bur 6-40782
24 volts
check circuit 49.
Revised 6-02
Printed in U.S.A.
Copyright
4002-53
TROUBLESHOOTING ENGINE OIL PRESSURE SWITCH, PILOT CONTROL,

PARKING BRAKE, AND REDUNDANT BRAKE SWITCHES
53
57
56
55
54
51
52
58
50
BC00N140
50.
51.
52.
53.
54.
Bur 6-40782
ENGINE OIL PRESSURE SWITCH

PILOT CONTROL RELAY NO. 10
PARKING BRAKE RELAY NO. 9
PARKING BRAKE SOLENOID
PILOT PRESSURE SOLENOID
55.
56.
57.
58.
FAN REVERSER SWITCH (OPTION)

FAN REVERSING SOLENOID (OPTION)
REDUNDANT BRAKE SWITCHES
RELAY SOCKET NO. 11
Revised 6-02
Printed in U.S.A.
Copyright
4002-54

Check Points
Reading
Between engine oil pressure switch

(50) terminals C and NC
Continuity
Bad engine oil pressure switch (50).

(50) terminals C and NO
Open Circuit

(50) terminal NC and ground
237 to 243
ohms
Bad ground connection or bad ground wire assembly.

(50) terminal NO and ground
90 to 92 ohms
NOTE: Disconnect wire 36P from terminal C of engine oil pressure switch. Put master disconnect switch and
ignition switch in ON position.
Approximately
5 volts
Bad instrument cluster (47) or bad circuit 36P.
NOTE: Start engine and operate at idle speed.

terminal C and ground
90 to 92 ohms
Bad engine oil pressure switch.
51 Pilot Control Relay No. 10

Check Points
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(48) is OFF.
24 volts
0 volt
24 volts

Bad instrument cluster (47). Also check circuit 53C.
Bad pilot control relay.
NOTE: Put the pilot control switch in ON position.

24 volts
52 Parking Brake Relay No. 9

Check Points
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (46) is OFF.
Terminal for wire 19D_B to ground
24 volts
0 volt
24 volts
Bad fuse D, also check circuit 19D.

Bad parking brake relay.

Bur 6-40782
24 volts
Bad instrument cluster (47). Also check wire 52C.
Revised 6-02
Printed in U.S.A.
Copyright
4002-55
53 Parking Brake Solenoid

Check Points
Reading
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 (52). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid (53).
54 Pilot Pressure Solenoid

Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control
switch (48) is OFF.
24 volts
Bad pilot control relay (51), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid (54).
55 Fan Reversing Switch (Option)

Check Points
Terminal for wire 0_DAF to ground
Reading
Continuity

Bad ground circuit.
Terminal for wire 19P_B to ground
24 volts
Check fuse P, ignition relay No. 1, and wires 19P_A and

13P_B.
NOTE: Put fan reversing switch in ON position (hold rocker in momentary position).
Terminal for wire 52_A to ground
24 volts
Bad fan reversing switch.
NOTE: Put five position rotary lamp switch in position 3 or higher.
Terminal for wire 49_U to ground
Bur 6-40782
24 volts
Check five position rotary lamp switch. If LEDs in fan reversing

switch are not ON with 24 volts at check point, replace fan
reversing switch.
Revised 6-02
Printed in U.S.A.
Copyright
4002-56
56 Fan Reversing Solenoid (Option)

Check Points
Reading
NOTE: Disconnect wiring harness connector 158 from fan reversing solenoid.
Between pins A and B of fan
reversing solenoid
Pin B of wiring harness connector
158 to ground
36 to 42 ohms
Continuity
Bad fan reversing solenoid.
Bad ground circuit.
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 A of wiring harness connector
158 to ground
24 volts
Bad fan reversing switch. Also check wire 52_A.
57 Redundant Brake Pressure Switches

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

Continuity
Bad ground circuit.
Terminal A for wire 33R to ground
Approximately
11.5 volts
Bad instrument cluster (47), also check circuit 33R.
NOTE: If the readings are good, replace the redundant brake pressure switch(es) (57).
58 Relay Socket No. 11

Check Points
Reading
0 volt
Bad instrument cluster (47). Also check circuit 23C to

instrument cluster.
24 volts
Bad fuse F. Also check circuit 19F to ignition relay No. 2 (15).
Terminal for wire 13K_B to ground
24 volts
Check wire 13K_B to ignition relay No. 2 (15).
Terminal for wire 13C_D to ground
24 volts
Check wires 13K_D and 13C_B and connectors 217F and

217M.
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-57
TROUBLESHOOTING BUCKET CONTROLS

63
62
65
64
60
59
61
BC00N140
59. DETENT SWITCH

60. BUCKET CONTROL VALVES ELECTROMAGNETIC DETENTS
61. RETURN TO TRAVEL/FLOAT SWITCH
62. RETURN TO DIG PROXIMITY SWITCH
Bur 6-40782
63. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY

SWITCH
64. FLOAT PRESSURE SWITCH
65. FLOAT SOLENOID
Revised 6-02
Printed in U.S.A.
Copyright
4002-58
59 Detent Switch
Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in
the OFF position.
24 volts
Bad pilot control relay (51), also check circuit 53P_B.
NOTE: Put the detent switch (59) in the ON position.

Terminal for wire 56_H to ground
24 volts
Bad detent switch (59).
Terminal for wire 49_M to ground
24 volts
Bad circuit 49_M. Also check five position rotary lamp switch
(114). If detent switch illumination LED does not turn ON with
24 volts at check point, replace detent switch (59).
60 Bucket Control Valve Electromagnetic Detents

Check Points
Reading
NOTE: Disconnect the wiring harness connector from the control valve electromagnetic detents connector.
Electromagnetic detents connector,
between pins 1 and 6
65 to 71 ohms
Bad return-to-travel detent electromagnet.

65 to 71 ohms
Bad height control detent electromagnet.

65 to 71 ohms
Bad return-to-dig control detent electromagnet.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (48) in OFF
position and detent switch (59) in ON position.
Wiring harness connector 17M, pin 4
to ground
24 volts
Bad detent switch (59). Also check wires 53P_B, 56_G, and
56_H.

to ground
24 volts
Bad detent switch (59). Also check wires 56_E and 56_H.

to ground
24 volts
Bad detent switch (59). Also check wires 56_F and 56_H.
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-59
61 Return-To-Travel/Float Switch
Check Points
Reading
Terminal for wire 0_DAG to ground
Continuity
Bad ground circuit.
Terminal for wire 0_DAH to ground
Continuity
Bad ground circuit.
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch (61). Put the return-totravel/float switch (61) in FLOAT position.
Between switch terminals 1 and 2
Continuity
Bad return-to-travel/float switch (61).
NOTE: Put the return-to-travel/float switch (61) in the TRAVEL position.

Continuity
Pin 2 of connector 39F to ground
24 volts
Bad return-to-travel detent electromagnet. Also check circuit

55A.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch (61).
Put ignition switch in ON position. Put five position rotary lamp switch (114) in position 3 or higher.
Terminal for wire 49_K to ground
24 volts
Bad circuit 49_K. Also check five position rotary lamp switch
(114). If return-to-travel/float switch illumination LED is not ON
with 24 volts at check point, replace return-to-travel/float
switch.
62 Return-To-Dig Proximity Switch

Check Points
Reading
NOTE: Disconnect the connector from the return-to-dig proximity switch (62). Put the master disconnect switch
and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position and the detent
switch (59) in the ON position.
Terminal B for wire 0_AM to ground
Continuity
Terminal A for wire 53B_A to ground
24 volts
Bad bucket control valve detent electromagnets (60) or detent

switch (59). Also check circuit 53B_A.
Terminal C for wire 56_D to ground
24 volts
Bad detent switch (59), also check circuit 56.
Bad ground circuit.
NOTE: If the readings are good, replace the return-to-dig proximity switch (62).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-60
63 Height Control/Return-To-Travel Proximity Switch

Check Points
Reading
NOTE: Disconnect the connector from the height control/return-to-travel proximity switch (63). Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position
and the detent switch (59) in the ON position.
Terminal B for wire 0_AA to ground
Continuity
Bad ground circuit.
Terminal A for wire 54B to ground
24 volts

switch (59). Also check circuit 54B.
Terminal C for wire 56_A to ground
24 volts
Bad detent switch (59). Also check circuit 56.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch (63).
64 Float Pressure Switch

Check Points
Reading
NOTE: Disconnect the wiring harness connector 178M from the float pressure switch.
Between terminals of float pressure
switch
Open Circuit
Bad float pressure switch.
NOTE: Start and run engine at idle speed. Put return-to-travel/float switch in FLOAT position. Put loader control
lever in FLOAT position.
switch
Continuity
NOTE: Shut down engine. Put ignition switch in ON position. Put pilot control switch in OFF position (switch LED
OFF).
Wiring harness connector 178M, pin
A and ground
24 volts
Bad pilot control relay. Also check wires 53P_C and 53P_D.
65 Float Solenoid
Check Points
Reading
NOTE: Disconnect the wiring harness connector 179F from the float solenoid.
Between terminals of float solenoid
37 to 43 ohms
Bad float solenoid.
Wiring harness connector 179F pin 2

to ground
Continuity
Bad ground circuit.
to ground
Bur 6-40782
24 volts
Bad float pressure switch. Also check wires 53S_A and 53S_B.
Revised 6-02
Printed in U.S.A.
Copyright
4002-61
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE

CONTROL
71
69
70
67
66
68A
73
72
68
BC00N140
66. SECONDARY STEERING MODULE (OPTION)

67. SECONDARY STEERING PRESSURE SWITCH (OPTION)
68. SECONDARY STEERING MOTOR (OPTION)
68A.SECONDARY STEERING SOLENOID (OPTION)
69. PIN ENGAGE SWITCH (OPTION)
Bur 6-40782
70.
71.
72.
73.
PIN ENGAGE SOLENOID (OPTION)

RIDE CONTROL SWITCH
RIDE CONTROL RELAY NO. 4
RIDE CONTROL SOLENOID
Revised 6-02
Printed in U.S.A.
Copyright
4002-62
66 Secondary Steering Module (Option)

Check Points
Reading
NOTE: Disconnect the wiring harness connector 90M from the secondary steering module.
Pin 2 of connector 90M to ground
Continuity
Bad relay on secondary steering motor (68) or bad secondary

steering solenoid (68A). Also Check wires 51_A, 51_B, and
51_C and ground circuit connections (wires 0_ND and 0_CF).
Continuity
Bad ground circuit.
Continuity
Bad secondary steering pressure switch (67). Also check wires

35X_D, 35X_C, and 35X_A.
Open Circuit

51P_A and 51P_B.
Continuity
Bad ground circuit.
Continuity
Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
24 volts
Bad wire 1_W to secondary steering motor (68) B+ stud.
24 volts
Bad fuse M or ignition switch. Also check circuits 19M and 12K.
24 volts
Check fuse R, ignition relay No. 1, ignition switch, and diode

module. Also check circuits 19R and 13P_B.
NOTE: Start and run engine at idle speed.

Continuity
11 volts
Bad secondary steering pressure switch.

Check circuit 35X to instrument cluster. If circuit 35X okay,
problem is bad instrument cluster.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector 90M to secondary
steering module. Disconnect wire 51_B from secondary steering motor (68) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector 131F from secondary steering pressure switch (67). Apply a
ground to pin C of connector 131F.
Terminal for wire 51_B to ground
24 volts
Bad secondary steering module.
67 Secondary Steering Pressure Switch (Option)

Check Points
Reading
NOTE: Disconnect wiring harness connector 131F from secondary steering pressure switch (67).
Pressure switch (67) pin B to pin C
Continuity
Pressure switch (67) pin B to pin A
Open Circuit
Pressure switch (67) pin A to pin C
Open Circuit

Continuity
Open Circuit
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-63
68 Secondary Steering Motor (Option)

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

ground terminal to ground
Continuity
Bad ground circuit.
Terminal for wire 51_B to ground.
10 to 45 ohms
Bad secondary steering motor (68) relay coil or secondary

steering solenoid (68A). 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
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.
24 volts
Check fuses M and R, secondary steering module (66), and

secondary steering pressure switch (67). If 24 volts is obtained
the secondary steering motor is bad. If fuse M or R was
replaced: if fuse M blows again, secondary steering module is
bad; if fuse R blows again, secondary steering module is bad
or secondary steering motor relay or secondary steering
solenoid is shorted.
68A Secondary Steering Solenoid (Option)

Check Points
Reading
NOTE: Disconnect connector 264M from secondary steering solenoid.

Between pins A and B of secondary
steering solenoid
Between pin B of connector 264M
and ground
36 to 42 ohms
Continuity
Bad secondary steering solenoid.
Bad ground circuit.
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 A of connector 264M
and ground
Bur 6-40782
24 volts
Check secondary steering module (66) and secondary steering

pressure switch (67).
Revised 6-02
Printed in U.S.A.
Copyright
4002-64
69 Pin Engage Switch (Option)

Check Points
Terminal for wire 0_DAL to ground
Reading
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.
24 volts
0 volt
Bad fuse P or ignition relay No. 2. Also check circuits 19P_A

and 13P_B.
Bad pin engage switch.
NOTE: Put the pin engage switch (69) in the ON position.

24 volts
24 volts
Check the five position rotary lamp switch (114). Also check
circuit 49. If LED in pin engage switch is not ON with 24 volts
at check point, replace pin engage switch.
70 Pin Engage Solenoid (Option)

Check Points
Terminal for wire 0_AB to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(69) in the ON position.
24 volts
Bad pin engage switch (69), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid (70).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-65
71 Ride Control Switch

Check Points
Reading
NOTE: Disconnect connector 44F from ride control switch (71).

Connector 44F pin 7 to ground
Continuity
Bad ground circuit.
Ride control switch terminal 6

(positive) to terminal 7 (negative)
Continuity
Bad ride control switch.
NOTE: Connect connector 44F to ride control switch (71). Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
24 volts
0 volt
Check fuse C and ignition relay No. 1. Also check circuits 19C
and 13P_A.
NOTE: Put the ride control switch (71) in the ON position.

24 volts
NOTE: Put the five position rotary light switch (114) in position 3 or higher.
24 volts
Check five position rotary lamp switch (114). Also check circuit
49. If LED in ride control switch is not ON with 24 volts at check
point, replace ride control switch.
Reading
72 Ride Control Relay No. 4

Check Points
Terminal 85 for wire 0_DD to
connector 19F pin 57
Continuity
Check wire 44F.
Terminal 86 for wire 58H_B to

connector 19F pin 8
Continuity
Check wire 58H_B.
Terminal 87 for wire 58_B to ride

control switch (71) pin 6
Continuity
Check wire 58_B
NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position.
24 volts
Bad ride control switch. Also check wire 58S.
NOTE: If readings are normal, replace ride control relay (72).
73 Ride Control Solenoid

Check Points
Reading
NOTE: Disconnect connector 5F from ride control solenoid.

Between terminals 1 and 2 of ride
control solenoid
Bur 6-40782
Continuity
20 to 26 ohms
Bad ground circuit.

Bad ride control solenoid.
Revised 6-02
Printed in U.S.A.
Copyright
4002-66
TROUBLESHOOTING WIPER/WASHER
74
79
75
77
78
76
BC00N140
74. FRONT WIPER MOTOR

75. FRONT WIPER AND WASHER SWITCH
76. FRONT WASHER PUMP MOTOR
Bur 6-40782
77. REAR WIPER AND WASHER SWITCH

78. REAR WASHER PUMP MOTOR
79. REAR WIPER MOTOR
Revised 6-02
Printed in U.S.A.
Copyright
4002-67
74 Front Wiper Motor

Check Points
Terminal for wire 0_KN to ground
Reading
Continuity

Bad ground circuit.
NOTE: Make sure the front wiper and washer switch (75) is in the OFF position.
Between terminals B and D for wires
63C and 63L
Continuity
Bad front wiper motor.
Terminal for wire 19J to ground
24 volts
Check fuse J, also check circuit 19J.
NOTE: Put the front wiper and washer switch (75) in the LOW position.
24 volts
0 volt
Check fuse J, also check circuit 19J. Bad front wiper and
washer switch (75).
Bad front wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (75) in the HIGH position.
24 volts
0 volt
washer switch (75).
Bad front wiper and washer switch (75).
NOTE: Put the front wiper and washer switch in the intermittent position.
24 volts pulse
24 volts pulse
NOTE: If the readings are good, replace the front wiper motor (74).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-68
75 Front Wiper and Washer Switch

Check Points
Terminal for wire 0_DAR to ground
Reading
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 (75) is in the OFF position.
Terminal for wire 19J_A to ground
24 volts
24 volts
0 volt
washer switch (75).
Bad front rotary wiper and washer switch (75)
24 volts
0 volt
Check fuse J, also check circuit 19J. Bad front rotary wiper and
washer switch (75).
Bad front rotary wiper and washer switch (75).
Terminal for wire 63L_A to ground
24 volts pulse
24 volts pulse
76 Front Washer Pump Motor

Check Points
Reading
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 (75).
Terminal for wire 63W to ground
24 volts
Bad front wiper and washer switch (75), also check wires 63W
and 63W_A.
NOTE: If the readings are good, replace the front washer pump motor (76).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-69
77 Rear Wiper and Washer Switch

Check Points
Terminal for wire 0_DW to ground
Reading
Continuity

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

Terminal for wire 19K_D to ground
24 volts
Bad fuse K or ignition relay No. 2 (15). Also check circuit 19K.
Terminal for wire 19K_C to ground
24 volts
NOTE: Put the rear wiper and washer switch in the ON position.
24 volts
Bad rear wiper and washer switch (77).
NOTE: Press and hold the rear wiper and washer switch (77) in the WASH position.
Terminal for wire 68W_A to ground
24 volts
NOTE: Put the five position rotary lamp switch in position 3 or higher.
Terminal for wire 49_L to ground
24 volts
Check rotary lamp switch and circuit 49. If LEDs in rear wiper
and washer switch are not ON with 24 volts at check point,
replace rear wiper and washer switch.
78 Rear Washer Pump Motor

Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (77) in WASH position.
24 volts
Bad rear wiper and washer switch (77) Also check wires
68W_A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor (78).
79 Rear Wiper Motor

Check Points
Terminal for wire 0_MA to ground
Reading
Continuity

Bad ground circuit.
NOTE: Make sure the rear wiper and washer switch (77) is in the OFF position.
Between terminals for wires 68C_B
and 68L_C
Continuity
24 volts
Check fuse K, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (77) in the ON position.
Terminal for wire 68L_C to ground
24 volts
0 volt
NOTE: If the readings are good, replace the rear wiper motor (79).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-70
TROUBLESHOOTING HORN, BLOWER, AND AIR CONDITIONING
86
81
87
90
83
80
89
88
82
84
85
BC00N140
80.
81.
82.
83.
84.
85.
HORN RELAY NO. 5

HORN
SEAT COMPRESSOR
BLOWER SWITCH
SPEED RESISTOR
BLOWER MOTOR
86.
87.
88.
89.
90.
A/C LOW PRESSURE SWITCH (IN CAB)

A/C HIGH PRESSURE SWITCH (IN REAR CHASSIS)
THERMOSTAT SWITCH
COMPRESSOR CLUTCH LOCKOUT RELAY NO. 14
COMPRESSOR CLUTCH
80 Horn Relay No. 5

Check Points
Reading
Terminal for wire 19U_B to ground
24 volts
Check fuse U, also check wire 19U_B.
Terminal for wire 19U_C to ground
24 volts
Check wire 19U_C.
24 volts
Bad horn relay (80).
NOTE: Have another person push and hold the horn switch.
Bur 6-40782
0 volt
24 volts
Bad horn switch.

Revised 6-02
Printed in U.S.A.
Copyright
4002-71
81 Horn
Check Points
Terminal for wire 0_AD to ground
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect the wire 64 from the horn (81). Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground.
24 volts
Check the horn relay (80). Also check wires 64 and 64_A.
NOTE: If the readings are good replace the horn (81).
82 Seat Compressor and Switch (Option)

Check Points
Terminal for wire 0_DY to ground
Reading
Continuity

Bad ground circuit.
Terminal for wire 19N_A at seat
switch
24 volts
Check fuse N and accessory relay (16). Also check wire 19N_A
and circuit 12P.
NOTE: Put the seat compressor (82) switch in the ON position.

Terminal for wire from seat switch at
compressor
24 volts
Bad seat switch, also check circuit from seat switch to

compressor.
NOTE: If the readings are good replace the seat compressor.
83 Blower Switch
Check Points
Reading
24 volts
Check fuse G and ignition relay No. 2 (15). Also check circuits
19G and 13R.
24 volts
Bad blower switch (83).
Terminal for wire 61T to ground
24 volts
Terminal for wire 19G to ground

NOTE: Turn the blower switch to LOW.
NOTE: Turn the blower switch to MEDIUM.

24 volts
24 volts
24 volts
24 volts
NOTE: Turn the blower switch to HIGH.
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-72
84 Blower Motor Speed Resistors with Thermal Fuse

Check Points
Reading
NOTE: Disconnect the wiring harness connector 29M from the blower motor (85).
Between terminals 1 and 2 of blower
motor connector
Approximately
4.5 ohms
Bad blower motor resistor.

motor connector
Approximately
1.5 ohms
85 Blower Motor
Check Points
Terminals for wire 0_DZ to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (83) to
HIGH.
24 volts
Check the blower switch (83).
NOTE: If the readings are correct and the blower motor (85) does not run, replace the blower motor (85). Turn the
blower switch (83) to LOW. If the blower motor (85) ran in HIGH but not in LOW or MEDIUM, check the blower
motor resistor (84).
86 A/C Low Pressure Switch (In Cab)

Check Points
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (83) to HIGH and
the thermostat switch (88) to COLD.
Terminal B for wire 61A_E to ground
24 volts
Check the thermostat switch (88), also check circuit 61A.
NOTE: Disconnect the wiring harness connector 27M from the A/C low pressure switch (86).
Between terminals of low pressure
switch (86)
Open Circuit
Bad A/C low pressure switch (86), also check refrigerant

charge level. (Pressure must be above 1.4 bar (20 psi) for
switch to open.)
87 A/C High Pressure Switch (In Rear Chassis)

Check Points
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and the
thermostat switch (88) to COLD.
24 volts
NOTE: Disconnect wiring harness connector 98 from A/C high pressure switch (87).
Between terminals of A/C high
pressure switch (87)
Bur 6-40782
Open Circuit
Bad A/C high pressure switch (87), also check for excessive
refrigerant pressure. (Switch closes at or above 27.6 bar (400
psi)).
Revised 6-02
Printed in U.S.A.
Copyright
4002-73
88 Thermostat Switch
Check Points
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH.
24 volts
Check the blower switch (83), also check wire 61T.
NOTE: Turn the thermostat switch (88) all the way to COLD.
24 volts
Bad thermostat switch (88).
89 Compressor Clutch Lockout Relay No. 14

Check Points
Terminal for wire 0_DK to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and
24 volts
Terminal for wire 61R_D to ground
0 volt
24 volts
Check thermostat switch (88), also check wire 61A_C.

Check A/C low pressure switch (86) and A/C high pressure
switch (87).
Bad compressor clutch lockout relay (89).
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector 98 from A/C high pressure
switch. Connect a jumper wire between pins A and B of connector 98. Put ignition switch in ON position.
24 volts
0 volt
Check wires 61R_C and 61R_D. If air conditioning indicator on

instrument cluster (47) is not ON, check wires 61R_F and
61R_G to instrument cluster.
90 Compressor Clutch
Check Points
Reading
Terminals for wire 61C to ground
Bur 6-40782
24 volts
Check the compressor clutch lockout relay (89), also check

circuit 61C.
Revised 6-02
Printed in U.S.A.
Copyright
4002-74
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER

OUTLET, RADIOS AND SPEAKERS
97
98
94
95
96
92
93
91
BC00N140
91. CIGAR LIGHTER

92. POWER CONVERTER
93. POWER OUTLET
94. REMOTE OR 24 VOLT RADIO

95. 12 VOLT RADIO
96. RADIO POWER CONVERTER
97. LEFT SPEAKER

98. RIGHT SPEAKER
91 Cigar Lighter (Option)

Check Points
Reading
24 volts
Continuity

Check fuse W, also check circuit 19W.
Bad ground circuit.
NOTE: If the readings are good replace the cigar lighter (91).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-75
92 Power Converter 24 volts to 12 volts (Option)

Check Points
Terminal for wire 0_RA to ground
Terminal for wire 1_V to ground
Reading
Continuity
24 volts

Bad ground circuit.
Check wire 1_V to cab power stud.

Terminal for wire 19L_B to ground
24 volts
Bad fuse L, also check circuit 19L.
Terminal for wire 12V_B to ground
12 volts
Bad power converter (92).
93 Power Outlet (Option)

Check Points
Reading
Terminal for wire 0_RB to ground
Continuity
Terminal for wire 12V_A to ground
12 volts

Bad ground circuit.
Bad power converter (92), also check wire 12V_A.
NOTE: If the readings are good replace the power outlet (93).
94 Remote Radio or 24 Volt Radio (Option)

Check Points
Reading
Terminal in radio connector for wire

0_QC to ground
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on. Put balance control for RH
and LH speakers to center position.
65C_A to ground
24 volts
Check fuse L, also check circuits 19L and 65C.
NOTE: Keep the ignition switch and radio ON. Disconnect wiring harness connectors at LH and RH speakers (97
and 98).
Pin A in wiring harness connector
111M to ground
Voltage
Bad circuit between the radio and the connector or bad radio
(94).

112M to ground
Voltage
(94).
95 12 Volt Radio Ready (Option)

Check Points
Reading

0_QC to ground
Continuity

Bad ground circuit.

65C_A to ground
Bur 6-40782
12 volts
Check fuse L, also check circuit 19L and 65C. Also check the
radio power converter (96).
Revised 6-02
Printed in U.S.A.
Copyright
4002-76
96 Radio Power Converter (24 volts to 12 volts) (Option)

Check Points
Terminal for wire 0_PD to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on.
12 volts
Check fuse L and circuit 19L. Bad radio power converter (96).
Reading
97 Left Speaker (Option)

Check Points
NOTE: Disconnect connector from left speaker (97). Put master disconnect switch and ignition switch in ON
position. Turn radio (94) on. Put balance control for RH and LH speakers to center position.
112M to ground
Voltage
Pin B in wiring harness connector

112M to ground
Continuity
Bad circuit between the left speaker (97) and the radio or a bad
radio (94).
Bad circuit between the left speaker (97) and the radio (94).
NOTE: If the readings are good, replace the left speaker (97).
98 Right Speaker (Option)

Check Points
Reading
NOTE: Disconnect connector from right speaker (98). Put master disconnect switch and ignition switch in ON
111M to ground
Voltage
Bad circuit between the right speaker (98) and the radio or a
bad radio (94).

111M to ground
Continuity
Bad circuit between the right speaker (98) and the radio (94).
NOTE: If the readings are good, replace the right speaker (98).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-77
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD

SWITCH, TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER
MODULE
100
103
101
99
104
102
105
BC00N140
99. BEACON SWITCH

100. ROTATING BEACON
101. BRAKE LAMP PRESSURE
SWITCH
102. BRAKE LAMPS RELAY NO. 15

103. HAZARD SWITCH
104. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH

105. FLASHER MODULE
99 Beacon Switch
Check Points
Terminal for wire 0_DAP to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3 or
higher.
Terminal for wire 49_R to ground
24 volts
Check the five position rotary lamp switch (114), also check
circuit 49. If LED in beacon switch is not ON with 24 volts at
check point, replace beacon switch.
Terminal for wire 19X to ground
24 volts
Check fuse X, also check wire 19X.
NOTE: Put the beacon switch (99) in the ON position.

Bur 6-40782
24 volts
Bad beacon switch (99).

Revised 6-02
Printed in U.S.A.
Copyright
4002-78
100 Rotating Beacon

Check Points
Reading
Bulb
Continuity
Bad bulb.
Terminal for wire 0_MC to ground
Continuity
Bad ground circuit.
NOTE: Put master disconnect switch and beacon switch (99) in ON position.
24 volts
Bad circuit between the beacon (100) and the beacon switch
(99). Also check the beacon switch (99).
NOTE: If readings are good replace the rotating beacon (100).
101 Brake Lamp Pressure Switch

Check Points
Reading
NOTE: Put master disconnect switch in ON position.

Terminal for wire 1B_A to ground
24 volts
0 volt
Check circuit breaker B, also check wires 1B_A and 1B_D.

Bad brake lamp pressure switch (101).
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
24 volts
102 Brake Lamps Relay No. 15

Check Points
Terminal for wire 0_DA to ground
Reading
Continuity

Bad ground circuit.

Terminal for wire 1B_E to ground
24 volts
0 volt
0 volt
Bad brake lamps relay (102).
Check circuit breaker B and wires 1B_E and 1B_F.
24 volts
24 volts
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-79
103 Hazard Switch

Check Points
Terminal for wire 0_KH to ground
Reading
Continuity
Bad ground circuit.

Terminal for wire 1B to ground
24 volts
Check circuit breaker B. Also check wires 1B and 1B_F.
NOTE: Put hazard switch in ON position.

Bad hazard switch (103). If hazard switch LED is not ON with

24 volts at check point, replace hazard switch.
24 volts
NOTE: Put five position rotary lamp switch (114) in position 3 or higher.
49 to lamp switch (114). If hazard switch LED is not ON with 24
volts at check point, replace hazard switch.
24 volts
104 Turn Signal, Hi/Low Beam, and Horn Switch

Check Points
Reading

HORN SWITCH
Terminal for wire 0_KG to ground
Continuity
Bad ground circuit.

Check fuse U and horn relay (80). Also check wires 64C,
64C_A, and 19U_C.
24 volts
NOTE: If readings are good, replace the switch (104).

TURN SIGNAL
24 volts
Check fuse B and ignition relay No. 1 (14). Also check wires
19B and 19B_A.
NOTE: Move turn signal lever to RIGHT turn position.

24 volts
Bad turn signal switch (104).
NOTE: Move turn signal lever to LEFT turn position.

24 volts
HI/LOW BEAM SWITCH

Terminal for wire 0_KF to ground
Continuity
Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in OFF position. Hold Hi/Low beam lever in HIGH beam
position.
Bur 6-40782
Continuity
Bad hi/low beam switch (104).
Revised 6-02
Printed in U.S.A.
Copyright
4002-80
105 Flasher Module

Check Points
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_DAN to ground
Continuity
Bad ground circuit.
Terminal for wire 0_DAQ to ground
Continuity
Bad ground circuit.
Terminal for wire 45N_A to terminal

for wire 45N_B (North American
machines only)
Continuity
Bad 45N circuit.

Terminal for wire 1B_B to ground
24 volts
Check flasher circuit breaker B. Also check wires 1B_B and

1B_F.
NOTE: Put ignition switch in the ON position. Put the hazard switch (103) ON.
Terminal for wire 45H_A to ground
24 volts
Terminal for wire 45L_D to ground
Intermittent 24
volts
Bad flasher module (105).
Terminal for wire 45R_E to ground
Intermittent 24
volts
Bad hazard switch (103). Also check wires 45H_A and 45H.
NOTE: Put hazard switch (103) in OFF position. Put turn signal switch (104) in RIGHT turn position.
24 volts
Intermittent 24
volts
Bad turn signal switch (104) or fuse B. Also check wires 45B_A
and 45B.
NOTE: Put turn signal switch (104) in LEFT turn position.

Terminal for wire 45A_A to ground
24 volts
Intermittent 24
volts
Bur 6-40782
Bad turn signal switch (104) or fuse B. Also check wires 45A_A
and 45A.
Revised 6-02
Printed in U.S.A.
Copyright
4002-81
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP

SWITCH, AND CAB LIGHTS
117
112
113
118
110
108
115
114
109
111
106
116
107
BC00N140
106. LH REAR COMBINATION LAMP

107. RH REAR COMBINATION LAMP
108. LH FRONT COMBINATION LAMP
109. RH FRONT COMBINATION LAMP
110. LH REAR WORK LAMP
111. RH REAR WORK LAMP
112. LH FRONT WORK LAMP
Bur 6-40782
113.
114.
115.
116.
117.
118.
RH FRONT WORK LAMP

FIVE POSITION ROTARY LAMP SWITCH
HIGH/LOW BEAM RELAY NO. 13
LICENSE PLATE LAMP
DOME LAMP
COURTESY LAMP
Revised 6-02
Printed in U.S.A.
Copyright
4002-82
106 LH Rear Combination Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 125 from LH rear combination lamp connector.
Combination lamp connector pin 1 to
pin 5
Continuity
Bad stop lamp bulb.

pin 5
Continuity
Bad turn lamp bulb.

pin 5
Continuity
Bad tail lamp bulb.

pin 5
Continuity
Bad reverse lamp bulb.
NOTE: Connect wiring harness connector 125 to LH rear combination lamp connector.
Continuity
Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
24 volts
Check brake lamps relay (102). Also check circuit 44 to brake

lamps relay (102).
NOTE: Have assistant put transmission in reverse.

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

backup alarm relay (35).
NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.
Intermittent 24
volts
Check the turn signal switch (104) and flasher module (105).
Also check circuit 45L to flasher module.
NOTE: Put five position rotary lamp switch (114) in position 2 or 3.
24 volts
Check fuse F and lamp switch (114). Also check wires 18F_A
and 18F_D to fuse F, and wire 41T_A from fuse F to lamp
switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp (106).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-83
107 RH Rear Combination Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 127 from RH rear combination lamp connector.
pin 5
Continuity
Bad stop lamp bulb.

pin 5
Continuity
Bad turn lamp bulb.

pin 5
Continuity
Bad tail lamp bulb.

pin 5
Continuity
NOTE: Connect wiring harness connector 127 to RH rear combination lamp connector.
Continuity
Bad ground circuit.
24 volts

lamps relay (102).

24 volts

NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R_A to ground
Intermittent 24
volts
Also check circuit 45R to flasher module.
Terminal for wire 18G_A to ground
24 volts
Check fuse G and lamp switch (114). Also check wires 18G_A,
18G_D, and 18G_F to fuse G, and wire 41T_A from fuse G to
lamp switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp (107).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-84
108 LH Front Combination Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 6 from LH front combination lamp connector.
pin 1
Continuity
Bad high beam lamp bulb.

pin 1
Continuity
Bad position lamp bulb.

pin 1
Continuity
Bad low beam lamp bulb.

pin 1
Continuity
Bad turn signal lamp bulb.
NOTE: Connect wiring harness connector 6 to LH front combination lamp connector.

Terminal for wire 0_AL to ground
Continuity
Bad ground circuit.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3.
24 volts
Check fuse F and five position rotary lamp switch (114). Also
check circuit 18F and wires 41T_A and 41T_B.
NOTE: Put high/low beam lever (104) in HIGH beam position.
24 volts
Check fuse B, high/low beam relay (115), five position rotary

lamp switch (114), and high/low beam switch (104). Also check
circuit 18B and wire 41H.
NOTE: Put high/low beam lever (104) in LOW beam position.
24 volts
Check fuse D, high/low beam relay (115), five position rotary

circuit 18D and wire 41L_A.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Intermittent 24
volts
NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp (108).
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-85
109 RH Front Combination Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 8 from RH front combination lamp connector.
pin 1
Continuity

pin 1
Continuity

pin 1
Continuity

pin 1
Continuity
NOTE: Connect wiring harness connector 8 to RH front combination lamp connector.

Terminal for wire 0_AG to ground
Continuity
Bad ground circuit.
24 volts
Check fuse G and five position rotary lamp switch (114). Also
check circuit 18G and wires 41T_A and 41T_B.
24 volts
Check fuse C, high/low beam relay (115), five position rotary

circuit 18C and wire 41H.
24 volts
Check fuse E, high/low beam relay (115), five position rotary

circuit 18E and wire 41L_A.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Intermittent 24
volts
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp (109).
110 LH Rear Work Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 83F from LH rear work lamp connector.
Flood lamp connector pin A to pin B
Continuity
Bad lamp bulb.
NOTE: Connect wiring harness connector 83F 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 five position rotary lamp switch (114) in position 4 or 5.
Bur 6-40782
24 volts
Check fuse A and five position rotary lamp switch (114). Also
check circuit 42R from flood lamp to lamp switch (114) and wire
18A to fuse A.
Revised 6-02
Printed in U.S.A.
Copyright
4002-86
111 RH Rear Work Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 80F from RH rear work lamp connector.
Continuity
Bad lamp bulb.
NOTE: Connect wiring harness connector 80F to RH rear work lamp connector.
Terminal for wire 0_MF to ground
Continuity
Bad ground circuit.
24 volts
18A to fuse A.
Reading
112 LH Front Work Lamp

Check Points
NOTE: Disconnect wiring harness connector 79F from LH front work lamp connector.
Continuity
Bad lamp bulb.
NOTE: Connect wiring harness connector 79F to LH front work lamp connector.
Terminal for wire 0_MH to ground
Continuity
Bad ground circuit.
24 volts
Check fuse Z and five position rotary lamp switch (114). Also
check circuit 42C from flood lamp to lamp switch (114) and wire
19Z to fuse Z.
Reading
113 RH Front Work Lamp

Check Points
NOTE: Disconnect wiring harness connector 78F from RH front work lamp connector.
Continuity
Bad lamp bulb.
NOTE: Connect wiring harness connector 78F to RH front work lamp connector.
Terminal for wire 0_MJ to ground
Continuity
Bad ground circuit.
Terminal for wire 42C_C to ground
Bur 6-40782
24 volts
19Z to fuse Z.
Revised 6-02
Printed in U.S.A.
Copyright
4002-87
114 Five Position Rotary Lamp Switch

Check Points
Reading

Terminal for wire 1_N to ground
24 volts
Check wire 1_N.
Terminal for wire 19Z to ground
24 volts
Check fuse Z, also check circuit 19Z.
24 volts
NOTE: Put the five position rotary lamp switch (114) in position 2.
24 volts
Bad five position rotary lamp switch (114).
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
115 High/Low Beam Relay No. 13

Check Points
Reading
NOTE: Put high/low beam lever in HIGH beam position.

Terminal for wire 64D_A to ground
Continuity
Check high/low beam switch (104). Also check circuits 64D and
0_KF to and through the high/low beam switch.

24 volts
Check circuit 1_H.
NOTE: Put the 5 position rotary lamp switch (114) in position 3 or 4.

24 volts
Bad five position rotary lamp switch (114). Also check wire
41J_A.
NOTE: Put high/low beam lever in LOW beam position.

24 volts
Bad high/low beam relay (115).

Bur 6-40782
24 volts

Revised 6-02
Printed in U.S.A.
Copyright
4002-88
116 License Plate Lamp

Check Points
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 five position rotary lamp switch (114) in position 2.
Terminal for wire 18G_E to ground
24 volts
Check fuse G and five 5 position rotary lamp switch (114). Also
check circuit 18G.
Reading
117 Dome Lamp

Check Points
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 (118) switch in ON position.
Terminal for wire 19U_D to ground
24 volts
Check fuse U, also check circuit 19U.
NOTE: If readings are good, replace dome lamp (118).
118 Courtesy Lamp

Check Points
Reading
Bulb
Continuity
Bad bulb.
Terminal for wire 0_ML to ground
Continuity
Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 2 or
higher.
Bur 6-40782
24 volts
Check circuit 49, also check five position rotary lamp switch
(114).
Revised 6-02
Printed in U.S.A.
Copyright
4002-89
CONNECTORS
CONNECTOR 1 - FRONT CHASSIS HARNESS TO
MAIN CAB HARNESS
CONNECTOR 1F - MAIN CAB HARNESS TO

FRONT CHASSIS HARNESS
291660A1
319148A1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
45L N-1.0
Left Turn Signal
53P_D W-1.0
Float Solenoid Power
53P_C W-0.8
45R N-1.0
Right Turn Signal
45R_D N-0.8
Right Turn Signal
None
D
18G_G Or-0.8
Position RH
45L_C N-0.8
Left Turn Signal
None
18G Or-1.0
Position RH
18F Or-1.0
Position LH
18F_E Or-0.8
Left Tail Position
18B Or-1.0
High Beam LH
18B_A Or-0.8
High Beam LH
19M_B Or-1.0
Secondary Steer Accessory
19M_A Or-0.8
19R_A Or-0.8
Secondary Steer Ignition
19R_B Or-1.0
35X_B Y-1.0
Secondary Steer Low Pres Sig
35X_E Y-0.8
54B W-1.0
Height-RTT Signal
54B_A W-0.8
Height-RTT Signal
53B W-1.0
RTD Signal
53B_B W-0.8
RTD Signal
64A Or-0.8
Horn
64 Or-1.0
Horn
18D Or-1.0
Low Beam LH
18D_A Or-0.8
Low Beam LH
18E Or-1.0
Low Beam RH
18E_A Or-0.8
Low Beam RH
18C Or-1.0
High Beam RH
18C_A Or-0.8
High Beam Fused Pwr
None
None
None
None
56_C W-1.0
Prox Switch Pwr
56_J W-0.8
Prox Switch Pwr
57 W-1.0
Pin Engage Sol Pwr
57_A W-0.8
Pin Engage Sol Pwr
Ride Cntrl Sol Pwr
58_A W-0.8
Ride Cntrl Sol Pwr
None
None
None
None
58 W-1.0
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-90
CONNECTOR 2 - FRONT WASHER PUMP MOTOR
TO REAR CHASSIS HARNESS
CONNECTOR 5F - RIDE CONTROL SOLENOID TO

3227856R1
CAV
WIRE IDENT
CIRCUIT
291718A1
CAV
WIRE IDENT
CIRCUIT
63W Or-1.0
Front Washer Pump
58_C W-1.0
Ride Control Solenoid Power
0_G Bk-1.0
Front Rear Washer Hot Ground
0_AC Bk-1.0
Ride Control Ground
CONNECTOR 3 - REAR WASHER PUMP MOTOR

CONNECTOR 6 - LH FRONT COMBINATION

LAMP TO FRONT CHASSIS HARNESS
225351C1
3227856R1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
0_AL Bk-1.0
Lights Ground LH
18D Or-1.0
Low Beam LH
68W Or-1.0
Rear Washer Pump
0_F Bk-1.0
18B Or-1.0
High Beam LH
18F Or-1.0
Position LH
45L N-1.0
Left Turn Signal
CONNECTOR 4 - BRAKE DECLUTCH PRESSURE

SWITCH TO REAR CHASSIS HARNESS
None
245482C1
CAV
WIRE IDENT
CIRCUIT
19A_A Or-1.0
Declutch Switch
25G LU-1.0
Declutch Switch
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-91
CONNECTOR 8 - RH FRONT COMBINATION
CONNECTOR 12F - RTD HARNESS FOR XT

CHASSIS TO FRONT CHASSIS HARNESS
245485C1
225351C1
CAV
WIRE IDENT
CIRCUIT
0_AG Bk-1.0
Lights Ground RH
18E Or-1.0
Low Beam RH
18C Or-1.0
High Beam RH
18G Or-1.0
Position RH
45R N-1.0
Right Turn Signal
CAV
WIRE IDENT
CIRCUIT
53B W-1.0
RTD Signal
0_AF Bk-1.0
RTD Ground
56_B W-1.0
RTD Power
CONNECTOR 12M - RTD HARNESS FOR XT

None
CONNECTOR 10 - HEIGHT CONTROL/RTT

PROXIMITY SWITCH TO FRONT CHASSIS
HARNESS
245484C1
CAV
WIRE IDENT
CIRCUIT
53B_A W-1.0
RTD Signal
0_AM Bk-1.0
RTD Ground
56_D W-1.0
RTD Power
245484C1
CAV
WIRE IDENT
CIRCUIT
54B W-1.0
Height/RTT Signal
0_AA Bk-1.0
Height/RTT Ground
56_A W-1.0
Height/RTT Power
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-92
PEDESTAL HARNESS
CAV
WIRE IDENT
33
None
34
50G_D Bk-0.8
CAN Ground
35
44_F T-0.8
Brake Light Signal
36
53C_A W-0.8
37
374972A1
CAV
WIRE IDENT
CIRCUIT
CIRCUIT
None
38
0_DAB Bk-0.8
Signal Ground
39
0_DL Bk-0.8
Signal Ground
40
0_DAA Bk-0.8
None
41
0_DX Bk-0.8
Horn Ground
42
64C_A Or-0.8
Horn Control
43
19A_S Or-0.8
Cab Switched Pwr
44
25F_A LU-0.8
Forward Signal
45
25R_A LU-0.8
Reverse Signal
19V Or-0.8
46
25T_C LU-0.8
Neutral Signal
19S Or-0.8
Instr Cluster Fused Del Power
47
33P_A Y-0.8
48
25W_A LU-0.8
3rd and 4th Gear Signal
31D_A Y-0.8
49
25Z_A LU-0.8
1st and 4th Gear Signal
35X_E Y-0.8
Sec Str Low Press Sig
50
25Y_A LU-0.8
31F_B Y-0.8
51
49_F S-0.8
Pilot Light Power
31H_A Y-0.8
52
28C_A W-0.8
Ether Start Control
0_DAU Bk-0.8
Analog Ground
53
0_DAC Bk-0.8
Relay Ground
None
54
A/C Telltale
55
64D_A Or-0.8
None
56
13K_G Or-0.8
Ignition Switch Pwr
9
10
61R_F Or-0.8
11
None
None
12
42R_C DU 0.8
Rear Work Light Pwr
57
63H_A Or-0.8
13
46_A K-0.8
Beacon Switched Pwr
58
63L_A Or-0.8
None
14
59
63C_A Or-0.8
Front Wiper Park
15
18C_B Or-0.8
High Beam Fused Pwr
60
19J_B Or-0.8
16
45L_E N-0.8
Left Turn Signal
61
0_DV Bk-0.8
Beacon Wpr Diode Ground
17
45R_C N-0.8
Right Turn Signal
62
1A_C R-0.8
18
36C_B P-0.8
ECT Signal
63
12K_B Or-0.8
ACC Power
19
36F_A P-0.8
Fuel Level Signal
64
21K_A W-0.8
Ign Switch Start Signal
20
36H_A P-0.8
Hot Signal
65
1B_C R-0.8
Hazard Switch Power
None
66
19B-A Or-0.8
Turn Signal Power
21
22
36P_B P-0.8
EOP Signal
67
45H_A N-0.8
Hazard Switch Power
23
23C_A W-0.8
68
19C_C Or-0.8
Ride Control Fused Power
None
69
45A_A N-0.8
Reset Signal
70
45B_A N-0.8
24
25
37R_C P-0.8
26
None
27
28
None
33R_D Y-0.8
29
Red Brake Sw Signal

None
30
52C_A W-0.8
31
50L_A G-0.5
CAN L
32
50H_A Y-0.5
CAN H
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-93
CONNECTOR 13M - PEDESTAL HARNESS TO
MAIN CAB HARNESS
CAV
WIRE IDENT
34
50G_A Bk-0.8
CAN Ground
35
44_G T-0.8
Brake Light Signal
36
53C W-0.8
37
374971A1
WIRE IDENT
CIRCUIT

None
38
0_KR Bk-0.8
Signal Ground
39
0_KD Bk-0.8
Signal Ground
41
0_KG Bk-0.8
Horn Hi Lo Beam Ground
42
64C Or-0.8
Horn Control
43
19A_G Or-0.8
Trans Control Pwr
40
CAV
CIRCUIT
None
44
25F LU-0.8
Forward Signal
45
25R LU-0.8
Reverse Signal
25T_B LU-0.8
Neutral Signal
19V_A Or-0.8
46
19S_A Or-0.8
47
33P_B Y-0.8
48
25W LU-0.8
31D_B Y-0.8
49
25Z LU-0.8
35X_F Y-0.8
50
25Y LU-0.8
31F_C Y-0.8
51
49_A S-0.8
Pilot Light
31H_B Y-0.8
52
28C W-0.8
Ether Start Control
0_KP Bk-0.8
Analog Ground
53
0_KM Bk-0.8
Pilot Light Ground
None
54
61R_G Or-0.8
A/C Telltale
55
64D Or-0.8
None
56
13K Or-0.8
Ignition Switch Pwr
12
42R_A Y-0.8
57
63H Or-0.8
13
46_B K-0.8
Beacon Telltale
58
63L Or-0.8
None
59
63C Or-0.8
Front Wiper Park
9
10
11
14
None
None
15
18C_C Or-0.8
High Beam Telltale
60
19J Or-0.8
16
45L_F N-0.8
Left Turn Signal
61
0_KN Bk-0.8
Front Wiper Ground
17
45R_F N-0.8
Right Turn Signal
62
1A_A R-0.8
Ign Prog Reset Switch Power
18
36C_C P-0.8
ECT Signal
63
12K_C Or-0.8
Ign Switch ACC Power
19
36F_B P-0.8
Fuel Level Signal
64
21K W-0.8
20
36H_B P-0.8
Hot Signal
65
1B R-0.8
Hazard Switch Power
None
66
19B Or-0.8
Turn Signal Power
45H N-0.8
Hazard Switch Power
21
22
36P_C P-0.8
EOP Signal
67
23
23C W-0.8
68
19C Or-0.8
None
69
45A N-0.8
Reset Signal
70
45B N-0.8
24
25
37R_A P-0.8
26
None
27
28
None
33R_E Y-0.8
29
Red Brake Sw Signal

None
30
52C W-0.8
31
50L G-0.5
CAN L
32
50H Y-0.5
CAN H
33
Bur 6-40782
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-94
CONNECTOR 17M - BUCKET CONTROL VALVE
ELECTROMAGNETIC DETENTS TO MAIN CAB
HARNESS
225351C1
CAV
WIRE IDENT
CIRCUIT
55A W-0.8
RTT Float Switch
54B_C W-0.8
Height Control Elec Mag
53B_B W-0.8
RTD Signal
56_G W-0.8
Detent Switched Power
56_F W-0.8
56_E W-0.8
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-95
FUSE BLOCK 18F TO MAIN CAB HARNESS
232118A1
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-96
CAV
A1
WIRE IDENT
13P_A Or-1.0
CIRCUIT
Ign Relay 1 Out (5 Way)*
B1
Ign Relay 1 (5 Way)
C1
Ign Relay 1 (5 Way)
D1
Ign Relay 1 (5 Way)
E1
Ign Relay 1 (5 Way)
F1
13R Or-1.0
G1
Ign Relay 2 (5 Way)
H1
Ign Relay 2 (5 Way)
J1
Ign Relay 2 (5 Way)
K1
Ign Relay 2 (5 Way)
CAV
WIRE IDENT
CIRCUIT
N2
19N_B Or-1.0
19N_A Or-1.0
Acces Seat Fused Pwr (3 Way)*
P2
19P_A Or-1.0
Fan Rev Pin Eng Fused Power
R2
19R_A Or-0.8
Sec Str Ignition
S2
19S Or-0.8
T2
19T_A Or-0.8
19T_B Or-0.8
Time Delay Fused Power
U2
19U_A Or-1.0
19U_B Or-1.0
Dome Lt Horn Fused Power
V2
19V Or-0.8
W2
19W Or-1.0
Cigarette Lighter Fused Power
X2
19X Or-1.0
Beacon Sw Fused Power
L1
12P_A Or-1.0
12P_B Or-1.0
ACC Relay
M1
12K_A Or-1.0
ACC Power
Z2
19Z Or-1.0
Frnt Flood Illum Fused Power
N1
12P_B Or-1.0
ACC Relay
A2
18A Or-2.0
Rear Fld Lts Fuse Power
P1
13P_B Or-1.0
B2
18B_A Or-0.8
High Beam LH
C2
18C_A Or-0.8
18C_B Or-0.8
High Beam Fused Power
D2
18D_A Or-0.8
Low Beam LH
18E_A Or-0.8
Low Beam RH
R1
S1
Ign Relay 1 (2 Way)

13D Or-1.0
T1
Y2
Delay Power (2 Way)*

Time Delay Module (2 Way)
None
U1
1_Q R-1.0
Dome Light Horn Power
E2
V1
13V Or-1.0
Voltmeter Relay Out
F2
18F_D Or-0.8
18F_E Or-0.8
Left Tail Pos
W1
1_R R-3.0
Cigar Lighter Power

G2
18G_F Or-0.8
18G_G Or-0.8
Right Tail Pos Lic
19N_B Or-1.0
X1
Power (4 Way)
Y1
Power (4 Way)
B+ Power (4 Way)*
None
Power (4 Way)
None
Hi Low Relay 13 (2 Way)
None
High Beam Signal (2 Way)*
None
41L_A K-2.0
Low Beam Signal (2 Way)*
Access to Fuse N (3 Way)
Rotary Lamp Switch (2 Way)
None
G1
41T_A K-1.0
Tail Light Sw Power (2 Way)*
None
A2
19A_N Or-0.8
19A_P Or-0.8
Cab Switched Power
10
None
11
Access to Fuse L (3 Way)
B2
19B_A Or-0.8
Turn Signal Power
12
None
C2
19C_A Or-1.0
19C_D Or-1.0
Pilot Ride Cntrl Fused Power
13
14
None
15
None
Z1
1_U R-3.0
A1
B1
C1
41H K-2.0
D1
E1
F1
D2
19D_A Or-1.0
Park Brake Rel Fused Power
E2
19E Or-1.0
Ether Start Rel Fused Power
F2
19F Or-1.0
Eng Shutdown Rel Fused Pwr
G2
19G Or-2.0
Blower Switch Fused Power
H2
19H Or-1.0
Backup Alarm Rel Fuse Power
J2
19J_A Or-1.0
Front Wip Wash Fused Power
K2
19K_A Or-1.0
Rear Wip Wash Fused Power
L2
19L Or-1.0
Access to Fuse L (3 Way)*
M2
19M_A Or-0.8
Sec Str Accessory
Bur 6-40782
16
19L Or-1.0
19W Or-1.0
17
18
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-97
CONNECTOR 19F - TRANSMISSION
ELECTRONIC CONTROL MODULE TO MAIN CAB
HARNESS
CAV
WIRE IDENT
CIRCUIT
0_DP Bk-0.8
Diag TECM Ground
0_DQ Bk-0.8
Diag TECM Ground
0_DM Bk-0.8
Speed Sensor Ground
0_DN Bk-0.8
Out Speed Sensor Ground
32J_C Y-0.8
Trans Enable Lt Signal
None
35C Y-0.8
Backup Alarm Pull Down
58H_B W-0.8
Ride Cntl Sw Power VPS2
25P_A LU-0.8
Trans Sol Valve Y5
10
25L_A LU-0.8
Trans Sol Valve Y2
11
None
12
25S_B LU-0.8
13
25S_C LU-0.8
14
15
None
37D_A P-0.8
16
Diagnostic Signal
None
17
32F_A Y-0.8
Trans Filter Maint Switch
18
37E P-0.8
Diagnostic Signal
19
25A_A LU-0.8
Engine Speed Signal
20
26F_B LU-0.8
FNR Forward Signal
21
52P_A W-0.8
Park Brake Relay Out
22
25Y_B LU-0.8
23
19T_A Or-0.8
24
WIRE IDENT
CIRCUIT
43
25F_A LU-0.8
Forward Signal
44
26N_B LU-0.8
FNR Neutral Signal
45
19A_K Or-0.8
Cab Switched Power
46
36R_E P-0.8
Valve Body Temp Return
47
None
48
None
49
36G_A P-1.0
50
51
TCO Temp Signal

None
25J_A LU-0.8
Trans Sol Valve Y6
52
None
53
None
54
None
55
25N_A LU-0.8
Trans Sol Valve Y4
56
25K_A LU-0.8
Trans Sol Valve Y1
57
0_DD Bk-0.8
Ride Control Relay Sink
58
None
59
None
60
None
61
None
62
25D_A LU-0.8
Output Speed Signal
63
25Z_A LU-0.8
64
25R_A LU-0.8
Reverse Signal
65
25W_A LU-0.8
66
25G_B LU-0.8
Declutch Signal
67
25T_D LU-0.8
Neutral Signal
68
19T_B Or-0.8
None
25
50H_A Y-0.5
CAN H
26
50L_B G-0.5
CAN L
27
50L_C G-0.5
CAN L
28
CONNECTOR 20M - TRANSMISSION KICK-DOWN

SWITCH TO MAIN CAB HARNESS
None
29
25H LU-0.8
Trans Auto Signal
30
26R_B LU-0.8
FNR Reverse Signal
31
26E LU-0.8
Trans Enable Signal
32
25M_A LU-0.8
Trans Sol Valve Y3
33
None
34
None
35
None
36
None
37
None
38
None
39
CAV
36T_A P-0.8
40
Valve Body Temp Signal
222136A1
CAV
WIRE IDENT
CIRCUIT
19A_U Or-0.8
Cab Switched Power
25Y_C LU-0.8
None
41
25B_A LU-0.8
Turb Speed Signal
42
25C_A LU-0.8
Int Speed Signal
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-98
CONNECTOR 21F - CAB MAIN HARNESS TO
REAR CHASSIS HARNESS
CONNECTOR 21M - REAR CHASSIS HARNESS

TO CAB MAIN HARNESS
291661A1
CAV
1
WIRE IDENT
28P_A W-0.8
374973A1
CIRCUIT
Ether Solenoid
CAV
None
WIRE IDENT
28P W-1.0
CIRCUIT
Ether Solenoid
31D_A Y-0.8
None
33P_A Y-0.8
31D Y-1.0
33P Y-1.0
18F_D Or-0.8
Left Tail Pos
35R_C Y-0.8
Backup Alarm Switch
18F_A Or-1.0
Left Tail
35A_D Y-0.8
35R_B Y-1.0
Backup Alarm Switch
44_D T-0.8
Brake Light Signal
35A_C K-1.0
Reverse Lights
44_C T-1.0
Brake Light Signal
18G_F Or-0.8
RH Tail Lic Lights
10
45L_B N-0.8
Left Turn Signal
18G_D Or-1.0
RH Tail Lic Lights
11
21C_E W-0.8
10
45L_A N-1.0
Left Turn Signal
12
45R_B N-0.8
Right Turn Signal
11
21C_D W-1.0
45R_A N-1.0
Right Turn Signal
13
36H_A P-0.8
Hot Signal
12
14
31H_A Y-0.8
13
36H P-1.0
Hot Signal
15
33R_D Y-0.8
Red Brake Sw Signal
14
31H Y-1.0
16
36F_A P-0.8
Fuel Level Signal
15
33R_C Y-1.0
Red Brake Sw Signal
None
16
36F P-1.0
Fuel Level Signal
17
19
None
18
20
None
19
None
Voltmeter Relay Power
20
None
22
None
21
23
None
22
Rear Washer Pump
23
Front Washer Pump
24
68W Or-1.0
Rear Washer Pump
None
25
63W Or-1.0
Front Washer Pump
17
18
21
24
25
52P_B W-0.8
1_P R-0.8
68W_A Or-1.0
63W_A Or-0.8
26
None
52P W-1.0
1_A R-1.0
B+
None
None
27
52_A W-0.8
Fan Reverse Solenoid
26
None
28
1B_D R-0.8
CB B Load
27
52 W-1.0
1B_A R-1.0
Brake Lt Sw Power
29
44A_B T-0.8
28
30
19A_T Or-0.8
Cab Switched Power
29
44 T-1.0
31
25G_A LU-0.8
Declutch Switch
30
19A_A Or-1.0
Declutch Switch
31
25G LU-1.0
Declutch Switch
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-99
TRANSMISSION HARNESS
CONNECTOR 22M - TRANSMISSION HARNESS

TO CAB MAIN HARNESS
291661A1
CAV
WIRE IDENT
373358A1
CIRCUIT
13C_D Or-0.8
Fuel Solenoid Power
CAV
WIRE IDENT
CIRCUIT
14_B LG-0.8
Alternator D+
13C_A Or-1.0
Fuel Solenoid
31F_B Y-0.8
14_A LG-1.0
Alternator D+
36C_B P-0.8
ECT Signal
31F_A Y-1.0
36C_A P-1.0
ECT Signal
36T_A P-0.8
36P_B P-0.8
EOP Signal
36T P-0.8
25A_A LU-0.8
Engine Speed Signal
36P_A P-1.0
EOP Signal
25B_A LU-0.8
Turb Speed Signal
25A W-0.8
Engine Speed Signal
25B W-0.8
Turb Speed Signal
25C_A LU-0.8
Int Speed Signal
10
25D_A LU-0.8
Output Speed Signal
25C W-0.8
Int Speed Signal
11
0_DM Bk-0.8
Speed Sensor Ground
10
25D LU-1.0
Output Speed Signal
12
36R_E P-0.8
Valve Body Temp Ret
11
0_HD Bk-1.0
Speed Sensor Ground
TCO Temp Signal
12
36R_A P-1.0
Valve Body Temp Ret
None
13
36G P-1.0
TCO Temp Signal
13
36G_A P-1.0
14
15
0_DAB Bk-0.8
Signal Ground
14
None
16
25K_A LU-0.8
Trans Solenoid Valve Y1
15
0_HB Bk-1.0
Signal Ground
25K LU-0.8
17
25L_A LU-0.8
16
18
25M_A LU-0.8
17
25L LU-0.8
19
25N_A LU-0.8
18
25M LU-0.8
20
25P_A LU-0.8
19
25N LU-0.8
25P LU-0.8
21
25J_A LU-0.8
20
22
25S_A LU-0.8
21
25J LU-0.8
23
0_DL Bk-0.8
Signal Ground
22
25S LU-0.8
None
23
0_HA Bk-1.0
24
Signal Ground
25
61C_B Or-0.8
AC Comp Clutch
24
None
26
61A_B Or-0.8
AC Relay Power
25
61C_A Or-1.0
AC Comp Clutch
27
61R_B Or-0.8
AC Relay Signal
26
61A_A Or-1.0
AC High Pressure Switch
28
0_DN Bk-0.8
27
61R_A Or-1.0
0_HE Bk-1.0
Out Speed Ground
29
19A_M Or-0.8
Cab Switched Power
28
30
0_DAU Bk-0.8
Analog Ground
29
19A Or-1.0
Out Speed Power
31
32F_A Y-0.8
30
0_HC Bk-1.0
Analog Ground
31
32F Y-1.0
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-100
CONNECTOR 23F - CAB MAIN HARNESS TO CAB
ROOF HARNESS
CONNECTOR 24F - CAB ROOF HARNESS TO

CAB MAIN HARNESS
3195530R1
3195530R1
CAV
WIRE IDENT
CAV
CIRCUIT
WIRE IDENT
CIRCUIT
68C_A Or-1.0
Rear Wiper Park
None
0_DT Bk-1.0
Dome Court Work Light Ground
None
None
None
0_DU Bk-1.0
Beacon Wiper Diode Ground
19U_A Or-1.0
Dome Light Horn Fused Power
46_A K-0.8
46_C K-1.0
19K_B Or-1.0
Rear Wiper Wash Fused Power
68L_A Or-1.0
42R_B DU-0.8
Rear Work Light Power
CONNECTOR 23M - CAB ROOF HARNESS TO

CAB MAIN HARNESS
0_MN Bk-0.8
Dome Courtesy Light Ground
49_V S-0.8
Courtesy Pilot Light
0_MK Bk-1.0
Front Work Light Ground
42C_D DU-1.0
Front Work Lights Power
CONNECTOR 24M - CAB MAIN HARNESS TO

CAB ROOF HARNESS
245430C1
245430C1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
None
68C_B Or-1.0
Rear Wiper Park
None
0_MG Bk-1.0
Rear Work Light Ground
None
0_MD Bk-1.0
Beacon Rear Wiper Ground
None
19U_D Or-1.0
Dome Light Fused Power
0_DR Bk-1.0
46_D K-1.0
49_S S-1.0
19K_E Or-1.0
0_DS Bk-1.0
42C_A DU-1.0
Front Flood Lights
68L_C Or-1.0
42R_F DU-1.0
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-101
CONNECTOR 25F - FIVE POSITION ROTARY
LAMP SWITCH TO CAB MAIN HARNESS
CONNECTOR 29M - BLOWER MOTOR TO CAB

MAIN HARNESS
255058C1
631801C1
CAV
A
WIRE IDENT
41J_B K-2.0
CAV
CIRCUIT
Driving Light Signal
CONNECTOR 27M - AC LOW PRESSURE

SWITCH TO CAB MAIN HARNESS
WIRE IDENT
CIRCUIT
62L Or-1.0
Blower Low Speed
62M Or-2.0
Blower Medium Speed
62H Or-2.0
Blower High Speed
0_DZ Bk-2.0
Blwr Wpr Seat Ground
CONNECTOR 30F - BLOWER SWITCH TO CAB

MAIN HARNESS
245482C1
CAV
WIRE IDENT
CIRCUIT
61R_E Or-0.8
AC Low Pressure Switch
61A_E Or-0.8

449797C1
CAV
CONNECTOR 28M - SEAT COMPRESSOR

MOTOR TO CAB MAIN HARNESS
WIRE IDENT
CIRCUIT
None
19G Or-2.0
62H Or-2.0
Blower High Speed
62M Or-2.0
Blower Medium Speed
62L Or-1.0
Blower Low Speed
61T Or-1.0
AC Thermostat Power
245482C1
CAV
WIRE IDENT
CIRCUIT
19N_A Or-1.0
Access Seat Fused Pwr (3 Way)
0_DY Bk-1.0
Blower Wpr Seat Ground
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-102
CONNECTOR 31 - FILTER MAINTENANCE
SWITCH TO TRANSMISSION HARNESS

266516C1
371614A1
CAV
WIRE IDENT
CAV
CIRCUIT
32F Y-1.0
Trans Filt Maint Sw
36R_B P-1.0
Valve Body Temp Ret
WIRE IDENT
CIRCUIT
41J_A K-2.0
41J_B K-2.0
41T_B K-1.0
Tail Light Switched Power
1_N R-3.0
Light Switch Power

225287C1
CAV
WIRE IDENT
CIRCUIT
245423C1
42R_B DU-0.8
42R_C DU-0.8
18A Or-2.0
Rear Fld Lts Fused Power
42C_A DU-1.0
Front Flood Lights
41T_A K-1.0
41T_B K-1.0
49_J S-0.8
49_K S-1.0
Pilot Light
19Z Or-1.0
Front Flood Illum Fused Power
Bur 6-40782
CAV
WIRE IDENT
CIRCUIT
Revised 6-02
Printed in U.S.A.
Copyright
4002-103
CONNECTOR 35F - WIPER AND WASHER
CONNECTOR 37 - PILOT CONTROL SWITCH TO

PEDESTAL HARNESS
892136C1
382391A1
CAV
WIRE IDENT
CIRCUIT
CAV
0_DAR Bk-1.0
Blower Wiper Seat Ground
19J_A Or-1.0
19J_B Or-0.8
63W_A Or-0.8
Front Washer Pump
63C_A Or-0.8
Front Wiper Park
63H_A Or-0.8
63H_B Or-0.8
63L_A Or-0.8
63L_B Or-0.8
CONNECTOR 36F - DETENT SWITCH TO CAB

MAIN HARNESS
WIRE IDENT
CIRCUIT
None
19C Or-0.8
31L Y-0.8
None
None
None
0_KH Bk-0.8
0_KJ Bk-0.8
Pilot Light Ground
49_B S-0.8
49_C S-0.8
Pilot Light
None
10
None
382391A1
CAV
WIRE IDENT
CIRCUIT
None
53P_B W-0.8
56_H W-0.8
None
None
None
0_DAJ Bk-1.0
0_DAK Bk-1.0
Switch Ground
49_M S-1.0
49_N S-1.0
Pilot Light
None
10
None
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-104
CONNECTOR 38F - DECLUTCH SWITCH TO CAB
MAIN HARNESS
CAV
8
WIRE IDENT
49_K S-1.0
49_M S-1.0
CIRCUIT
Pilot Light
None
10
None
CONNECTOR 40F - PIN ENGAGE SWITCH TO

CAB MAIN HARNESS
382391A1
CAV
WIRE IDENT
25G_A LU-0.8
25G_B LU-0.8
19A_R Or-0.8
CIRCUIT
Declutch Switch
Cab Switched Power
None
None
None
None
382391A1
CAV
0_DAK Bk-1.0
Switch Ground
49_N S-1.0
Pilot Light
None
10
None
CONNECTOR 39F - RETURN-TO-TRAVEL

WIRE IDENT
CIRCUIT
57_A W-0.8
Pin Engage Solenoid Power
19P_A Or-1.0
19P_B Or-1.0
None
None
None
None
None
None
0_DAF Bk-1.0
0_DAL Bk-1.0
Switch Ground
10
49_H S-0.8
49_P S-1.0
Pilot Light
382391A1
CAV
WIRE IDENT
CIRCUIT
0_DAH Bk-1.0
0_DAJ Bk-1.0
Switch Ground
55A W-0.8
RTT Float Switch
54B_B W-0.8
RTT Float Switch Load
None
None
None
0_DAG Bk-1.0
0_DAH Bk-1.0
Bur 6-40782
Switch Ground
Revised 6-02
Printed in U.S.A.
Copyright
4002-105
CONNECTOR 41F - TRANSMISSION AUTO
CAV
8
WIRE IDENT
49_R S-1.0
49_T S-1.0
CIRCUIT
Pilot Light
None
10
None
CONNECTOR 44F - RIDE CONTROL SWITCH TO

CAB MAIN HARNESS
382391A1
CAV
WIRE IDENT
CIRCUIT
None
19A_Q Or-0.8
Cab Switched Power
25H LU-0.8
Trans Auto Signal
None
None
382391A1
None
CAV
0_DAM Bk-1.0
Switch Ground
49_Q S-1.0
Pilot Light
19C_B Or-1.0
Ride Ctrl Fused Power
None
58S W-0.8
Ride Control Relay Power
10
None
None
None
CONNECTOR 42F - BEACON SWITCH TO CAB

MAIN HARNESS
WIRE IDENT
CIRCUIT
None
58_B W-0.8
Ride Cntrl Sol Power
0_DAL Bk-1.0
0_DAM Bk-1.0
Switch Ground
49_P S-1.0
49_Q S-1.0
Pilot Light
None
10
None
382391A1
CAV
WIRE IDENT
CIRCUIT
None
19X Or-1.0
Beacon Switch Fused Power
46_C K-1.0
None
None
None
0_DAP Bk-1.0
0_DAW Bk-1.0
Bur 6-40782
Ground
Revised 6-02
Printed in U.S.A.
Copyright
4002-106
CONNECTOR 45F - REAR WIPER AND WASHER
CONNECTOR 48F - IGNITION RELAY NO. 2 TO

CAB MAIN HARNESS
382391A1
245731C1
CAV
WIRE IDENT
CIRCUIT
CAV
68C_A Or-1.0
Rear Wiper Park
68L_A Or-1.0
68L_B Or-0.8
19K_C Or-1.0
WIRE IDENT
CIRCUIT
30
1_T R-3.0
Ign Relay No. 2 Power
85
0_DE Bk-0.8
0_DF Bk-0.8
Relay Ground
None
86
13K_A Or-1.0
13K_B Or-1.0
13R Or-1.0
Ignition Relay 2 Out (5 Way)
19K_D Or-0.8
87
68W_A Or-1.0
Rear Washer Pump
87A
0_DW Bk-0.8
Ground
49_L S-0.8
Pilot Light
None
10
None
None
CONNECTOR 49F - ACCESSORY RELAY TO CAB

MAIN HARNESS

CAB MAIN HARNESS
245731C1
CAV
245731C1
CAV
WIRE IDENT
CIRCUIT
30
1_S R-3.0
85
0_DE Bk-0.8
Relay Ground
86
13K_A Or-1.0
87
13P_A Or-1.0
13P_B Or-1.0
Ignition Relay 1 Out
87A
Bur 6-40782
WIRE IDENT
CIRCUIT
30
1_G R-3.0
ACC Relay Power
85
0_DF Bk-0.8
0_DC Bk-0.8
Relay Ground
86
12K_A Or-1.0
12K_B Or-0.8
ACC Power
87
12P_A Or-1.0
ACC Relay
87A
None
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-107
CONNECTOR 50F - RIDE CONTROL RELAY TO
CAB MAIN HARNESS
CONNECTOR 52F - ETHER START RELAY TO

CAB MAIN HARNESS
245731C1
CAV
WIRE IDENT
CIRCUIT
CAV
30
58S W-0.8
85
0_DD Bk-0.8
Ride Control Relay Ground
86
58H_B W-0.8
Ride Control Signal
87
58_A W-0.8
58_B W-0.8
87A
245731C1
None
WIRE IDENT
19E Or-1.0
Ether Start Relay Fused Power
85
0_DC Bk-0.8
0_DG Bk-0.8
Relay Ground
86
28C_A W-0.8
Ether Start Control
87
28P-A W-0.8
Ether Solenoid
87A
CONNECTOR 51F - HORN RELAY TO CAB MAIN

HARNESS
CIRCUIT
30
None
CONNECTOR 53F - BACKUP ALARM RELAY TO

CAB MAIN HARNESS
245731C1
CAV
WIRE IDENT
CIRCUIT
30
19U_B Or-1.0
19U_C Or-0.8
85
64C_A Or-0.8
Horn Control
86
19U_C Or-0.8
87
64_A Or-0.8
87A
Bur 6-40782
245731C1
CAV
WIRE IDENT
CIRCUIT
30
19H Or-1.0
Backup Alrm Rly Fuse Power
85
35C Y-0.8
86
19A_P Or-0.8
Cab Switched Power
Horn
87
35A_E Y-0.8
35A_D Y-0.8
None
87A
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-108
CONNECTOR 54F - NEUTRAL START RELAY TO
CAB MAIN HARNESS
CONNECTOR 56F - PILOT CONTROL RELAY TO

CAB MAIN HARNESS
245731C1
CAV
WIRE IDENT
CIRCUIT
30
21K_A W-0.8
85
0_DH Bk-0.8
0_DJ Bk-0.8
Relay Ground
86
25T_E LU-0.8
Neutral Signal
87
21C_E W-0.8
21C_F W-0.8
87A
245731C1
CAV
30
WIRE IDENT
19C_D Or-1.0
19C_E Or-1.0
Pilot Ride Control Fused Power
85
53C_A W-0.8
86
19C_E Or-1.0
87
53P_A W-0.8
53P_B W-0.8
53P_C W-0.8
None
87A
CONNECTOR 55F - PARKING BRAKE RELAY TO

CAB MAIN HARNESS
CIRCUIT
None
CONNECTOR 57F - RELAY SOCKET N0. 11 TO

CAB MAIN HARNESS
245731C1
245731C1
CAV
WIRE IDENT
CIRCUIT
19D_A Or-1.0
19D_B Or-1.0
Park Brake Relay Fused Power
85
52C_A W-0.8
86
19D_B Or-1.0
87
52P_B W-0.8
52P_A W-0.8
30
87A
CAV
30

None
13K_B Or-1.0
13K_C Or-1.0
13K_D Or-0.8
CIRCUIT
85
23C_A W-0.8
86
19F Or-1.0
Engine Shtdwn Rly Fused Pwr
87
13C_B Or-0.8
13C_C Or-0.8
13C_D Or-0.8
Fuel Solenoid Power
87A
Bur 6-40782
WIRE IDENT
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-109
CONNECTOR 58F - VOLTMETER RELAY TO CAB
MAIN HARNESS
CONNECTOR 60 - FRONT WIPER MOTOR TO

PEDESTAL HARNESS
245480C1
245731C1
CAV
WIRE IDENT
CIRCUIT
30
1_P R-0.8
85
0_DG Bk-0.8
0_DH Bk-0.8
Relay Ground
86
13K_C Or-1.0
13K_E Or-0.8
87
13V Or-1.0
Voltmeter Relay Out
87A
CAV
1
WIRE IDENT
0_KN Bk-0.8
CIRCUIT
Front Wiper Ground

PEDESTAL HARNESS
None
CONNECTOR 59F - HIGH/LOW BEAM RELAY TO

CAB MAIN HARNESS
245715C1
CAV
194791A1
CAV
WIRE IDENT
CIRCUIT
63H Or-0.8
63L Or-0.8
19J Or-0.8
Front Wiper Wash Fused Power
63C Or-0.8
Front Wiper Park
CIRCUIT
41J_A K-2.0
41L_A K-2.0
Low Beam Power
41H K-2.0
Hi/Low Beam Relay Power
64D_A Or-0.8
1_H R-3.0
Bur 6-40782
WIRE IDENT
Revised 6-02
Printed in U.S.A.
Copyright
4002-110
CONNECTOR 62M - FLASHER MODULE TO CAB
MAIN HARNESS
CONNECTOR 64F - FLASHER MODULE TO CAB

MAIN HARNESS
225389C1
CAV
WIRE IDENT
CIRCUIT
1B_B R-0.8
Flasher Module Power
45N_A N-0.8
Flasher Opp Side Control
0_DAN Bk-0.8
Flasher Module Ground
0_DAQ Bk-0.8
None
None
45R_E N-0.8
Right Turn Signal
45L_D N-0.8
Left Turn Signal
45B_A N-0.8
10
45A_A N-0.8
11
45H_A N-0.8
Hazard Switch Power
12
45N_B N-0.8
739070C1
CAV
1
WIRE IDENT
45N_A N-0.8
CIRCUIT

MAIN HARNESS
CONNECTOR 63M - TIME DELAY MODULE TO

CAB MAIN HARNESS
631801C1
CAV
1
WIRE IDENT
45N_B N-0.8
CIRCUIT
CONNECTOR 65F - ETHER START SOLENOID TO

ETHER START TEMPERATURE SWITCH
225351C1
CAV
WIRE IDENT
CIRCUIT
13D Or-1.0
Delay Power (2 Way)
1A_E R-0.8
Time Delay Power
0_DAS Bk 0.8
Time Delay Module Ground
37R_C P-0.8
Reset Signal
CAV
13K_F Or-0.8
Bur 6-40782
245481C1
WIRE IDENT
28T_A W-1.0
CIRCUIT
Ether Start Temp Switch
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-111
CONNECTOR 65M - ETHER START
TEMPERATURE SWITCH TO ETHER START
SOLENOID
CONNECTOR 68 - TURN SIGNAL SWITCH TO

PEDESTAL HARNESS
1964527C1
CAV
245480C1
CAV
1
WIRE IDENT
28T W-1.0
WIRE IDENT
45B N-0.8
CIRCUIT
CIRCUIT
CONNECTOR 69 - IGNITION SWITCH TO

PEDESTAL HARNESS
PEDESTAL HARNESS
225253C1
1964527C1
CAV
1
WIRE IDENT
45A N-0.8
CAV
CIRCUIT

PEDESTAL HARNESS
WIRE IDENT
CIRCUIT
1A_A R-0.8
1A_B R-0.8
21K W-0.8
13K Or-0.8
12K_C Or-0.8
Ign Switch Acc Power
Ign Prog Reset Sw Power
None
None
1964527C1
CAV
1
WIRE IDENT
19B Or-0.8
Bur 6-40782
CIRCUIT
Turn Signal Power
Revised 6-02
Printed in U.S.A.
Copyright
4002-112
CONNECTOR 70 - TRANSMISSION SHIFTER TO
PEDESTAL HARNESS
CONNECTOR 72 - PARKING BRAKE SWITCH TO

PEDESTAL HARNESS
382391A1
245486C1
CAV
WIRE IDENT
CAV
CIRCUIT
19A_H Or-0.8
Trans Control Power
25F LU-0.8
Forward Signal
25R LU-0.8
Reverse Signal
25T_A LU-0.8
Neutral Signal
WIRE IDENT
CONNECTOR 71 - HAZARD SWITCH TO

PEDESTAL HARNESS
CIRCUIT
None
19A_H Or-0.8
19A_G Or-0.8
Trans Control Power
33U Y-0.8
Park Brake Signal
None
None
None
0_KJ Bk-0.8
0_KK Bk-0.8
Pilot Light Ground
49_C S-0.8
49_D S-0.8
Pilot Light
None
10
None
382391A1
CAV
WIRE IDENT
CIRCUIT
None
1B R-0.8
Hazard Switch Power
45H N-0.8
Hazard Switch Power
None
None
None
0_KH Bk-0.8
Pilot Light Ground
49_A S-0.8
49_B S-0.8
Pilot Light
None
10
None
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-113
CONNECTOR 74 - UP/DOWN COUNT SWITCH TO
PEDESTAL HARNESS
CONNECTOR 75 - PROGRAM/RESET SWITCH TO

PEDESTAL HARNESS
382391A1
382391A1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
37D P-0.8
Down Count Signal
Reset Signal
19S_A Or-0.8
19S_B Or-0.8
37R_A P-0.8
37R_B P-0.8
1A_B R-0.8
37U P-0.8
Up Count Signal
37P P-0.8
Program Signal
None
None
None
None
None
None
0_KL Bk-0.8
0_KM Bk-0.8
Pilot Light Ground
49_E S-0.8
Pilot Light
6
7
0_KK Bk-0.8
0_KL Bk-0.8
Pilot Light Ground
49_D S-0.8
49_E S-0.8
Pilot Light
None
10
None
Bur 6-40782
None
10
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-114
CONNECTOR 76 - INSTRUMENT CLUSTER TO
PEDESTAL HARNESS
CAV
33
WIRE IDENT
50T Bk-0.8
34
CAV
1
WIRE IDENT
35
44_G T-0.8
Brake Light Signal
36
53C W-0.8
37
0_KQ Bk -0.8
Signal Ground
38
0_KE Bk-0.8
Signal Ground
39
0_KD Bk-0.8
19S_B Or-0.8
33P_B Y-0.8
31D_B Y-0.8
35X_F Y-0.8
31F_C Y-0.8
31H_B Y-0.8
0_KP Bk-0.8
Analog Ground
33U Y-0.8
Park Brake Signal
61R_G Or-0.8
11
291729A1
A/C Telltale
None
49_V S-0.8
Courtesy Pilot Lamp
0_ML Bk-0.8
Courtesy Lamp Ground
42R_A Y-0.8
13
46_B K-0.8
Beacon Telltale
None
15
18C_C Or-0.8
High Beam Telltale
16
45L_F N-0.8
Left Turn Signal
17
45R_F N-0.8
Right Turn Signal
18
36C_C P-0.8
ECT Signal
19
36F_B P-0.8
Fuel Level Signal
20
36H_B P-0.8
Hot Signal
21
50T Bk-0.8
CAN T
22
36P_C P-0.8
EOP Signal
23
23C W-0.8
24
37P P-0.8
Program Signal
25
37R_B P-0.8
Reset Signal
26
37U P-0.8
Up Count Signal
27
37D P-0.8
Down Count Signal
28
33R_E Y-0.8
Red Brake Sw Signal
29
31L Y-0.8
30
52C W-0.8
31
50L G-0.5
CAN L
32
50H Y-0.5
CAN H
Bur 6-40782
CONNECTOR 77F - COURTESY LAMP TO CAB

MAIN HARNESS
CAV
12
14
Signal Ground
None
CIRCUIT
19V_A Or-0.8
10
CAN T
None
40
282763A1
CIRCUIT
WIRE IDENT
CIRCUIT
CONNECTOR 78F - RH FRONT WORK LAMP TO

CAB MAIN HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
42C_C DU-1.0
RH Front Work Lamp Power
0_MJ Bk-1.0
RH Front Work Lamp Ground
Revised 6-02
Printed in U.S.A.
Copyright
4002-115
CONNECTOR 79F - LH FRONT WORK LAMP TO
CAB MAIN HARNESS
CONNECTOR 81M - REAR WIPER MOTOR TO

CAB MAIN HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
42C_B DU-1.0
LH Front Work Lamp Power
0_MH Bk-1.0
LH Front Work Lamp Ground
245715C1
CAV
WIRE IDENT
CONNECTOR 80F - RH REAR WORK LAMP TO

CAB MAIN HARNESS
CIRCUIT
None
68L_C Or-1.0
19K_E Or-1.0
Rear Wpr Wash Fused Power
68C_B Or-1.0
Rear Wiper Park

CAB MAIN HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
42R_E DU-1.0
RH Rear Work Lamp Power
0_MF Bk-1.0
RH Rear Work Lamp Ground
245480C1
CAV
1
Bur 6-40782
WIRE IDENT
0_MA Bk-1.0
CIRCUIT
Rear Wiper Motor Ground
Revised 6-02
Printed in U.S.A.
Copyright
4002-116
CONNECTOR 83F - LH REAR WORK LAMP TO
CAB MAIN HARNESS
CONNECTOR 85F - BEACON LAMP TO CAB

MAIN HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
245426C1
42R_D DU-1.0
LH Rear Work Lamp Power
CAV
0_ME Bk-1.0
LH Rear Work Lamp Ground
46_D K-1.0
0_MC Bk-1.0
Beacon Lamp Ground
CONNECTOR 84F - DOME LAMP TO CAB MAIN

HARNESS
WIRE IDENT
CIRCUIT
CONNECTOR 86 - REDUNDANT BRAKE SWITCH

245483C1
266516C1
CAV
WIRE IDENT
CIRCUIT
19U_D Or-1.0
Dome Lamp Fused Power
0_MB Bk-0.8
0_MM Bk-0.8
Dome Lamp Ground
0_MM Bk-0.8
Dome Lamp Ground
CAV
WIRE IDENT
CIRCUIT
33R_B Y-1.0
Redundant Brake Switch Sig
0_M Bk-1.0
Ground
CONNECTOR 87 - PARKING BRAKE SOLENOID

291718A1
CAV
Bur 6-40782
WIRE IDENT
CIRCUIT
52P W-1.0
Parking Brake Relay Out
0_Q Bk-1.0
Park Str Fuel Relay Ground
Revised 6-02
Printed in U.S.A.
Copyright
4002-117
CONNECTOR 88 - BRAKE PRESSURE WARNING
CONNECTOR 90M - SECONDARY STEERING

MODULE TO SECONDARY STEERING HARNESS
225389C1
222135A1
CAV
WIRE IDENT
CIRCUIT
33P Y-1.0
Low Brake Press Warning
0_N Bk-1.0
Brake Press Warning Switch
CONNECTOR 89M - PILOT PRESSURE

SOLENOID TO CAB MAIN HARNESS
CAV
WIRE IDENT
19R_C Or-1.0
Secondary Steering Ignition
51_A W-1.0
Secondary Steer Mtr Rel
1_W R-1.0
Secondary Steer Module B+
0_CE Bk-1.0
Secondary Steer Chassis Grnd
None
None
19M_C Or-1.0
35X_D Y-1.0
Secondary Steer Low Press Sig
51P_A W-1.0
Secondary Steer High Press
10
245482C1
CAV
WIRE IDENT
CIRCUIT
53P_A W-0.8
0_DB Bk-0.8
CAN Pilot Solenoid Ground
CIRCUIT
None
11
0_CA Bk-1.0
Secondary Steer Signal Grnd
12
0_CB Bk-1.0
CONNECTOR 92 - ETHER START SWITCH TO

PEDESTAL HARNESS
739070C1
CAV
1
Bur 6-40782
WIRE IDENT
25T_A LU-0.8
25T_B LU-0.8
CIRCUIT
Neutral Signal
Revised 6-02
Printed in U.S.A.
Copyright
4002-118
CONNECTOR 93F - REAR CHASSIS HARNESS
TO FUEL AND STARTER RELAY HARNESS
CONNECTOR 94F - TRANSMISSION HARNESS

TO ENGINE HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
21C_D W-1.0
0_U Bk-2.0
Part Str Fuel Relay Ground
291659A1
CONNECTOR 93M - FUEL AND STARTER RELAY

HARNESS TO REAR CHASSIS HARNESS
CAV
WIRE IDENT
13C_A Or-1.0
Fuel Solenoid
61A_A Or-1.0
61R-A Or-1.0
61C_A Or-1.0
AC Comp Clutch
14_A LG-1.0
Alternator D+
36P_A P-1.0
EOP Sender
31F_A Y-1.0
Air Filter Rest Switch Signal
8
9
None
0_HA Bk-1.0
10
11
245482C1
CAV
WIRE IDENT
CIRCUIT
13
21C_C W-1.0
14
0_GA Bk-2.0
Relay Ground
15
Signal Ground
None
0_HB Bk-1.0
12
Bur 6-40782
CIRCUIT
Signal Ground
None
36C_A P-1.0
ECT Sender
None
0_HC Bk-1.0
Analog Ground
16
None
17
None
18
None
19
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-119
CONNECTOR 94M - ENGINE HARNESS TO
CONNECTOR 95 - INTERMEDIATE SPEED

SENSOR TO TRANSMISSION HARNESS
291718A1
373356A1
CAV
WIRE IDENT
CIRCUIT
13C Or-1.0
Fuel Solenoid
61A Or-1.0
61R Or-1.0
61C Or-1.0
AC Comp Clutch
14 LG-1.0
Alternator D+
36P P-1.0
EOP Sender
31F Y-1.0
8
9
0_BF Bk-1.0
0_BH Bk-1.0
0_HG Bk-0.8
Intermediate Speed Signal
25C W-0.8
CONNECTOR 96 - TURBINE SPEED SENSOR TO

Signal Ground
Signal Ground
None
36C P-1.0
14
15
CIRCUIT
None
12
13
WIRE IDENT
None
10
11
CAV
ECT Sender
None
0_BG Bk-1.0
291718A1
Analog Ground
16
None
17
None
18
None
19
None
CAV
WIRE IDENT
CIRCUIT
25B W-0.8
Turbine Speed Signal
0_HH Bk-0.8
Turbine Speed Ground
CONNECTOR 97 - ETHER START TEMPERATURE

SWITCH TO ENGINE HARNESS
245483C1
CAV
Bur 6-40782
WIRE IDENT
CIRCUIT
28T W-1.0
0_BC Bk-1.0
Ether Fuel Solenoid Ground

Revised 6-02
Printed in U.S.A.
Copyright
4002-120
CONNECTOR 98 - AC HIGH PRESSURE SWITCH
TO ENGINE HARNESS
CONNECTOR 101 - ENGINE SPEED SENSOR TO

245482C1
CAV
A
B
WIRE IDENT
61A Or-1.0
61R Or-1.0
CIRCUIT
291718A1

CAV
CONNECTOR 99 - AC COMPRESSOR CLUTCH

TO ENGINE HARNESS
WIRE IDENT
CIRCUIT
25A W-0.8
Engine Speed Signal
0_HF Bk-0.8
Engine Speed Ground
CONNECTOR 102 - TRANSMISSION CONTROL

VALVE TO TRANSMISSION HARNESS
245480C1
CAV
1
WIRE IDENT
61C Or-1.0
CIRCUIT
371566A1
CAV
CONNECTOR 100 - OUTPUT SPEED SENSOR TO

291719A1
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
25K LU-0.8
25L LU-0.8
25M LU-0.8
25N LU-0.8
25P LU-0.8
25J LU-0.8
25S LU-0.8
36T P-0.8
36R_C P-0.8
Valve Body Temp Ret
10
None
11
None
12
None
13
None
0_HE Bk-1.0
Output Speed Ground
14
None
25D LU-1.0
Output Speed Signal
15
None
19A Or-1.0
Output Speed Power
16
None
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-121
CONNECTOR 103 - ETHER START SOLENOID TO
CONNECTOR 108F - DIAGNOSTIC CONNECTOR

TO CAB MAIN HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
28P W-1.0
Ether Solenoid
28T_A W-1.0
291663A1
CAV
CONNECTOR 104 - COOLANT LEVEL SENDER

WIRE IDENT
CIRCUIT
19A_L Or-0.8
Cab Switched Power
37D_A P-0.8
Diagnostic Signal
0_DAV Bk-0.8
Diagnostic TECM Ground
37E P-0.8
Diagnostic Signal
None
None
CONNECTOR 109M - RADIO POWER

CONVERTER TO RADIO HARNESS
194788A1
CAV
WIRE IDENT
CIRCUIT
31D Y-1.0
0_V Bk-1.0
Fuel Rdndnt Brake Cool Ground
CONNECTOR 107M - PIN ENGAGE SOLENOID TO

291730A1
CAV
WIRE IDENT
CIRCUIT
19L_A Or-1.0
Radio Power
0_PD Bk-1.0
Radio Ground
245482C1
CAV
WIRE IDENT
CIRCUIT
57 W-1.0
0_AB Bk-1.0
Pin Engage Ground
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-122
CONNECTOR 110F - RADIO POWER
CONNECTOR 113 - RADIO TO REMOTE RADIO

ADAPTOR HARNESS
CAV
WIRE IDENT
1
2
CIRCUIT
None
0_QB Bk-0.8
Right Speaker Ground

None
0_QA Bk-0.8
Left Speaker Ground
0_QC Bk-0.8
Radio Ground
18_ H Or-0.8
Radio Power
None
None
245426C1
9
CAV
WIRE IDENT
CIRCUIT
65C Or-0.8
Radio Power
0_PC Bk-0.8
Radio Ground
65R_A Or-0.8
10
11
CONNECTOR 111M - RIGHT SPEAKER TO RADIO

HARNESS
Right Speaker Signal

None
65L_A Or-0.8
Left Speaker Signal
12
None
13
None
14
65C_B Or-0.8
Radio Power
CONNECTOR 114F - RADIO ADAPTOR TO RADIO

HARNESS
195552A1
CAV
WIRE IDENT
CIRCUIT
65R Or-0.8
0_PB Bk-0.8

892136C1
CAV
CONNECTOR 112M - LEFT SPEAKER TO RADIO

HARNESS
WIRE IDENT
CIRCUIT
65L Or-0.8
Left Speaker Signal
0_PA Bk-0.8
Left Speaker Ground
0_PC Bk-0.8
Radio Ground
0_PB Bk-0.8
65R Or-0.8
65C Or-0.8
Radio Power
195552A1
CAV
WIRE IDENT
CIRCUIT
65L Or-0.8
Left Speaker Signal
0_PA Bk-0.8
Left Speaker Ground
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-123
CONNECTOR 114M - RADIO ADAPTOR TO
REMOTE RADIO ADAPTOR HARNESS
CONNECTOR 118F - BACKUP ALARM DISABLE

382391A1
449797C1
CAV
1
WIRE IDENT
65L_A Or-0.8
CAV
CIRCUIT
Left Speaker Signal
WIRE IDENT
CIRCUIT
35R_C Y-0.8
35R_D Y-0.8
Backup Alarm Switch
35A_E Y-0.8
35A_F Y-0.8
0_QA Bk-0.8
Left Speaker Ground
0_QC Bk-0.8
Radio Ground
0_QB Bk-0.8
None
65R_A Or-0.8
None
65C_B Or-0.8
Radio Power
None
None
CONNECTOR 117 - AIR FILTER RESTRICTION

0_DW Bk-0.8
0_DAW Bk-1.0
Ground
49_L S-0.8
49_T S-1.0
Pilot Light
None
10
None
CONNECTOR 125 - LH REAR COMBINATION

LAMP TO REAR CHASSIS HARNESS
291718A1
CAV
WIRE IDENT
CIRCUIT
31F Y-1.0
Air Fltr Restriction Switch Signal
0_BD Bk-1.0
Air Fltr Restriction Switch Grnd
225351C1
CAV
CIRCUIT
44_A T-1.0
Brake Light Signal
45L_A N-1.0
Left Turn Signal
18F_A Or-1.0
Left Tail
35A_A K-1.0
Left Reverse
0_A Bk-1.0
Ground
Bur 6-40782
WIRE IDENT
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-124
CONNECTOR 127 - RH REAR COMBINATION
CONNECTOR 128M - HOOD HARNESS TO REAR

CHASSIS HARNESS
245484C1
225351C1
CAV
WIRE IDENT
CAV
CIRCUIT
WIRE IDENT
CIRCUIT
44_B T-1.0
Brake Light Signal
18G_E Or-1.0
License Plate Light
45R_A N-1.0
Right Turn Signal
35R_A Y-1.0
Backup Alarm Switch
0_JA Bk-1.0
Hood Ground
18G_A Or-1.0
Right Tail
35A_B K-1.0
Right Reverse
0_C Bk-1.0
Ground
CONNECTOR 131F - SECONDARY STEERING

PRESSURE SWITCH TO FRONT CHASSIS
HARNESS
None

TO HOOD HARNESS
245485C1
CAV
245485C1
CAV
WIRE IDENT
CIRCUIT
18G_C Or-1.0
License Plate Light
35R_B Y-1.0
Backup Alarm Switch
0_J Bk-1.0
Hood Grounds
WIRE IDENT
CIRCUIT
51P_B W-1.0
Secondary Steer High Pressure
0_AN Bk-1.0
Secondary Steer Signal Ground
35X_A Y-1.0
CONNECTOR 133F - FUEL AND STARTER RELAY

HARNESS TO ENGINE HARNESS
245481C1
CAV
1
Bur 6-40782
WIRE IDENT
23F_A W-20
CIRCUIT
Fuel Solenoid Pull In
Revised 6-02
Printed in U.S.A.
Copyright
4002-125
FUEL AND STARTER RELAY HARNESS
CONNECTOR 138 - ENGINE COOLANT

TEMPERATURE SENDER TO ENGINE HARNESS
194788A1
CAV
245480C1
CAV
1
WIRE IDENT
23F W-2.0
CIRCUIT
WIRE IDENT
CIRCUIT
36C P-1.0
ECT Signal
0_BE Bk-1.0
ECT Ground
CONNECTOR 139F - ENGINE HARNESS TO

DISCONNECT HARNESS
CONNECTOR 134 - FUEL SHUTOFF SOLENOID

HARNESS TO ENGINE HARNESS
245483C1
245484C1
CAV
WIRE IDENT
CIRCUIT
13M Or-1.0
Fuel Solenoid Hold In
23F W-2.0
0_BB Bk-2.0
Ether Fuel Solenoid Ground
CAV
WIRE IDENT
CIRCUIT
13C Or-1.0
Fuel Solenoid
13M Or-1.0
CONNECTOR 139M - DISCONNECT HARNESS TO

ENGINE HARNESS
CONNECTOR 136 - HYDRAULIC OIL

TEMPERATURE SENDER TO REAR CHASSIS
HARNESS
245482C1
CAV
194788A1
CAV
WIRE IDENT
CIRCUIT
36H P-1.0
Hot Signal
0_W Bk-1.0
Front Rear Wash Hot Ground
Bur 6-40782
WIRE IDENT
CIRCUIT
13C_E Or-1.0
Fuel Solenoid Power
13M_A Or-1.0
Revised 6-02
Printed in U.S.A.
Copyright
4002-126
CONNECTOR 140M - DIODE MODULE TO CAB
MAIN HARNESS
CONNECTOR 157 - REDUNDANT BRAKE

PRESSURE SWITCH TO REAR CHASSIS
HARNESS
245483C1
245488C1
CAV
WIRE IDENT
CIRCUIT
63L_B Or-0.8
63H_B Or-0.8
0_DAX Bk-0.8
13C_C Or-0.8
Fuel Solenoid Power
21C_F W-0.8
68L_B Or-0.8
CAV
WIRE IDENT
CIRCUIT
33R_A Y-1.0
Red Brake Switch Signal
0_L Bk-1.0
Ground
CONNECTOR 158 - FAN REVERSING SOLENOID

CONNECTOR 142 - TORQUE CONVERTER

OUTPUT TO TRANSMISSION HARNESS
225316C1
CAV
WIRE IDENT
CIRCUIT
52 W-1.0
0_X Bk-1.0
Fan Reversing Solenoid Ground
CONNECTOR 159 - BRAKE LAMP PRESSURE

291718A1
CAV
WIRE IDENT
CIRCUIT
36G P-1.0
TCO Temperature Signal
36R_D P-1.0
Valve Body Temperature Ret
222136A1
CAV
Bur 6-40782
WIRE IDENT
CIRCUIT
1B_A R-1.0
Brake Lamp Switch Power
44 T-1.0
Brake Lamp Input Signal
Revised 6-02
Printed in U.S.A.
Copyright
4002-127
CONNECTOR 168 - LICENSE PLATE LAMP TO
HOOD HARNESS
CONNECTOR 180F - FRONT CHASSIS HARNESS

TO SECONDARY STEERING MODULE HARNESS
245482C1
CAV
WIRE IDENT
CIRCUIT
225350C1
18G_E Or-1.0
License Plate Lamp
0_JC Bk-1.0
License Plate Lamp Ground
CONNECTOR 178M - FLOAT PRESSURE SWITCH

TO FRONT CHASSIS HARNESS
CAV
WIRE IDENT
CIRCUIT
19M_B Or-1.0
Secondary Steering Accessory
19R_B Or-1.0
35X_C Y-1.0
Sec Steer Low Pressure Signal
51P_B W-1.0
Sec Steer High Pressure
0_AN Bk-1.0
Sec Steer Signal Ground
None

MODULE HARNESS TO FRONT CHASSIS
HARNESS
245482C1
CAV
WIRE IDENT
CIRCUIT
53P_D W-1.0
53S_A W-1.0
Float Solenoid Signal
CONNECTOR 179F - FLOAT SOLENOID TO

225351C1
CAV
WIRE IDENT
CIRCUIT
19M_C Or-1.0
19R_C Or-1.0
35X_D Y-1.0
51P_A W-1.0
0_CC Bk-1.0
None
291718A1
CAV
WIRE IDENT
CIRCUIT
53S_B W-1.0
0_AP Bk-1.0
Float Solenoid Ground
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-128
PEDESTAL HARNESS

FNR HARNESS
739070C1
225350C1
CAV
1
WIRE IDENT
28C W-0.8
CIRCUIT
CAV
Ether Start Control

PEDESTAL HARNESS
WIRE IDENT
CIRCUIT
19A_C Or-0.8
Transmission Enable Sw Power
26F_B LU-0.8
FNR Forward Signal
26N_B LU-0.8
FNR Neutral Signal
26R_B LU-0.8
FNR Reverse Signal
32J_B Y-0.8
Trans Enable LT Signal
None
CONNECTOR 197M - FNR HARNESS TO CAB

MAIN HARNESS
245487C1
CAV
WIRE IDENT
CIRCUIT
None
25W LU-0.8
25Z LU-0.8
25Y LU-0.8
Transmission Kick Down Signal
225351C1
CAV
CIRCUIT
19A_B Or-0.8
FNR Switched Power
26F_A LU-0.8
FNR Forward Signal
26N_A LU-0.8
FNR Neutral Signal
26R_A LU-0.8
FNR Reverse Signal
32J_A Y-0.8
FNR LT Signal
Bur 6-40782
WIRE IDENT
None
Revised 6-02
Printed in U.S.A.
Copyright
4002-129
CONNECTOR 198 - FNR SWITCH TO FNR
HARNESS
CAV
WIRE IDENT
CIRCUIT
49_G S-0.8
49_R S-1.0
Pilot Light
32J_B Y-0.8
32J_C Y-0.8
10
19A_C Or-0.8
19A_E Or-0.8
None
CONNECTOR 200 - RETURN-TO-DIG PROXIMITY

SWITCH TO RETURN-TO-DIG HARNESS FOR XT
CHASSIS
382391A1
CAV
WIRE IDENT
CIRCUIT
26R_A LU-0.8
FNR Reverse Signal
26J LU-0.8
FNR Switch Jumper
26N_A LU-0.8
FNR Neutral Signal
26J LU-0.8
FNR Switch Jumper
19A_B Or-0.8
19A_F Or-0.8
FNR Switched Power
26F-A LU-0.8
FNR Forward Signal
32J_A Y-0.8
FNR LT Signal
CAV
19A_F Or-0.8
FNR Switched Power
53B_A W-1.0
RTD Signal
None
0_AM Bk-1.0
RTD Ground
10
None
56_D W-1.0
RTD Power
245484C1
CONNECTOR 199F - TRANSMISSION ENABLE

WIRE IDENT
CIRCUIT
CONNECTOR 202F - DIODE MODULE TO FRONT

CHASSIS
245485C1
382391A1
CAV
WIRE IDENT
CIRCUIT
None
19A_D Or-0.8
19A_E Or-0.8
Trans Enable Switched Power
26E LU-0.8
Trans Enable Signal
None
None
None
0_DAE Bk-1.0
0_DAP Bk-1.0
Bur 6-40782
WIRE IDENT
58_D W-1.0
B
C
CAV
CIRCUIT
None
53S_C W-1.0
Float Switch Signal
Ground
Revised 6-02
Printed in U.S.A.
Copyright
4002-130
CONNECTOR 203F - COMPRESSOR CLUTCH
LOCKOUT RELAY TO CAB MAIN HARNESS
CONNECTOR 207F - THERMOSTAT SWITCH TO

CAB MAIN HARNESS
CAV
A
WIRE IDENT
61T Or-1.0
CIRCUIT

CAB MAIN HARNESS
CAV
A
245731C1
CAV
WIRE IDENT
CIRCUIT
30
61A_B Or-0.8
61A_C Or-0.8
Relay Power
85
0_DK Bk-0.8
AC BRK LT Time Del Horn Gnd
86
61R_C Or-0.8
AC Relay Signal
87
61R_B Or-0.8
61R_C Or-0.8
61R_D Or-0.8
AC Relay Signal
87A
61C_B Or-0.8
AC Comp Clutch
CONNECTOR 204F - BRAKE LAMPS RELAY TO

CAB MAIN HARNESS
WIRE IDENT
61A_D Or-0.8
CIRCUIT
AC Thermostat

JUMPER
739070C1
CAV
A
WIRE IDENT
35R_D Y-0.8
CIRCUIT
Backup Alarm Switch
CONNECTOR 209M - BACKUP ALARM DISABLE

JUMPER
245731C1
CAV
WIRE IDENT
CIRCUIT
30
1B_E R-0.8
Brake Lamp Relay Power
85
0_DA Bk-0.8
0_DK Bk-0.8
86
44A_B T-0.8
Brake LT Input Signal
87
44_E T-0.8
Brake LT Relay Signal
CAV
None
87A
Bur 6-40782
631801C1
WIRE IDENT
35A_F Y-0.8
CIRCUIT
Revised 6-02
Printed in U.S.A.
Copyright
4002-131
CONNECTOR 210F - FAN REVERSER SWITCH TO
CAB MAIN HARNESS
CONNECTOR 216F - ALTERNATOR RESISTOR

TO CAB MAIN HARNESS
199436A1
382391A1
CAV
WIRE IDENT
CIRCUIT
CAV
1
WIRE IDENT
19R_E Or-0.8
CIRCUIT
Cab Switched Power
None
19P_B Or-1.0
Fan Rev Pin Engage Fused Pwr
52_A W-0.8
None
None
None
0_DAF Bk-1.0
0_DAY Bk-1.0
Switch Ground
49_H S-0.8
49_U S-0.8
Pilot Light
None
10
None
CONNECTOR 217F - ENGINE SHUTDOWN

JUMPER
739070C1

TO CAB MAIN HARNESS
CAV
A
WIRE IDENT
13K_D Or-0.8
CIRCUIT
CONNECTOR 217M - ENGINE SHUTDOWN

JUMPER
199436A1
CAV
1
WIRE IDENT
14_B LG-0.8
CIRCUIT
Alternator D+
631801C1
CAV
A
Bur 6-40782
WIRE IDENT
13C_B Or-0.8
CIRCUIT
Fuel Solenoid Power
Revised 6-02
Printed in U.S.A.
Copyright
4002-132
CONNECTOR 229M - DIODE MODULE TO FRONT
CHASSIS HARNESS
CONNECTOR 259F - CIGAR LIGHTER TO CIGAR

LIGHTER HARNESS
245488C1
CAV
WIRE IDENT
CIRCUIT
3227856R1
CAV
WIRE IDENT
CIRCUIT
58_E W-1.0
19W_A Or-3.0
Cigar Lighter Power
53S_D W-1.0
0_S Bk-3.0
Cigar Lighter Ground
0_AQ Bk-1.0
Ground
None
None
None
CONNECTOR 260M - FUSE BLOCK TERMINAL 16

TO CIGAR LIGHTER HARNESS

TO RADIO HARNESS
CAV
A
WIRE IDENT
19L_A Or-1.0
CIRCUIT
Radio Power

TO CONVERTER HARNESS
CAV
A
WIRE IDENT
19L_B Or-1.0
CIRCUIT
276720A1
CAV
Converter Power Ignition
CONNECTOR 253F - POWER OUTLET TO

CONVERTER HARNESS
WIRE IDENT
19W_A Or-3.0
CIRCUIT
Cigar Lighter Power
CONNECTOR 262F - DIODE MODULE TO CAB

MAIN CHASSIS HARNESS
245485C1
314908A1
CAV
WIRE IDENT
CIRCUIT
12V_A R-3.0
12 V Power to Outlet
0_RB Bk-3.0
Outlet Ground
Bur 6-40782
CAV
A
WIRE IDENT
19R_F Or-0.8
B
C
CIRCUIT
None
19R_D Or-0.8

Revised 6-02
Printed in U.S.A.
Copyright
4002-133
SOLENOID TO SECONDARY STEERING
HARNESS
CONNECTOR 267F - ENGINE HARNESS TO AIR

CONDITIONING DIODE HARNESS
245481C1
225316C1
CAV
WIRE IDENT
CIRCUIT
CAV
1
51_C W-1.0
Sec Steer Solenoid Power
0_CF Bk-1.0
Secondary Steering Ground
WIRE IDENT
61C_D Or-1.0
CIRCUIT
CONNECTOR 269 - RADIO FUSE HOLDER

(REMOTE RADIO ADAPTER HARNESS)
CONNECTOR 265F - AIR CONDITIONING DIODE
MODULE TO AIR CONDITIONING DIODE
HARNESS
CAV
WIRE IDENT
CIRCUIT
1_X R-1.0
Radio Memory Power
18_H Or-0.8
Radio Memory Fused Power
CONNECTOR 270F - RADIO MEMORY POWER

CAV
1
WIRE IDENT
61C_C Or-1.0
B
C
1_X R-1.0
CIRCUIT
Radio Memory Power
CONNECTOR 271M - FRONT CHASSIS

ROLLBACK JUMPER HARNESS
245485C1
CAV
WIRE IDENT
CIRCUIT
None
0_BJ Bk-1.0
Ground
CONNECTOR 266M - AIR CONDITIONING DIODE

HARNESS TO AIR COMPRESSOR CLUTCH
245484C1
CAV
A
WIRE IDENT
58_F W-1.0
B
C
CIRCUIT
Float Switch Signal
None
53S_E W-1.0
245480C1
CAV
1
WIRE IDENT
61C_E Or-1.0
Bur 6-40782
CIRCUIT
Revised 6-02
Printed in U.S.A.
Copyright
4002-134
CONNECTOR 272F - ROLLBACK JUMPER
PRESSURE SWITCH (ROLLBACK SWITCH
JUMPER HARNESS)
CONNECTOR 274F - REAR CHASSIS COOLANT

JUMPER (COOLANT SENSOR JUMPER
HARNESS)
CAV
WIRE IDENT
CIRCUIT
31D_C Y-0.8
0_VA Y-0.8
Fuel Red Br Coolant Ground
CONNECTOR 275M - COOLANT JUMPER

COOLANT SENDER (COOLANT SENSOR
JUMPER HARNESS)
245483C1
CAV
WIRE IDENT
CIRCUIT
58A_A W-1.0
Float Switch Signal
58_F W-1.0
CONNECTOR 273F - ROLLBACK JUMPER DIODE

MODULE (ROLLBACK SWITCH JUMPER
HARNESS)
194788A1
CAV
WIRE IDENT
CIRCUIT
31D_C Y-0.8
0_VA Y-0.8
245485C1
CAV
A
WIRE IDENT
58A_A W-1.0
B
C
CIRCUIT
None
53S_E W-1.0
Bur 6-40782
Float Switch Signal
Revised 6-02
Printed in U.S.A.
Copyright
4002-135
INDEX
Symbols
12 Volt Radio ..........................................................75
24 Volt Radio ..........................................................75
A
A/C High Pressure Switch (In Rear Chassis) .........72
A/C Low Pressure Switch (In Cab) .........................72
Accessory Relay No. 3 ...........................................42
Air Filter Restriction Switch.....................................49
Alarm
Back-up ..............................................................45
Back-up, Disable Switch ....................................45
Back-up, Relay No. 7 .........................................44
Alternator ................................................................37
B
Back-up Alarm ........................................................45
Back-up Alarm Disable Switch ...............................45
Back-up Alarm Relay No. 7 ....................................44
Batteries .................................................................36
Beacon Switch ........................................................77
Beacon, Rotating ....................................................78
Blower Motor ..........................................................72
Blower Motor Speed Resistors with Thermal Fuse 72
Blower Switch .........................................................71
Brake Lamp Pressure Switch .................................78
Brake Lamps Relay No. 15.....................................78
Brake Warning Pressure Switch .............................47
Bucket Control Valve Electromagnet Detents ........58
Bulb
See Lamp ...........................................................78
C
Cigar Lighter ...........................................................74
Cluster, Instrument .....................................50, 51, 52
Compressor Clutch .................................................73
Compressor Clutch Lockout Relay No. 14 .............73
Compressor, Seat...................................................71
Connector 1 ............................................................89
Connector 10 ..........................................................91
Connector 100 ......................................................120
Connector 101 ......................................................120
Connector 102 ......................................................120
Connector 103 ......................................................121
Connector 104 ......................................................121
Connector 107M ...................................................121
Connector 108F....................................................121
Connector 109M ...................................................121
Connector 110F....................................................122
Connector 111M ...................................................122
Connector 112M ...................................................122
Connector 113 ......................................................122
Connector 114F....................................................122
Connector 114M ...................................................123
Bur 6-40782
Connector 117 ...................................................... 123

Connector 118F.................................................... 123
Connector 125 ...................................................... 123
Connector 127 ...................................................... 124
Connector 128F.................................................... 124
Connector 128M ...................................................124
Connector 12F........................................................ 91
Connector 12M....................................................... 91
Connector 131F.................................................... 124
Connector 133F.................................................... 124
Connector 133M ...................................................125
Connector 134 ...................................................... 125
Connector 136 ...................................................... 125
Connector 138 ...................................................... 125
Connector 139F.................................................... 125
Connector 139M ...................................................125
Connector 13F........................................................ 92
Connector 13M....................................................... 93
Connector 140M ...................................................126
Connector 142 ...................................................... 126
Connector 157 ...................................................... 126
Connector 158 ...................................................... 126
Connector 159 ...................................................... 126
Connector 168 ...................................................... 127
Connector 178M ...................................................127
Connector 179F.................................................... 127
Connector 17M....................................................... 94
Connector 180F.................................................... 127
Connector 180M ...................................................127
Connector 182 ...................................................... 128
Connector 183 ...................................................... 128
Connector 197F.................................................... 128
Connector 197M ...................................................128
Connector 198 ...................................................... 129
Connector 199F.................................................... 129
Connector 19F........................................................ 97
Connector 1F..........................................................89
Connector 2 ............................................................90
Connector 200 ...................................................... 129
Connector 202F.................................................... 129
Connector 203F.................................................... 130
Connector 204F.................................................... 130
Connector 207F.................................................... 130
Connector 208F.................................................... 130
Connector 209F.................................................... 130
Connector 209M ...................................................130
Connector 20M....................................................... 97
Connector 210F.................................................... 131
Connector 215F.................................................... 131
Connector 216F.................................................... 131
Connector 217F.................................................... 131
Connector 217M ...................................................131
Connector 21F........................................................ 98
Connector 21M....................................................... 98
Connector 229M ...................................................132
Revised 6-02
Printed in U.S.A.
Copyright
4002-136
Connector 22F........................................................99
Connector 22M .......................................................99
Connector 23F......................................................100
Connector 23M .....................................................100
Connector 246M ...................................................132
Connector 24F......................................................100
Connector 24M .....................................................100
Connector 253F....................................................132
Connector 259F....................................................132
Connector 25F......................................................101
Connector 260M ...................................................132
Connector 262F....................................................132
Connector 264M ...................................................133
Connector 265F....................................................133
Connector 266M ...................................................133
Connector 267F....................................................133
Connector 269 ......................................................133
Connector 270F....................................................133
Connector 271M ...................................................133
Connector 272F....................................................134
Connector 273F....................................................134
Connector 274F....................................................134
Connector 275M ...................................................134
Connector 27M .....................................................101
Connector 28M .....................................................101
Connector 29M .....................................................101
Connector 3 ............................................................90
Connector 30F......................................................101
Connector 31 ........................................................102
Connector 32F......................................................102
Connector 33F......................................................102
Connector 34F......................................................102
Connector 35F......................................................103
Connector 36F......................................................103
Connector 37 ........................................................103
Connector 38F......................................................104
Connector 39F......................................................104
Connector 4 ............................................................90
Connector 40F......................................................104
Connector 41F......................................................105
Connector 42F......................................................105
Connector 44F......................................................105
Connector 45F......................................................106
Connector 47F......................................................106
Connector 48F......................................................106
Connector 49F......................................................106
Connector 50F......................................................107
Connector 51F......................................................107
Connector 52F......................................................107
Connector 53F......................................................107
Connector 54F......................................................108
Connector 55F......................................................108
Connector 56F......................................................108
Connector 57F......................................................108
Connector 58F......................................................109
Connector 59F......................................................109
Connector 5F..........................................................90
Bur 6-40782
Connector 6 ............................................................ 90
Connector 60........................................................ 109
Connector 61........................................................ 109
Connector 62M..................................................... 110
Connector 63M..................................................... 110
Connector 64F...................................................... 110
Connector 64M..................................................... 110
Connector 65F...................................................... 110
Connector 65M..................................................... 111
Connector 66........................................................ 111
Connector 67........................................................ 111
Connector 68........................................................ 111
Connector 69........................................................ 111
Connector 70........................................................ 112
Connector 71........................................................ 112
Connector 72........................................................ 112
Connector 74........................................................ 113
Connector 75........................................................ 113
Connector 76........................................................ 114
Connector 77F...................................................... 114
Connector 78F...................................................... 114
Connector 79F...................................................... 115
Connector 8 ............................................................ 91
Connector 80F...................................................... 115
Connector 81M..................................................... 115
Connector 82M..................................................... 115
Connector 83F...................................................... 116
Connector 84F...................................................... 116
Connector 85F...................................................... 116
Connector 86........................................................ 116
Connector 87........................................................ 116
Connector 88........................................................ 117
Connector 89M..................................................... 117
Connector 90M..................................................... 117
Connector 92........................................................ 117
Connector 93F...................................................... 118
Connector 93M..................................................... 118
Connector 94F...................................................... 118
Connector 94M..................................................... 119
Connector 95........................................................ 119
Connector 96........................................................ 119
Connector 97........................................................ 119
Connector 98........................................................ 120
Connector 99........................................................ 120
Connector, Diagnostic ............................................ 44
Converter, Radio Power (24 volts to 12 volts)........ 76
Coolant Level Sender .............................................47
Courtesy Lamp ....................................................... 88
D
Declutch Brake Switch ........................................... 44
Declutch Switch...................................................... 44
Detent Switch ......................................................... 57
Diagnostic Connector .............................................44
Dome Lamp ............................................................ 88
Revised 6-02
Printed in U.S.A.
Copyright
4002-137
E
Engine Coolant Temperature Sender .....................48
Engine Oil Pressure Switch ....................................54
Engine Speed Sensor.............................................44
Ether Start Relay No. 6...........................................39
Ether Start Solenoid ...............................................39
Ether Start Switch ...................................................39
Ether Start Temperature Switch .............................38
F
Fan Reversing Solenoid .........................................56
Fan Reversing Switch.............................................55
Filter Maintenance Switch ......................................44
Five Position Rotary Lamp Switch ..........................87
Flasher Module.......................................................80
Float Pressure Switch.............................................59
Float Solenoid.........................................................60
FNR Switch.............................................................44
Front
LH Work Lamp ...................................................86
RH Work Lamp...................................................86
Front LH Combination Lamp ..................................84
Front RH Combination Lamp ..................................85
Front Washer Pump Motor .....................................68
Front Wiper and Washer Switch .............................68
Front Wiper Motor...................................................67
Fuel Level Sender ..................................................47
Fuel Relay ..............................................................38
Fuel Shutoff Solenoid .............................................37
Fuse Block 18F.......................................................95
License Plate .....................................................88

Low Beam ....................................................84, 85
Position ........................................................84, 85
Reverse........................................................82, 83
RH Front Combination .......................................85
RH Front Work ................................................... 86
RH Rear Combination ........................................ 83
RH Rear Work.................................................... 86
Stop..............................................................82, 83
Switch, Five Position Rotary .............................. 87
Tail ...............................................................82, 83
Turn..................................................82, 83, 84, 85
Left Speaker ........................................................... 76
LH Front Combination Lamp ..................................84
LH Front Work Lamp ..............................................86
LH Rear Combination Lamp ................................... 82
LH Rear Work Lamp............................................... 85
License Plate Lamp ................................................ 88
Locating Components on the Schematic Posters .. 31
M
Master Disconnect Switch ...................................... 37
Module
Flasher ............................................................... 80
Secondary Steering............................................ 62
Time Delay ......................................................... 42
Transmission Electronic Control ........................ 44
Motor, Starter ......................................................... 38
N
Neutral Start Relay No. 8 .......................................40
H
Hazard Switch ........................................................79
Height Control/Return-To-Travel Proximity Switch .59
Hi/Low Beam Switch...............................................79
High/Low Beam Relay No. 13 ................................87
Horn ........................................................................71
Horn Relay No. 5 ....................................................70
Horn Switch ............................................................79
Hydraulic Filter Restriction Switch ..........................48
Hydraulic Oil Temperature Sender .........................48
I
Ignition Relay No. 1 ................................................40
Ignition Relay No. 2 ................................................41
Ignition Switch ........................................................40
Instrument Cluster ......................................50, 51, 52
Intermediate Speed Sensor....................................44
L
Lamp
Courtesy .............................................................88
Dome..................................................................88
High Beam ...................................................84, 85
LH Front Combination ........................................84
LH Rear Combination.........................................82
LH Rear Work ....................................................85
Bur 6-40782
O
Outlet, Power..........................................................75
Output Speed Sensor ............................................. 44
P
Parking Brake Relay No. 9 ..................................... 54
Parking Brake Solenoid .......................................... 55
Parking Brake Switch ............................................. 49
Pilot Control Relay No. 10 ...................................... 54
Pilot Control Switch ................................................ 52
Pilot Pressure Solenoid .......................................... 55
Pin Engage Solenoid ..............................................64
Pin Engage Switch ................................................. 64
Power Converter (24 volts to 12 volts) ................... 75
Power Outlet........................................................... 75
Program Reset Switch............................................ 49
Proximity Switch
Height Control/Return-To-Travel........................ 59
Return-To-Dig .................................................... 59
R
Radio
12 Volt ................................................................ 75
24 volt ................................................................ 75
Power Converter (24 volts to 12 volts) ...............76
Revised 6-02
Printed in U.S.A.
Copyright
4002-138
Remote...............................................................75
Rear
LH Combination Lamp .......................................82
LH Work Lamp ...................................................85
RH Combination Lamp .......................................83
RH Work Lamp...................................................86
Rear Washer Pump Motor......................................69
Rear Wiper and Washer Switch .............................69
Rear Wiper Motor ...................................................69
Redundant Brake Pressure Switches .....................56
Relay
Accessory, No. 3 ................................................42
Backup Alarm, No. 7 ..........................................44
Brake Lamps No. 15 ..........................................78
Compressor Clutch Lockout No. 14 ...................73
Ether Start No. 6 ................................................39
Fuel ....................................................................38
High/Low Beam No. 13 ......................................87
Horn No. 5 ..........................................................70
Ignition, No. 1 .....................................................40
Ignition, No. 2 .....................................................41
Neutral Start No. 8 .............................................40
Parking Brake No. 9 ...........................................54
Pilot Control No. 10 ............................................54
Ride Control No. 4..............................................65
Start....................................................................38
Voltmeter, No. 12 ...............................................42
Relay Socket No. 11 ...............................................56
Remote Radio.........................................................75
Return-To-Dig Proximity Switch .............................59
Return-To-Travel/Float Switch................................58
RH Front Combination Lamp..................................85
RH Front Work Lamp..............................................86
RH Rear Combination Lamp ..................................83
RH Rear Work Lamp ..............................................86
Ride Control Relay No. 4 ........................................65
Ride Control Solenoid.............................................65
Ride Control Switch ................................................65
Right Speaker.........................................................76
Rotating Beacon .....................................................78
S
Seat Compressor and Switch .................................71
Secondary Steering Module ...................................62
Secondary Steering Motor......................................63
Secondary Steering Pressure Switch .....................62
Secondary Steering Solenoid .................................63
Sender
Coolant Level .....................................................47
Engine Coolant Temperature .............................48
Fuel Level...........................................................47
Hydraulic Oil Temperature .................................48
Torque Converter Output Temperature..............44
Sensor
Engine Speed.....................................................44
Intermediate Speed ............................................44
Output Speed .....................................................44
Bur 6-40782
Transmission Solenoid Valve and Temperature 44

Turbine Speed ................................................... 44
Shifter, Transmission.............................................. 44
Shutoff, Fuel Solenoid ............................................ 37
Solenoid
Ether ..................................................................39
Ether Start .......................................................... 39
Fan Reversing....................................................56
Float ................................................................... 60
Fuel Shutoff........................................................ 37
Parking Brake ....................................................55
Pilot Pressure..................................................... 55
Pin Engage ........................................................ 64
Ride Control ....................................................... 65
Secondary Steering ........................................... 63
Speaker
Left ..................................................................... 76
Right................................................................... 76
Specifications ........................................................... 7
Speed Resistors
Blower Motor ...................................................... 72
Start Relay.............................................................. 38
Starter Motor .......................................................... 38
Steering
Secondary, Module ............................................ 62
Secondary, Motor...............................................63
Secondary, Pressure Switch .............................. 62
Secondary, Solenoid .......................................... 63
Switch ..................................................................... 73
A/C High Pressure (In Rear Chassis) ................ 72
A/C Low Pressure (In Cab) ................................ 72
Air Filter Restriction............................................ 49
Back-up Alarm Disable ...................................... 45
Beacon ............................................................... 77
Blower ................................................................ 71
Brake Lamp Pressure ........................................78
Brake Warning Pressure .................................... 47
Declutch ............................................................. 44
Declutch Brake................................................... 44
Detent ................................................................ 57
Engine Oil Pressure ........................................... 54
Ether Start .......................................................... 39
Ether Start Temperature .................................... 38
Fan Reversing....................................................55
Filter Maintenance .............................................44
Five Position Rotary Lamp .................................87
Float Pressure....................................................59
FNR.................................................................... 44
Front Wiper and Washer .................................... 68
Hazard ............................................................... 79
Hi/Low Beam...................................................... 79
Horn ................................................................... 79
Hydraulic Filter Restriction .................................48
Ignition ............................................................... 40
Master Disconnect .............................................37
Parking Brake ....................................................49
Pilot Control Switch ............................................ 52
Revised 6-02
Printed in U.S.A.
Copyright
4002-139
Pin Engage.........................................................64
Program Reset ...................................................49
Proximity, Height Control/Return-To-Travel .......59
Proximity, Return-To-Dig....................................59
Rear Wiper and Washer.....................................69
Redundant Brake Pressure ................................56
Return-To-Travel/Float .......................................58
Ride Control .......................................................65
Seat Compressor ...............................................71
Secondary Steering Pressure ............................62
Transmission Auto .............................................44
Transmission Enable..........................................44
Transmission Kick-down ....................................44
Turn Signal .........................................................79
Up/down Count ..................................................52
T
Thermal Fuse
Blower Motor ......................................................72
Thermostat .............................................................73
Thermostat Switch ..................................................73
Time Delay Module.................................................42
Torque Converter Output Temperature Sender .....44
Transmission Auto Switch ......................................44
Transmission Electronic Control Module ................44
Transmission Enable Switch ..................................44
Transmission Kick-down Switch .............................44
Transmission Shifter ...............................................44
Transmission Solenoid Valve and Temperature
Sensors .....................................................44
Turbine Speed Sensor............................................44
Turn Signal Switch..................................................79
U
Understanding the Troubleshooting Tables............31
Up/down Count Switch ...........................................52
V
Voltmeter Relay No. 12 ..........................................42
W
Wiper
Front Motor.........................................................67
Front Switch .......................................................68
Front Washer Pump Motor .................................68
Front Washer Switch ..........................................68
Rear Motor .........................................................69
Rear Switch ........................................................69
Rear Washer Pump Motor .................................69
Rear Washer Switch ..........................................69
Bur 6-40782
Revised 6-02
Printed in U.S.A.
Copyright
4002-140
Bur 6-40782
Revised 6-02
Printed in U.S.A.
4002
Copyright
Section
4002
ELECTRICAL SPECIFICATIONS AND
TROUBLESHOOTING
CASE CORPORATION
700 State Street
Bur 6-48930

Printed in U.S.A.
February, 2003
Copyright
NOTES
Copyright
4002-3
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLESHOOTING BATTERIES, ENGINE FUEL SOLENOID, CHARGING, STARTING,
ALTERNATOR, FUEL FILTER HEATER, GRID HEATER, IGNITION SWITCH AND RELAYS . . . . . . . . . . .
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter Heater Relay No. 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter Heater Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second Fuel Filter Heater (621D Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grid Heater Relay No. 15 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grid Heater (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grid Heater Temperature Sensor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grid Heater Controller (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Start Relay No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
37
37
37
38
38
38
39
39
39
39
40
40
40
41
41
41
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER RELAY, AND TIME DELAY
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessory Relay No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltmeter Relay No. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
42
43
43
43
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND SWITCHES, CONTROL MODULE,

SHIFTER, DIAGNOSTIC CONNECTOR, AND BACK-UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Kick-down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FNR Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Alarm Relay No. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
46
46
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-4
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS, PROGRAM/RESET SWITCH,
PARK BRAKE SWITCH, INSTRUMENT CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN
COUNT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program/Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Up/down Count Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
48
48
48
49
49
49
50
50
50
51
53
53
TROUBLESHOOTING ENGINE OIL PRESSURE SWITCH, PILOT CONTROL, PARKING BRAKE, AND
REDUNDANT BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Control Relay No. 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Relay No. 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Brake Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Socket No. 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
55
55
55
56
56
56
57
57
57
TROUBLESHOOTING BUCKET CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Detent Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bucket Control Valve Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Float Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Float Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
59
59
60
60
61
61
61
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE CONTROL . . . . . . . . . . . . . . .

Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Relay No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
63
63
64
64
65
65
66
66
66
TROUBLESHOOTING WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
68
69
69
70
70
70
TROUBLESHOOTING HORN, BLOWER, AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horn Relay No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
71
72
72
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-5
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Low Pressure Switch (In Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C High Pressure Switch (In Rear Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Clutch Lockout Relay No. 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
73
73
73
73
74
74
74
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER OUTLET,

RADIOS AND SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Radio or 24 Volt Radio (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radio Power Converter (24 volts to 12 volts) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
75
76
76
76
76
77
77
77
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD SWITCH,

TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER MODULE . . . . . . . . . . . . . . . . . . . . . . . . .
Beacon Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lamps Relay No. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal, Hi/Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
78
79
79
79
80
80
81
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP SWITCH,

AND CAB LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Five Position Rotary Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High/Low Beam Relay No. 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
83
84
85
86
86
87
87
87
88
88
89
89
89
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-6
NOTES
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage............................................................................................................................................... 24 volts
Batteries
Specifications are the same for production battery and replacement battery.
Production Battery Case P/N ................................................................................................................... A176482
Replacement Battery Case P/N ............................................................................................................... A180406
Group Size .......................................................................................................................................................... 31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17C (0F) for 60 Seconds At 6.0 Volts .................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Plates per Cell ..................................................................................................................................................... 17
Approximate weight with electrolyte ..................................................................................... 25.9 kg (57.1 pounds)
Nonspill caps ............................................................................................................................................ Standard
Alternator ..................................................................................................................................... 24 volt, 45 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20C (68F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20C (68F) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20C (68F) .......................................... 3521 ohms
Coolant and Hydraulic Temperature Sender (Yellow Line) 105C (221F) ................................................. 154 ohms
Coolant and Hydraulic Temperature Sender (Red Line) 110 C (230F) .................................................. 133.9 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Setpoint ............................................................................................................................. 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Setpoint ............................................... 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Setpoint .................................. -6.4 kPa (Gauge) (-0.928 psig)
Brake Warning Pressure Switch (Normally Closed) Opening Setpoint ...................................... 117.2 Bar (1700 psi)
A/C High Pressure Switch (Normally Open) Closing Setpoint..................... 27.6 Bar (400 psi) (increasing pressure)
A/C Low Pressure Switch (Normally Closed) Opening Setpoint .................... 1.4 Bar (20 psi) (decreasing pressure)
Thermostat Switch
Contacts 2 to 3 close at initial turn of the switch. Contacts 1 to 2 close with thermal setting.
Engine Oil Pressure Switch (Normally Closed) Opening Setpoint ................................................... 0.69 Bar (10 psi)
Fuel Solenoid Resistance At 20C (68F) (Nominal) ................................................................................ 12.7 Ohms
Brake Declutch Pressure Switch (Normally Closed) Opening Setpoint............................................. 24 Bar (350 psi)
Redundant Brake Pressure Switches (Normally Open) Closing Setpoint ......................................... 62 Bar (900 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Setpoint....................................................... 4.1 Bar (60 psi)
Float Pressure Switch (Normally Open) Closing Setpoint ................................................................. 19 Bar (275 psi)
Secondary Steering Pressure Switch (Form C) Closing Setpoint ...................................................... 2.4 Bar (35 psi)
Fuel Filter Heater Switch
Opens.................................................................................................................................. 13 3C (55.4 5.4F)
Closes ............................................................................................................................. 1.5 4.5C (34.7 8.1F)
Fuel Filters Heater Resistance At 20 C (68F) (Nominal)............................................................................ 1.9 ohms
Grid Heater Temperature Sensor Resistance At:
80C (176F)................................................................................................................................ 304 to 342 ohms
20C (68F)............................................................................................................................ 2,262 to 2,760 ohms
-10C (14F) ........................................................................................................................ 8,244 to 10,661 ohms
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-8
Parking Brake Solenoid DC Resistance At 20C (68F) (Nominal) ........................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20C (68F) (Nominal) ........................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20C (68F) (Nominal) ...................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20C (68F) (Nominal) .............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20C (68F) (Nominal) ............................................................... 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20C (68F) (Nominal) .................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20C (68F) (Nominal)........................................................... 39.3 ohms
Float Solenoid DC Resistance At 20C (68F) (Nominal) .......................................................................... 39.7 ohms
Rollback Pressure Switch (Normally Closed) Opening Setpoint ........................................................ 6.2 Bar (90 psi)
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-9
ELECTRICAL WIRE IDENTIFICATION

21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
Circuit
5.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Alternator B+
R-13.0-SXL
153 Alternator B+
149 Starter Power
14
Alternator D+
LG-1.0-SXL
94M Engine Trans
154 Alternator
30
Alternator B+
R-1.0-SXL
153 Alternator B+
154 Alternator
44
T-1.0-SXL
159 Brake Lt Press Sw
21M Rear Cab
29
52
Fan Reverse Sol
W-1.0-SXL
158 Fan Rev Sol Opt
21M Rear Cab
27
57
Pin Engage Sol Pwr
W-1.0-SXL
1 Cab-Frnt Chas
107M Pin Engage Opt
58
Ride Cntrl Sol Pwr
W-1.0-SXL
1 Cab-Frnt Chas
64
Horn
Or-1.0-SXL
1 Cab-Frnt Chas
147 Horn Pwr
0_A
Ground
Bk-1.0-SXL
125 LH Rear Comb Lt
SPL_E4 SPL_E4
0_AA
Height-RTT Grnd
Bk-1.0-SXL
10 Height Cntrl-RTT
SPL_A2 Splice A2
SPL_A2
0_AB
Pin Engage Grnd
Bk-1.0-SXL
107M Pin Engage Opt
SPL_A1 Splice A1
SPL_A1
0_AC
Ride Cntrl Grnd
Bk-1.0-SXL
5F Ride Control Opt
SPL_A1 Splice A1
SPL_A1
0_AD
Horn Grnd
Bk-1.0-SXL
146 Horn Grnd
SPL_A1 Splice A1
SPL_A1
0_AF
RTD Grnd
Bk-1.0-SXL
12F RTD
SPL_A2 Splice A2
SPL_A2
0_AG
Lights Grnd RH
Bk-1.0-SXL
8 Lights RH
SPL_A1 Splice A1
SPL_A1
0_AH
Grnd Frnt Chas
Bk-5.0-SXL
144 Grnd Rear Chas
143 Grnd Frnt Chas
0_AJ
Grnd Cab
Bk-2.0-SXL
145 Grnd Cab
SPL_A1 Splice A1
SPL_A1
0_AK
Grnd Cab
Bk-1.0-SXL
145 Grnd Cab
SPL_A2 Splice A2
SPL_A2
0_AL
Lights Grnd LH
Bk-1.0-SXL
6 Lights LH
SPL_A1 Splice A1
SPL_A1
0_AM
RTD Grnd
Bk-1.0-SXL
12M RTD
200 RTD
0_AN
Sec Str Signal Grd
Bk-1.0-SXL
0_AP
Splice
Bk-1.0-SXL
SPL_A6 SPL_A6
0_AQ
Ground
Bk-1.0-SXL
229M Diode Module
0_AR
Splice
Bk-1.0-SXL
SPL_A2 Splice A2
0_BA
Signal Grnd
Bk-1.0-SXL
150 Signal Grnd
SPL_B1
0_BC
Grid Htr Temp Sensor Grnd
Bk-1.0-SXL
290 Grid Htr Temperature Sw
165 Engine Grnd
0_BD
Air Filter Rest Sw Grnd
Bk-1.0-SXL
SPL_B1
0_BE
Eng Cool Temp Ground
Bk-1.0-SXL
138 Eng Cool Temp
SPL_B1
0_BF
Signal Ground
Bk-1.0-SXL
94M Engine Trans
SPL_B1
Bur 6-48930
SPL_A6 179F Float Solenoid

C
SPL_A7
SPL_A6 SPL_A6
SPL_A6
SPL_A2 SPL_A6 SPL_A6
SPL_A6
Issued 2-03
Printed in U.S.A.
Copyright
4002-10
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_BG
Analog Ground
Bk-1.0-SXL
94M Engine Trans
15
152 Analog Grnd
0_BH
Signal Ground
Bk-1.0-SXL
94M Engine Trans
11
SPL_B1
0_BJ
Ground
Bk-1.0-SXL
268 AC Diode Ground
265F Diode Module
0-BK
Fuel Filter Heater Grnd
Bk-2.0-SXL
287 Fuel Filter Heater
151 Solenoid Ground
0-BL
Fuel Solenoid Grnd
Bk-2.0-SXL
151 Solenoid Grnd
0-BM
Fuel Solenoid Grnd
Bk-1.0-SXL
289 Fuel Filter Temp Sw
151 Solenoid Grnd
0_C
Ground
Bk-1.0-SXL
127 RH Rear Comb Lt
SPL_E4 SPL_E4
0_CA
Sec Str Signal Grd
Bk-1.0-SXL
90M Sec Str Mod
11
SPL_C1
0_CB
Sec Str Signal Grd
Bk-1.0-SXL
90M Sec Str Mod
12
SPL_C1
0_CC
Sec Str Signal Grd
Bk-1.0-SXL
SPL_C1
0_CD
Sec Str Signal Grd
Bk-1.0-SXL
177 Sec Str Mod Sig Grnd
SPL_C1
0_CE
Sec Str Chassis Grnd
Bk-1.0-SXL
90M Sec Str Mod
176 Sec Str Mod Chas Grnd
0_CF
Sec Str Grnd
Bk-1.0-SXL
264M Sec Str Sol Opt
SPL_C1
0_D
Hood Ground
Bk-2.0-SXL
164 Engine Grounds
SPL_E4 SPL_E4
0_DA
Bk-0.8-SXL
204F Relay Ac
85
220F Ground Cab
0_DAB Signal Ground
Bk-0.8-SXL
15
13F Cab-Pedestal
38
0_DAC Relay Grnd
Bk-0.8-SXL
13F Cab Pedestal
53
222F Ground Cab
0-DAD
Bk-1.0-SXL
222F Ground Cab
SPL_D13 Ground
0_DAE Ground
Bk-1.0-SXL
SPL_D13 Ground
0_DAF Switch Grnd
Bk-1.0-SXL
40F Pin Engage Sw
0_DAG Switch Grnd
Bk-1.0-SXL
SPL_D13 Ground
0_DAH Switch Grnd
Bk-1.0-SXL
0_DAJ
Switch Grnd
Bk-1.0-SXL
36F Detent Switch
0_DAK Switch Grnd
Bk-1.0-SXL
36F Detent Switch
38F Declutch Switch
0_DAL
Switch Grnd
Bk-1.0-SXL
40F Pin Engage Sw
44F Ride Control Sw
0_DAM Switch Grnd
Bk-1.0-SXL
44F Ride Control Sw
41F Trans Auto Sw
0_DAN Flasher Module Grnd
Bk-0.8-SXL
62M Flasher Module
0_DAP Ground
Bk-1.0-SXL
42F Beacon Sw
0_DAQ Flasher Module Grnd
Bk-0.8-SXL
62M Flasher Module
0_DAR Blwr Wiper Seat Grnd
Bk-1.0-SXL
218F Ground Cab
0_DAS Time Delay Mod Grnd
Bk-0.8-SXL
Relay Grnd
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-11
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_DAT Brk Lt Time Del Horn Grnd
Bk-0.8-SXL
220F Ground Cab
0_DAU Analog Ground
Bk-0.8-SXL
30
13F Cab-Pedestal
0_DAV Diag TECM Grnd
Bk-0.8-SXL
221F Ground Cab
0_DAW Ground
Bk-1.0-SXL
42F Beacon Sw
0_DAX Beacon Wiper Diode Grnd
Bk-0.8-SXL
140M Diode Module
0_DAY Switch Grnd
Bk-1.0-SXL
SPL_D13 Ground
0_DB
Can Pilot Sol Grnd
Bk-0.8-SXL
89M Pilot Pres Sol
219F Ground Cab
0-DBA
Grid Heater Lamp Grnd
Bk-0.8-SXL
13F Cab Pedestal
11
219F Ground Cab
0-DBB
Ground
Bk-0.8-SXL
201 Grid Htr Controller
202 Radio Ground
0_DC
Ac Brk Lt Time Delay Horn Grnd
Bk-0.8-SXL
204F Relay Brake Lamps
85
49F Accessory Relay
85
0_DD
Ride Cntrl Relay Sink
Bk-0.8-SXL
19F TECM
57
85
0_DE
Relay Grnd
Bk-0.8-SXL
85
85
0_DF
Relay Grnd
Bk-0.8-SXL
49F Accessory Relay
85
85
0_DG
Ac Brk Lt Time Delay Horn Grnd
Bk-0.8-SXL
204F Relay Brake Lamps
85
85
0_DH
Relay Grnd
Bk-0.8-SXL
85
85
0_DJ
Relay Grnd
Bk-0.8-SXL
85
222F Ground Cab
0_DL
Signal Ground
Bk-0.8-SXL
23
13F Cab-Pedestal
39
0_DM
Speed Sensor Grounds
Bk-0.8-SXL
19F TECM
11
0_DN
Out Speed Sensor Grnd
Bk-0.8-SXL
19F TECM
28
0_DP
Diag TECM Grnd
Bk-0.8-SXL
19F TECM
221F Ground Cab
0_DQ
Diag TECM Grnd
Bk-0.8-SXL
19F TECM
221F Ground Cab
0_DR
Bk-1.0-SXL
24M Cab Roof
223F Ground Cab
0_DS
Bk-1.0-SXL
24M Cab Roof
223F Ground Cab
0_DT
Bk-1.0-SXL
23F Cab Roof
223F Ground Cab
0_DU
Bk-1.0-SXL
23F Cab Roof
0_DV
Bk-0.8-SXL
13F Cab-Pedestal
61
0_DW
Ground
Bk-0.8-SXL
45F Rear Wiper Sw
0_DX
Horn Ground
Bk-0.8-SXL
13F Cab-Pedestal
41
220F Ground Cab
0_DY
Bk-1.0-SXL
28M Seat Comp Motor
218F Ground Cab
0_DZ
Bk-2.0-SXL
29M Blower Motor
218F Ground Cab
0_E
Bk-1.0-SXL
160 Engine Grounds
171 Fuel Sender Grnd
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-12
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_F
Bk-1.0-SXL
162 Engine Ground
3 Rear Washer
0_G
Bk-1.0-SXL
2 Front Washer
162 Engine Ground
0_HA
Signal Ground
Bk-1.0-SXL
23
94F Eng-Trans
0_HB
Signal Ground
Bk-1.0-SXL
15
94F Eng-Trans
11
0_HC
Analog Ground
Bk-1.0-SXL
30
94F Eng-Trans
15
0_HD
Speed Sense Grnd
Bk-1.0-SXL
11
SPL_H2 Splice H2
0_HE
Out Speed Grnd
Bk-1.0-SXL
28
100 Out Speed Sens
0_HF
Eng Speed Grnd
Bk-0.8-BLD
101 Eng Speed Sense
SPL_H2 Splice H2
Splice
0_HG
Int Speed Sig
Bk-0.8-BLD
95 Int Speed Sense
SPL_H2 Splice H2
Splice
0_HH
Turb Speed Grnd
Bk-0.8-BLD
96 Turb Speed Sense
SPL_H2 Splice H2
Splice
0_J
Hood Ground
Bk-1.0-SXL
164 Engine Grounds
128F Rear-Hood
0_JA
Hood Ground
Bk-1.0-SXL
SPL_J1 SPL_J1
0_JB
Backup Alarm Grnd
Bk-1.0-SXL
174 Backup Alarm Grnd
SPL_J1 SPL_J1
0_JC
Lic Plate Lt Grnd
Bk-1.0-SXL
168 Lic Plate Light
SPL_J1 SPL_J1
0_KD
Signal Grnd
Bk-0.8-SXL
39
13M Pedestal-Cab
39
0_KE
Signal Grnd
Bk-0.8-SXL
38
SPL_K1 SPL_K1
0_KF
Bk-0.8-SXL
187 High Low Beam
185 Horn Switch
0_KG
Bk-0.8-SXL
13M Pedestal-Cab
41
185 Horn Switch
0_KH
Pilot Light Grnd
Bk-0.8-SXL
71 Hazard Switch
0_KJ
Pilot Light Grnd
Bk-0.8-SXL
0_KK
Pilot Light Grnd
Bk-0.8-SXL
0_KL
Pilot Light Grnd
Bk-0.8-SXL
0_KM
Pilot Light Grnd
Bk-0.8-SXL
13M Pedestal-Cab
53
0_KN
Front Wiper Grnd
Bk-0.8-SXL
13M Pedestal-Cab
61
0_KP
Analog Grnd
Bk-0.8-SXL
13M Pedestal-Cab
0_KQ
Signal Grnd
Bk-0.8-SXL
37
SPL_K1 SPL_K1
0_KR
Signal Grnd
Bk-0.8-SXL
13M Pedestal-Cab
38
SPL_K1 SPL_K1
0_L
Ground
Bk-1.0-SXL
SPL_E9 SPL_E9
0_M
Ground
Bk-1.0-SXL
SPL_E9 SPL_E9
0_MA
Rear Wiper Mtr Grnd
Bk-1.0-SXL
82M Rear Wiper Mtr
0_MB
Dome Lt Grnd
Bk-0.8-SXL
84F Dome Light
Bur 6-48930
Issued 2-03
Splice
1
Printed in U.S.A.
Copyright
4002-13
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0_MC
Beacon Light Ground
Bk-1.0-SXL
85F Beacon Light
0_MD
Beacon-Rear Wiper Grnd
Bk-1.0-SXL
23M Roof-Cab
0_ME
LH Rear Work Lt Grnd
Bk-1.0-SXL
83F LH Rear Work Lt
0_MF
RH Rear Work Lt Grnd
Bk-1.0-SXL
80F RH Rear Work Lt
0_MG
Rear Work Light Grnd
Bk-1.0-SXL
23M Roof-Cab
0_MH
LH Frnt Work Lt Grnd
Bk-1.0-SXL
0_MJ
RH Frnt Work Lt Grnd
Bk-1.0-SXL
0_MK
Frnt Work Lt Grnd
Bk-1.0-SXL
24F Roof-Cab
0_ML
Courtesy Lt Grnd
Bk-0.8-SXL
77F Courtesy Lt
0_MM
Dome Lt Grnd
Bk-0.8-SXL
84F Dome Light
84F Dome Light
0_MN
Dome Courtesy Lt Grnd
Bk-0.8-SXL
24F Roof-Cab
0_N
Brk Warn Pr Sw
Bk-1.0-SXL
88 Brk Warn Pr Sw
SPL_E9 SPL_E9
0_NA
Chas Grnd Blck Grnd
Bk-62.0-SGR
0_NB
Discon-Blck Grnd
Bk-62.0-SGR
0_NC
Disconnect Battery
Bk-62.0-SGR
237F Disconnect Battery
236F Disconnect Battery
0_ND
Chas Grnd-Sec Strg Mtr
Bk-62.0-SGT
0_P
Bk-1.0-SXL
160 Engine Grounds
SPL_E9 SPL_E9
0_PA
Left Spkr Ground
Bk-0.8-SXL
114F
112M
0_PB
Right Spkr Ground
Bk-0.8-SXL
114F
111M
0_PC
Radio Ground
Bk-0.8-SXL
114F
0_PD
Radio Ground
Bk-1.0-SXL
247F Radio Ground
0_Q
Bk-1.0-SXL
87 Parking Brk Sol
165 Engine Ground
0_QA
Left Spkr Ground
Bk-0.8-SXL
114M
113 Radio
0_QB
Right Spkr Ground
Bk-0.8-SXL
114M
113 Radio
0_QC
Radio Ground
Bk-0.8-SXL
114M
113 Radio
0_RA
Converter Ground
Bk-5.0-SXL
0_RB
Outlet Ground
Bk-3.0-SXL
252F Outlet Ground
253F Power Outlet
0_S
Cigar Lighter Grnd
Bk-3.0-SXL
261F Cigar Lighter Grnd
259F Cigar Lighter
0_U
Splice
Bk-2.0-SXL
SPL_G1 Splice G1
165 Engine Ground
0_UA
Grid Heater Feedback
Bk-2.0-SXL
276F Grid Heater Relay
SPL_G1 Splice G1
0_UB
Starter Relay Ground
Bk-2.0-SXL
132 Starter Relay
SPL_G1 Splice G1
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-14
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
0_UC
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Bk-2.0-SXL
276M Relay Rear
279M Grid Heater Relay
0_V
Bk-1.0-SXL
160 Engine Grounds
0_VA
Y-0.8-SOLID
274F Cool Jmpr Rear Chsis
0_W
Bk-1.0-SXL
162 Engine Ground
0_X
Fan Rev Sol Grd
Bk-1.0-SXL
158 Fan Rev Sol Opt
163 Engine Ground
0_Y
Engine Cab Grd
Bk-13.0-SXL
161 Engine Ground
167 Engine Cab Grnd
12K_A
Acc Power
Or-1.0-SXL
49F Accessory Relay
86
18F Fuse Block
M1
12K_B
Acc Power
Or-0.8-SXL
49F Accessory Relay
86
13F Cab-Pedestal
63
12K_C
Ign Sw Acc Pwr
Or-0.8-SXL
13M Pedestal-Cab
63
69 Ignition Switch
12P_A
Acc Relay
Or-1.0-SXL
49F Accessory Relay
87
18F Fuse Block
L1
12P_B
Acc Relay
Or-1.0-SXL
18F Fuse Block
N1
18F Fuse Block
L1
12V_A
12V Pwr To Outlet
R-3.0-SXL
257F 12V Pwr To Outlet
253F Power Outlet
12V_B
12V Pwr To Fuse Blck
R-5.0-SXL
258F 12V Pwr To Fuse Blck
18F Fuse Block
13C
Fuel Sol
Or-1.0-SXL
94M Engine Trans
SPL_B2 B+ Power
13C_A
Fuel Sol
Or-1.0-SXL
94F Eng-Trans
13C_B
Fuel Sol Pwr
Or-0.8-SXL
87
217M Engine Shutdown Jumper
13C_C
Fuel Sol Pwr
Or-0.8-SXL
87
140M Diode Module
13C_D
Fuel Sol Pwr
Or-0.8-SXL
87
13C_E
Fuel Sol Pwr
Or-1.0-SXL
13C_F
Disconnect Fuel Filter Heater
Or-1.0-SXL
SPL_B2 B+ Power
139F Disconnect Harness
13C_G Disconnect Fuel Filter Heater
Or-1.0-SXL
SPL_B2 B+ Power
277F Engine Relay
13C_H
Fuel Filter Heater Signal Power
Or-1.0-SXL
280 Fuel Filter Heater Relay
86
277M Relay Engine
13D
Delay Pwr (2 Way)
Or-1.0-SXL
18F Fuse Block
S1
13K
Ignition Switch Pwr
Or-0.8-SXL
13M Pedestal-Cab
56
69 Ignition Switch
13K_A
Ignition Switch Pwr
Or-1.0-SXL
86
86
13K_B
Ignition Switch Pwr
Or-1.0-SXL
86
30
13K_C
Ignition Switch Pwr
Or-1.0-SXL
86
30
13K_D
Ignition Switch Pwr
Or-0.8-SXL
30
217F Engine Shutdown Jumper
13K_E
Ignition Switch Pwr
Or-0.8-SXL
86
13K_F
Ignition Switch Pwr
Or-0.8-SXL
13K_G Ignition Switch Pwr
Or-0.8-SXL
13F Cab-Pedestal
56
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-15
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
13M
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Fuel Sol Hold In
Or-1.0-SXL
139F Disc Harness
133M Fuel Solenoid
13M_A Fuel Sol Hold In
Or-1.0-SXL
13P_A
Ign Rel 1 Out
Or-1.0-SXL
87
18F Fuse Block
A1
13P_B
Ign Rel 1 Out
Or-1.0-SXL
87
18F Fuse Block
P1
13R
Ign Rel 2 Out (5 Way)
Or-1.0-SXL
87
18F Fuse Block
F1
13V
Voltmeter Relay Out
Or-1.0-SXL
87
18F Fuse Block
V1
14
Alternator D+
LG-1.0-SXL
154 Alternator
94M Eng-Trans
14_A
Alternator D+
LG-1.0-SXL
94F Eng-Trans
14_B
Alternator D+
LG-0.8-SXL
14_C
Alternator D+
LG-0.8-SXL
201 Grid Heater Controller
18A
Rear Fld Lts Fuse Pwr
Or-2.0-SXL
32F Light Switch
18F Fuse Block
18B
High Beam LH
Or-1.0-SXL
1 Cab-Frnt Chas
6 Lights LH
18B_A
High Beam LH
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
18C
High Beam RH
Or-1.0-SXL
1 Cab-Frnt Chas
8 Lights RH
18C_A
High Beam Fused Pwr
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
C2
18C_B
High Beam Fused Pwr
Or-0.8-SXL
13F Cab-Pedestal
15
18F Fuse Block
C2
18C_C
High Beam Telltale
Or-0.8-SXL
15
13M Pedestal-Cab
15
18D
Low Beam LH
Or-1.0-SXL
1 Cab-Frnt Chas
6 Lights LH
18D_A
Low Beam LH
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
18E
Low Beam RH
Or-1.0-SXL
1 Cab-Frnt Chas
8 Lights RH
18E_A
Low Beam RH
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
Position LH
Or-1.0-SXL
1 Cab-Frnt Chas
6 Lights LH
18F_A
Left Tail
Or-1.0-SXL
125 LH Rear Comb Lt
21M Rear-Cab
18F_D
Left Tail Pos
Or-0.8-SXL
21F Cab-Rear
18F Fuse Block
F2
18F_E
Left Tail Pos
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
F2
18G
Position RH
Or-1.0-SXL
1 Cab-Frnt Chas
8 Lights RH
18G_A Right Tail
Or-1.0-SXL
127 RH Rear Comb Lt
SPL_E8 SPL_E8
18G_C Lic Plate Light
Or-1.0-SXL
128F Rear-Hood
SPL_E8 SPL_E8
18G_D RH Tail Lic Lts
Or-1.0-SXL
21M Rear-Cab
SPL_E8 SPL_E8
18G_E Lic Plate Light
Or-1.0-SXL
168 Lic Plate Light
18G_F
Or-0.8-SXL
21F Cab-Rear
18F Fuse Block
18F
RH Tail Lic Lts
Bur 6-48930
Issued 2-03
A2
3
B2
3
D2
2
E2
G2
Printed in U.S.A.
Copyright
4002-16
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
18G_G Position RH
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
18L_C
Indicator Lamp
Or-0.8-SXL
13F Cab Pedestal
18L_D
Grid Heater Lamp
Bk-0.8-SXL
13M Pedestal Cab
97 Preheater Lamp
18_H
Radio Power
Or-0.8-SXL
113 Radio
19A
Out Speed Power
Or-1.0-SXL
29
100 Out Speed Sens
19A_A
Declutch Switch
Or-1.0-SXL
4 Dec Press Sw
21M Rear-Cab
30
19A_B
FNR Switched Pwr
Or-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
19A_C
Trans Ena Sw Pwr
Or-0.8-SXL
197F Main Cab FNR
10
19A_D
Trans Ena Sw Pwr
Or-0.8-SXL
SPL_D15
19A_E
Trans Ena Sw Pwr
Or-0.8-SXL
10
19A_F
FNR Switched Pwr
Or-0.8-SXL
198 FNR Switch
198 FNR Switch
19A_G Trans Control Pwr
Or-0.8-SXL
13M Pedestal-Cab
43
19A_H
Trans Control Pwr
Or-0.8-SXL
19A_K
Cab Switched Pwr
Or-0.8-SXL
19F TECM
45
SPL_D15
19A_L
Cab Switched Pwr
Or-0.8-SXL
SPL_D15
19A_M Cab Switched Pwr
Or-0.8-SXL
29
SPL_D15
19A_N
Cab Switched Pwr
Or-0.8-SXL
18F Fuse Block
A2
SPL_D15
19A_P
Cab Switched Pwr
Or-0.8-SXL
86
18F Fuse Block
A2
19A_Q Cab Switched Pwr
Or-0.8-SXL
41F Trans Auto Sw
SPL_D15
19A_R
Cab Switched Pwr
Or-0.8-SXL
38F Declutch Switch
SPL_D15
19A_S
Cab Switched Pwr
Or-0.8-SXL
13F Cab-Pedestal
43
SPL_D15
19A_T
Cab Switched Pwr
Or-0.8-SXL
21F Cab-Rear
30
SPL_D15
19A_U
Cab Switched Pwr
Or-0.8-SXL
20M Trans Kick-Down
SPL_D15
19B
Turn Signal Power
Or-0.8-SXL
13M Pedestal-Cab
66
19B_A
Turn Signal Power
Or-0.8-SXL
13F Cab-Pedestal
66
18F Fuse Block
B2
19C
Or-0.8-SXL
13M Pedestal-Cab
68
19C_A
Or-1.0-SXL
18F Fuse Block
C2
19C_B
Ride Ctrl Fused Pwr
Or-1.0-SXL
44F Ride Control Sw
19C_C
Ride Ctrl Fused Pwr
Or-0.8-SXL
13F Cab-Pedestal
68
19C_D
Or-1.0-SXL
30
18F Fuse Block
C2
19C_E
Or-1.0-SXL
30
86
Bur 6-48930
Issued 2-03
G2
Printed in U.S.A.
Copyright
4002-17
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
19D_A
Or-1.0-SXL
30
18F Fuse Block
D2
19D_B
Or-1.0-SXL
30
86
19E
Switched Power
Or-1.0-SXL
18F Fuse Block
E2
19F
Eng Shtdwn Rel Fused Pwr
Or-1.0-SXL
86
18F Fuse Block
F2
19G
Blower Switch Fused Pwr
Or-2.0-SXL
30F Blower Switch
18F Fuse Block
G2
19H
Backup Alarm Rel Fuse Pwr
Or-1.0-SXL
30
18F Fuse Block
H2
19J
Or-0.8-SXL
13M Pedestal-Cab
60
19J_A
Or-1.0-SXL
18F Fuse Block
J2
19J_B
Or-0.8-SXL
13F Cab-Pedestal
60
19K_A
Or-1.0-SXL
18F Fuse Block
K2
19K_B
Or-1.0-SXL
23F Cab-Roof
19K_C
Or-1.0-SXL
45F Rear Wiper Sw
19K_D
Or-0.8-SXL
45F Rear Wiper Sw
19K_E
Rear Wip Wshr Fused Pwr
Or-1.0-SXL
23M Roof-Cab
81M Rear Wiper Mtr
19L
Access To Fuse L (3 Way)
Or-1.0-SXL
18F Fuse Block
L2
18F Fuse Block
19L_A
Radio Power
Or-1.0-SXL
246M Radio Power
19L_B
Converter Pwr Ign
Or-1.0-SXL
249M Converter Pwr Ign
256F Converter Pwr Ign
19M_A Sec Str Accessory
Or-0.8-SXL
1F Cab-Frnt Chas
18F Fuse Block
M2
19M_B Sec Str Accessory
Or-1.0-SXL
1 Cab-Frnt Chas
19M_C Sec Str Accessory
Or-1.0-SXL
90M Sec Str Mod
19N_A
28M Seat Comp Motor
18F Fuse Block
N2
19N_B
18F Fuse Block
N2
18F Fuse Block
19P_A
Or-1.0-SXL
40F Pin Engage Sw
18F Fuse Block
P2
19P_B
Or-1.0-SXL
40F Pin Engage Sw
19R_A
Sec Str Ignition
Or-0.8-SXL
1F Cab-Frnt Chas
SPL_D25 SPL_D25
Splice
19R_B
Sec Str Ignition
Or-1.0-SXL
1 Cab-Frnt Chas
19R_C
Sec Str Ignition
Or-1.0-SXL
90M Sec Str Mod
19R_D
Sec Strg Ignition
Or-0.8-SXL
SPL_D25 SPL_D25
Splice
262F Diode Module
19R_E
Cab Switched Pwr
Or-0.8-SXL
SPL_D25 SPL_D25
Splice
19R_F
Sec Strg Ignition
Or-0.8-SXL
262F Diode Module
18F Fuse Block
R2
Or-0.8-SXL
13F Cab-Pedestal
18F Fuse Block
S2
19S
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-18
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
19S_A
Or-0.8-SXL
13M Pedestal-Cab
19S_B
Or-0.8-SXL
19T_A
Or-0.8-SXL
19F TECM
23
18F Fuse Block
T2
19T_B
Or-0.8-SXL
19F TECM
68
18F Fuse Block
T2
19U_A
Or-1.0-SXL
23F Cab-Roof
18F Fuse Block
U2
19U_B
Or-1.0-SXL
51F Horn Relay
30
18F Fuse Block
U2
19U_C
Or-0.8-SXL
51F Horn Relay
86
51F Horn Relay
30
19U_D
Dome Lt Fused Pwr
Or-1.0-SXL
23M Roof-Cab
84F Dome Light
Or-0.8-SXL
13F Cab-Pedestal
18F Fuse Block
V2
Cluster Main Fused Pwr
Or-0.8-SXL
13M Pedestal-Cab
Cigarette Lighter Fused Pwr
Or-1.0-SXL
18F Fuse Block
18F Fuse Block
16
Or-3.0-SXL
259F Cigar Lighter
260M Cigar Lighter Pwr
19V
19V_A
19W
19W_A Cigar Lighter Pwr
W2
19X
Beacon Sw Fused Pwr
Or-1.0-SXL
42F Beacon Sw
18F Fuse Block
X2
19Z
Frnt Flood Illum Fused Pwr
Or-1.0-SXL
34F Light Switch
18F Fuse Block
Z2
1A_A
R-0.8-SXL
13M Pedestal-Cab
62
69 Ignition Switch
1A_B
R-0.8-SXL
69 Ignition Switch
1A_C
R-0.8-SXL
13F Cab-Pedestal
62
SPL_D21 CB A Load
1A_D
CB A Load
R-0.8-SXL
SPL_D21 CB A Load
1A_E
Time Delay Pwr
R-0.8-SXL
SPL_D21 CB A Load
Hazard Switch Pwr
R-0.8-SXL
13M Pedestal-Cab
65
71 Hazard Switch
1B_A
Brake Lt Sw Pwr
R-1.0-SXL
159 Brake Lt Pres Sw
21M Rear-Cab
28
1B_B
Flasher Module Pwr
R-0.8-SXL
62M Flasher Module
SPL_D19 CB B Load
1B_C
Hazard Switch Power
R-0.8-SXL
13F Cab-Pedestal
65
SPL_D19 CB B Load
1B_D
CB B Load
R-0.8-SXL
21F Cab-Rear
28
1B_E
Brake Lt Relay Pwr
R-0.8-SXL
30
SPL_D19 CB B Load
1B_F
CB B Load
R-0.8-SXL
SPL_D19 CB B Load
1Y
Fuel Filter Heater Relay Power
R-8.0-SXL
283 Fuel Filter Heater Fuse
278 J Block Power
1Y_A
Fuel Filter Heater Relay Power
R-8.0-SXL
281 Fuel Filter Heater Fuse
87
1Y_B
Fuel Filter Heater Power
R-2.0-SXL
277F Engine Relay
1Y_C
R-2.0-SXL
277F Engine Relay
1Y_D
R-2.0-SXL
277M Relay Engine
30
1B
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-19
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
1Y_E
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
K = Pink
U = Blue
Y = Yellow
To Connector
Connector
Cavity
Connector
Cavity
R-2.0-SXL
30
277M Relay Engine
1Z
Grid Heater Power
R-19.0-SGT
137 Grid Heater Relay
285 Grid Heater
1_A
B+
R-1.0-SXL
21M Rear-Cab
21
156 Fuel Str Rel B+
1_B
B+
R-13.0-SXL
156 Fuel Str Rel B+
155 Cab Power B+
1_C
Grid Heater Relay Pwr
R-8.0-SXL
190 Jblock Power
191 Jblock-Relay
1_D
R-19.0-SGT
284 Jblock Power
282 Grid Heater Fuse
1_DA
R-19.0-SGT
189 Jblock Power
192 Jblock Relay
1_E
Starter Battery
R-62.0-SGR
240F Starter Battery
195 Jblock Power
1_F
Starter Sol Pwr
R-8.0-GPT
193 Starter Relay
194 Starter Signal
1_G
Acc Relay Pwr
R-3.0-SXL
49F Accessory Relay
30
SPL_D16 B+ Power
1_H
R-3.0-SXL
59F High/Low Beam
SPL_D16 B+ Power
1_J
B+ Pwr
R-3.0-SXL
228F Power Cab
SPL_D17 B+ Power
1_K
B+ Pwr
R-3.0-SXL
226F Power Cab
SPL_D16 B+ Power
1_L
CB A Power
R-3.0-SXL
SPL_D17 B+ Power
1_M
CB B Power
R-3.0-SXL
SPL_D17 B+ Power
1_N
Light Sw Power
R-3.0-SXL
33F Light Switch
224F Power Cab
1_NA
Battery Crossover
R-62.0-SGR
239 Discon-Blck Grnd
238F Battery Crossover
1_NB
Starter-Battery
R-62.0-SGR
1_NC
Starter-Sec Strg Mtr
R-62.0-SGR
1_P
Voltmeter Rel Pwr
R-0.8-SXL
30
21F Cab-Rear
21
1_Q
Dome Lt Horn Pwr
R-1.0-SXL
18F Fuse Block
U1
SPL_D16 B+ Power
1_R
Cigar Lighter Pwr
R-3.0-SXL
18F Fuse Block
W1
227F Power Cab
1_S
Ign Relay #1 Pwr
R-3.0-SXL
30
SPL_D17 B+ Power
1_T
Ign Relay #2 Pwr
R-3.0-SXL
30
SPL_D17 B+ Power
1_U
B+ Power (4 Way)
R-3.0-SXL
18F Fuse Block
Z1
225F Power Cab
1_V
Converter 24V Pwr
R-5.0-SXL
1_W
Sec Strg Mtr B+
R-1.0-SXL
263F Sec Str Mtr
90M Sec Str Mod
1_X
Radio Memory Power
R-1.0-SXL
270F Radio Memory Power
21C_D
W-1.0-SXL
135 Starter Relay
21M Rear-Cab
11
21C_E
W-0.8-SXL
87
21F Cab-Rear
11
21C_F
W-0.8-SXL
87
140M Diode Module
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-20
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
21C_G Cranking Power
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
W-0.8-SXL
87
21K
Ign Sw Start Signal
W-0.8-SXL
13M Pedestal-Cab
64
69 Ignition Switch
21K_A
Ign Sw Start Signal
W-0.8-SXL
30
13F Cab-Pedestal
64
23C
W-0.8-SXL
23
13M Pedestal-Cab
23
23C_A
W-0.8-SXL
85
13F Cab-Pedestal
23
25A
Eng Speed Sig
W-0.8-BLD
101 Eng Speed Sens
25A_A
Eng Speed Sig
LU-0.8-SXL
19F TECM
19
25B
Turb Speed Sig
W-0.8-BLD
96 Turb Speed Sens
25B_A
Turb Speed Sig
LU-0.8-SXL
19F TECM
41
25C
Int Speed Sig
W-0.8-BLD
95 Int Speed Sens
25C_A
Int Speed Sig
LU-0.8-SXL
19F TECM
42
25D
Output Speed Sig
LU-1.0-SXL
10
100 Out Speed Sens
25D_A
Output Speed Sig
LU-0.8-SXL
19F TECM
62
10
25F
Forward Signal
LU-0.8-SXL
13M Pedestal-Cab
44
25F_A
Forward Signal
LU-0.8-SXL
19F TECM
43
13F Cab-Pedestal
44
25G
Declutch Switch
LU-1.0-SXL
4 Declutch Press Sw
21M Rear-Cab
31
25G_A Declutch Switch
LU-0.8-SXL
38F Declutch Switch
21F Cab-Rear
31
25G_B Declutch Switch
LU-0.8-SXL
19F TECM
66
38F Declutch Switch
25H
Trans Auto Signal
LU-0.8-SXL
19F TECM
29
41F Trans Auto Sw
25J
Trans Sol Valve Y6
LU-0.8-TXL
21
102 Trans Control
25J_A
Trans Sol Valve Y6
LU-0.8-SXL
19F TECM
51
21
25K
Trans Sol Valve Y1
LU-0.8-TXL
16
102 Trans Control
25K_A
Trans Sol Valve Y1
LU-0.8-SXL
19F TECM
56
16
25L
Trans Sol Valve Y2
LU-0.8-TXL
17
102 Trans Control
25L_A
Trans Sol Valve Y2
LU-0.8-SXL
19F TECM
10
17
25M
Trans Sol Valve Y3
LU-0.8-TXL
18
102 Trans Control
25M_A Trans Sol Valve Y3
LU-0.8-SXL
19F TECM
32
18
25N
Trans Sol Valve Y4
LU-0.8-TXL
19
102 Trans Control
25N_A
Trans Sol Valve Y4
LU-0.8-SXL
19F TECM
55
19
25P
Trans Sol Valve Y5
LU-0.8-TXL
20
102 Trans Control
25P_A
Trans Sol Valve Y5
LU-0.8-SXL
19F TECM
20
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-21
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
25R
Reverse Signal
LU-0.8-SXL
13M Pedestal-Cab
45
25R_A
Reverse Signal
LU-0.8-SXL
19F TECM
64
13F Cab-Pedestal
45
25S
LU-0.8-TXL
22
102 Trans Control
25S_A
LU-0.8-SXL
22
25S_B
LU-0.8-SXL
19F TECM
12
25S_C
LU-0.8-SXL
19F TECM
13
25T_A
Neutral Signal
LU-0.8-SXL
92 Ether Switch
25T_B
Neutral Signal
LU-0.8-SXL
13M Pedestal-Cab
46
92 Ether Switch
25T_C
Neutral Signal
LU-0.8-SXL
13F Cab-Pedestal
46
25T_D
Neutral Signal
LU-0.8-SXL
19F TECM
67
25T_E
Neutral Signal
LU-0.8-SXL
86
3rd And 4th Gear Signal
LU-0.8-SXL
13M Pedestal-Cab
48
25W_A 3rd And 4th Gear Signal
LU-0.8-SXL
19F TECM
65
13F Cab-Pedestal
48
25W
25Y
LU-0.8-SXL
13M Pedestal-Cab
50
25Y_A
LU-0.8-SXL
13F Cab-Pedestal
50
25Y_B
Trans Kickdown Sig
LU-0.8-SXL
19F TECM
22
25Y_C
LU-0.8-SXL
20M Trans Kick-Down
25Z
LU-0.8-SXL
13M Pedestal-Cab
49
25Z_A
LU-0.8-SXL
19F TECM
63
13F Cab-Pedestal
49
26E
Trans Enable Signal
LU-0.8-SXL
19F TECM
31
26F_A
FNR Forward Signal
LU-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
26F_B
FNR Forward Signal
LU-0.8-SXL
19F TECM
20
197F Main Cab FNR
26J
FNR Switch Jumper
LU-0.8-SXL
198 FNR Switch
198 FNR Switch
26N_A
FNR Neutral Signal
LU-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
26N_B
FNR Neutral Signal
LU-0.8-SXL
19F TECM
44
197F Main Cab FNR
26R_A
FNR Reverse Signal
LU-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
26R_B
FNR Reverse Signal
LU-0.8-SXL
19F TECM
30
197F Main Cab FNR
28C
Ether Start Control
W-0.8-SXL
13M Pedestal Cab
52
182 Ether Switch
28GC
Grid Heater Signal
W-0.8-SXL
SPL_D26 B+ Power
28GC_A Grid Heater Signal
W-0.8-SXL
SPL_D26 B+ Power
21F Cab Rear
20
28GC_B Grid Heater Signal
W-1.0-SXL
276F Relay Rear
21M Rear Cab
20
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-22
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
28GC_C Grid Heater Signal
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
W-1.0-SXL
276M Relay Rear
279M Grid Heater Relay
28GP
Feedback of Grid Heater
W-1.0-SXL
SPL_D26 B+ Power
31D
Y-1.0-SXL
21M Rear-Cab
31D_A
Y-0.8-SXL
21F Cab-Rear
13F Cab-Pedestal
31D_B
Y-0.8-SXL
13M Pedestal-Cab
31D_C
Y-0.8-SOLID
274F Coolant Jmpr Rear Chs
31F
Y-1.0-SXL
94M Engine Trans
31F_A
Y-1.0-SXL
94F Eng-Trans
31F_B
Y-0.8-SXL
13F Cab-Pedestal
31F_C
Y-0.8-SXL
13M Pedestal-Cab
Y-1.0-SXL
21M Rear-Cab
14
170 Hyd Oil Filter Res Sw
31H_A
Y-0.8-SXL
21F Cab-Rear
14
13F Cab-Pedestal
31H_B
Y-0.8-SXL
13M Pedestal-Cab
31L
Y-0.8-SXL
29
31T
Temperature Sender Signal
Y-0.8-SXL
10
21F Cab Rear
22
31T_A
Grid Htr Temp Sender Signal
Y-1.0-SXL
21M Rear Cab
22
290 Grid Heater Temperature Sw
31U
Fuel Filter Heater Signal
W-1.0-SXL
289 Fuel Filter Temp Switch
277F Engine Relay
31U_X
W-1.0-SXL
277M Relay Engine
85
31Y_B
Grid Heater Lamp Ground
Y-0.9-SXL
13M Pedestal Cab
11
97 Preheater Lamp
32F
Y-1.0-SXL
31
31 Filter Maint Sw
32F_A
Y-0.8-SXL
19F TECM
17
31
32J_A
FNR Lt Signal
Y-0.8-SXL
198 FNR Switch
197M FNR-Main Cab
32J_B
Trans Enable Lt Sig
Y-0.8-SXL
197F Main Cab FNR
32J_C
Trans Enable Lt Sig
Y-0.8-SXL
19F TECM
33P
Y-1.0-SXL
88 Brk Warn Pr Sw
21M Rear-Cab
33P_A
Y-0.8-SXL
21F Cab-Rear
13F Cab-Pedestal
33P_B
Y-0.8-SXL
13M Pedestal-Cab
33R_A
Y-1.0-SXL
SPL_E10 SPL_E10
33R_B
Y-1.0-SXL
SPL_E10 SPL_E10
33R_C
Y-1.0-SXL
21M Rear-Cab
15
SPL_E10 SPL_E10
33R_D
Y-0.8-SXL
21F Cab-Rear
15
13F Cab-Pedestal
28
31H
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-23
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
33R_E
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Y-0.8-SXL
28
13M Pedestal-Cab
28
Y-0.8-SXL
35A_A
Left Reverse
K-1.0-SXL
125 LH Rear Comb Lt
SPL_E2 SPL_E2
35A_B
Right Reverse
K-1.0-SXL
127 RH Rear Comb Lt
SPL_E2 SPL_E2
35A_C
Reverse Lights
K-1.0-SXL
21M Rear-Cab
SPL_E2 SPL_E2
35A_D
Y-0.8-SXL
87
21F Cab-Rear
35A_E
Y-0.8-SXL
87
35A_F
Y-0.8-SXL
209M Backup Alarm Disa Jmp
35C
Backup Alarm Pull-Dwn
Y-0.8-SXL
19F TECM
85
35R_A
Backup Alarm Sw
Y-1.0-SXL
175 Backup Alarm
35R_B
Backup Alarm Sw
Y-1.0-SXL
21M Rear-Cab
128F Rear-Hood
35R_C
Backup Alarm Sw
Y-0.8-SXL
21F Cab-Rear
35R_D
Backup Alarm Sw
Y-0.8-SXL
209F Backup Alarm Disa Jmp
35X_A
Y-1.0-SXL
SPL_A4 SPL_A4
SPL_A4
35X_B
Y-1.0-SXL
1 Cab-Frnt Chas
SPL_A4 SPL_A4
SPL_A4
35X_C
Y-1.0-SXL
SPL_A4 SPL_A4
SPL_A4
35X_D
Y-1.0-SXL
90M Sec Str Mod
35X_E
Y-0.8-SXL
13F Cab-Pedestal
1 Cab-Frnt Chas
35X_F
Y-0.8-SXL
13M Pedestal-Cab
36C
P-1.0-SXL
94M Engine Trans
13
138 Eng Cool Temp
36C_A
P-1.0-SXL
94F Eng-Trans
13
36C_B
P-0.8-SXL
13F Cab-Pedestal
18
36C_C
P-0.8-SXL
18
13M Pedestal-Cab
18
36F
Fuel Level Signal
P-1.0-SXL
141 Fuel Sender
21M Rear-Cab
16
36F_A
Fuel Level Signal
P-0.8-SXL
21F Cab-Rear
16
13F Cab-Pedestal
19
36F_B
Fuel Level Signal
P-0.8-SXL
19
13M Pedestal-Cab
19
Torque Conv Outpt Temp Signal
P-1.0-SXL
13
142 Torque Conv Temp Sender
36G_A Torque Conv Outpt Temp Signal
P-1.0-SXL
19F TECM
49
13
33U
36G
36H
Hot Signal
P-1.0-SXL
21M Rear-Cab
13
36H_A
Hot Signal
P-0.8-SXL
13F Cab-Pedestal
20
21F Cab-Rear
13
36H_B
Hot Signal
P-0.8-SXL
20
13M Pedestal-Cab
20
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-24
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
36P
P-1.0-SXL
94M Engine Trans
36P_A
P-1.0-SXL
94F Engine Trans
36P_B
P-0.8-SXL
13F Cab-Pedestal
22
36P_C
P-0.8-SXL
22
13M Pedestal-Cab
22
36R_A
Valve Body Temp Ret
P-1.0-SXL
12
SPL_H1 Splice H1
Splice
36R_B
Valve Body Temp Ret
P-1.0-SXL
31 Filter Maint Sw
SPL_H1 Splice H1
Splice
36R_C
Valve Body Temp Ret
P-0.8-SXL
102 Trans Control
SPL_H1 Splice H1
Splice
36R_D
Valve Body Temp Ret
P-1.0-SXL
142 Trq Conv Temp Sender
SPL_H1 Splice H1
Splice
36R_E
Valve Body Temp Ret
P-0.8-SXL
19F TECM
46
12
36T
Valve Body Temp Sig
P-0.8-SXL
102 Trans Control
36T_A
Valve Body Temp Sig
P-0.8-SXL
19F TECM
39
Down Count Signal
P-0.8-SXL
27
37D_A
Diagnostic Signal
P-0.8-SXL
19F TECM
15
37E
Diagnostic Signal
P-0.8-SXL
19F TECM
18
37P
Program Signal
P-0.8-SXL
24
37R_A
Reset Signal
P-0.8-SXL
13M Pedestal-Cab
25
37R_B
Reset Signal
P-0.8-SXL
25
37R_C
Reset Signal
P-0.8-SXL
13F Cab-Pedestal
25
37U
Up Count Signal
P-0.8-SXL
26
41H
High/Low Beam Relay Pwr
K-2.0-SXL
59F High/Low Beam
18F Fuse Block
41J_A
Driving Light Sig
K-2.0-SXL
33F Light Switch
59F High/Low Beam
41J_B
Driving Light Sig
K-2.0-SXL
25F Light Switch
33F Light Switch
41L_A
Low Beam Sig (2-Way)
K-2.0-SXL
18F Fuse Block
E1
59F High/Low Beam
41T_A
K-1.0-SXL
32F Light Switch
18F Fuse Block
G1
41T_B
K-1.0-SXL
33F Light Switch
32F Light Switch
42C_A
Front Flood Lts
DU-1.0-SXL
24M Cab-Roof
34F Light Switch
42C_B
LH Frnt Work Lt Pwr
DU-1.0-SXL
42C_C
RH Frnt Work Lt Pwr
DU-1.0-SXL
42C_D
Front Work Lts Pwr
DU-1.0-SXL
24F Roof-Cab
42R_A
Y-0.8-SXL
12
13M Pedestal-Cab
12
42R_B
Rear Work Light Pwr
DU-0.8-SXL
23F Cab-Roof
32F Light Switch
37D
Bur 6-48930
Issued 2-03
C1
Printed in U.S.A.
Copyright
4002-25
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
To Connector
Wire
Circuit
42R_C
Rear Work Light Pwr
DU-0.8-SXL
13F Cab-Pedestal
12
32F Light Switch
42R_D
LH Rear Work Lt Pwr
DU-1.0-SXL
83F LH Rear Work Lt
42R_E
RH Rear Work Lt Pwr
DU-1.0-SXL
80F RH Rear Work Lt
42R_F
Rear Work Light Pwr
DU-1.0-SXL
23M Roof-Cab
44A_B
T-0.8-SXL
86
21F Cab-Rear
29
44_A
Brake Light Signal
T-1.0-SXL
125 LH Rear Comb Lt
SPL_E1 SPL_E1
44_B
Brake Light Signal
T-1.0-SXL
127 RH Rear Comb Lt
SPL_E1 SPL_E1
44_C
Brake Light Signal
T-1.0-SXL
21M Rear-Cab
SPL_E1 SPL_E1
44_D
Brake Light Signal
T-0.8-SXL
21F Cab-Rear
44_E
Brake Lt Relay Signal
T-0.8-SXL
87
44_F
Brake Light Signal
T-0.8-SXL
13F Cab-Pedestal
35
44_G
Brake Light Signal
T-0.8-SXL
35
13M Pedestal-Cab
35
45A
N-0.8-SXL
13M Pedestal-Cab
69
45A_A
N-0.8-SXL
62M Flasher Module
10
13F Cab-Pedestal
69
45B
N-0.8-SXL
13M Pedestal-Cab
70
45B_A
N-0.8-SXL
62M Flasher Module
13F Cab-Pedestal
70
45H
Hazard Switch Power
N-0.8-SXL
13M Pedestal-Cab
67
71 Hazard Switch
45H_A
Hazard Switch Power
N-0.8-SXL
62M Flasher Module
11
13F Cab-Pedestal
67
45L
Left Turn Signal
N-1.0-SXL
1 Cab-Frnt Chas
6 Lights LH
45L_A
Left Turn Signal
N-1.0-SXL
125 LH Rear Comb Lt
21M Rear-Cab
10
45L_B
Left Turn Signal
N-0.8-SXL
21F Cab-Rear
10
45L_C
Left Turn Signal
N-0.8-SXL
1F Cab-Frnt Chas
45L_D
Left Turn Signal
N-0.8-SXL
62M Flasher Module
45L_E
Left Turn Signal
N-0.8-SXL
13F Cab-Pedestal
16
45L_F
Left Turn Signal
N-0.8-SXL
16
13M Pedestal-Cab
16
45N_A
N-0.8-SXL
64F Flasher Connector
62M Flasher Module
45N_B
N-0.8-SXL
64M Flasher Connector
62M Flasher Module
12
45R
Right Turn Signal
N-1.0-SXL
1 Cab-Frnt Chas
8 Lights RH
45R_A
Right Turn Signal
N-1.0-SXL
127 RH Rear Comb Lt
21M Rear-Cab
12
45R_B
Right Turn Signal
N-0.8-SXL
21F Cab-Rear
12
45R_C
Right Turn Signal
N-0.8-SXL
13F Cab-Pedestal
17
Bur 6-48930
Connector
K = Pink
U = Blue
Y = Yellow
Cavity
Connector
Issued 2-03
Cavity
Printed in U.S.A.
Copyright
4002-26
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
45R_D
Right Turn Signal
N-0.8-SXL
1F Cab-Frnt Chas
45R_E
Right Turn Signal
N-0.8-SXL
62M Flasher Module
45R_F
Right Turn Signal
N-0.8-SXL
17
13M Pedestal-Cab
17
46_A
Beacon Switched Pwr
K-0.8-SXL
23F Cab-Roof
13F Cab-Pedestal
13
46_B
Beacon Telltale
K-0.8-SXL
13
13M Pedestal-Cab
13
46_C
Beacon Switched Pwr
K-1.0-SXL
23F Cab-Roof
42F Beacon Sw
46_D
K-1.0-SXL
23M Roof-Cab
85F Beacon Light
49_A
Pilot Light
S-0.8-SXL
13M Pedestal-Cab
51
71 Hazard Switch
49_B
Pilot Light
S-0.8-SXL
71 Hazard Switch
49_C
Pilot Light
S-0.8-SXL
49_D
Pilot Light
S-0.8-SXL
49_E
Pilot Light
S-0.8-SXL
49_F
Pilot Light Pwr
S-0.8-SXL
13F Cab-Pedestal
51
SPL_D8 Pilot Lights
49_G
Pilot Light
S-0.8-SXL
SPL_D8 Pilot Lights
49_H
Pilot Light
S-0.8-SXL
40F Pin Engage Sw
10
49_J
Pilot Light
S-0.8-SXL
34F Light Switch
SPL_D8 Pilot Lights
49_K
Pilot Light
S-1.0-SXL
34F Light Switch
49_L
Pilot Light
S-0.8-SXL
45F Rear Wiper Sw
49_M
Pilot Light
S-1.0-SXL
36F Detent Switch
49_N
Pilot Light
S-1.0-SXL
36F Detent Switch
38F Declutch Switch
49_P
Pilot Light
S-1.0-SXL
40F Pin Engage Sw
10
44F Ride Control Sw
49_Q
Pilot Light
S-1.0-SXL
44F Ride Control Sw
41F Trans Auto Sw
49_R
Pilot Light
S-1.0-SXL
42F Beacon Sw
49_S
Courtesy Pilot Lt
S-1.0-SXL
24M Cab-Roof
SPL_D8 Pilot Lights
49_T
Pilot Light
S-1.0-SXL
42F Beacon Sw
49_U
Pilot Light
S-0.8-SXL
SPL_D8 Pilot Lights
49_V
Courtesy Pilot Lt
S-0.8-SXL
24F Roof-Cab
77F Courtesy Lt
50G_A Can Ground
Bk-0.8-SXL
13M Pedestal-Cab
34
SPL_K2 SPL_K2
50G_B Can Ground
Bk-0_5-SXL
SPL_K3 SPL_K3
SPL_K2 SPL_K2
50G_C Can Ground
R-0_5-SXL
SPL_K2 SPL_K2
SPL_K3 SPL_K3
50G_D Can Ground
Bk-0.8-SXL
13F Cab-Pedestal
34
SPL_D6 Can Ground
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-27
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
Circuit
5.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
50G_E Can Ground
Bk-0_5-SXL
SPL_D7 Can Ground
SPL_D6 Can Ground
50G_F
R-0_5-SXL
SPL_D7 Can Ground
SPL_D6 Can Ground
Bk-0.8-SXL
219F Ground Cab
SPL_D7 Can Ground
Can Ground
50G_G Can Pilot Sol Grnd

50H
Can H
Y-0_5-SXL
32
13M Pedestal-Cab
32
50H_A
Can H
Y-0_5-SXL
19F TECM
25
13F Cab-Pedestal
32
50L
Can L
G-0_5-SXL
31
13M Pedestal-Cab
31
50L_A
Can L
G-0_5-SXL
13F Cab-Pedestal
31
SPL_D5 Can L
50L_B
Can L
G-0_5-SXL
19F TECM
26
SPL_D5 Can L
50L_C
Can L
G-0_5-SXL
19F TECM
27
SPL_D5 Can L
50T
Can T
Bk-0.8-SXL
21
33
51P_A
Sec Str High Pres
W-1.0-SXL
90M Sec Str Mod
51P_B
Sec Str High Pres
W-1.0-SXL
51_A
Sec Str Mtr Rel
W-1.0-SXL
90M Sec Str Mod
SPL_C2
51_B
SPL_C2
W-1.0-SXL
SPL_C2
181 Sec Str Mtr Relay
51_C
Sec Strg Sol Pwr
W-1.0-SXL
264M Sec Strg Sol Opt
SPL_C2
52C
W-0.8-SXL
30
13M Pedestal-Cab
30
52C_A
W-0.8-SXL
85
13F Cab-Pedestal
30
52P
W-1.0-SXL
87 Parking Brk Sol
21M Rear-Cab
18
52P_A
W-0.8-SXL
19F TECM
21
87
52P_B
W-0.8-SXL
87
21F Cab-Rear
18
52_A
Fan Reverse Sol
W-0.8-SXL
21F Cab-Rear
27
53B
RTD Signal
W-1.0-SXL
1 Cab-Frnt Chas
12F RTD
53B_A
RTD Signal
W-1.0-SXL
12M RTD
200 RTD
53B_B
RTD Signal
W-0.8-SXL
1F Cab-Frnt Chas
53C
W-0.8-SXL
36
13M Pedestal-Cab
36
53C_A
W-0.8-SXL
85
13F Cab-Pedestal
36
53P_A
W-0.8-SXL
87
89M Pilot Pres Sol
53P_B
W-0.8-SXL
36F Detent Switch
87
53P_C
W-0.8-SXL
87
1F Cab-Frnt Chas
53P_D
Float Sol Power
W-1.0-SXL
178M Float Switch
1 Cab-Frnt Chas
53S_A
Float Sol Signal
W-1.0-SXL
178M Float Switch
SPL_A5 SPL_A5
SPL_A5
Issued 2-03
Printed in U.S.A.
Bur 6-48930
Copyright
4002-28
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
2.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
Circuit
5.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
53S_B
Float Sol Signal
W-1.0-SXL
179F Float Solenoid
SPL_A5 SPL_A5
SPL_A5
53S_C
Float Sw Signal
W-1.0-SXL
202F Diode Module
SPL_A5 SPL_A5
SPL_A5
53S_D
Float Sol Signal
W-1.0-SXL
229M Diode Module
SPL_A5 SPL_A5
SPL_A5
53S_E
Float Switch Signal
W-1.0-SXL
273F Rollbck Jmpr Diode Mdl
271M Frt Chassis Rollbck Jmpr
54B
Height-RTT Signal
W-1.0-SXL
1 Cab-Frnt Chas
10 Height Cntrl-RTT
54B_A
Height-RTT Signal
W-0.8-SXL
1F Cab-Frnt Chas
54B_B
RTT-Float Sw Load
W-0.8-SXL
54B_C
Height Cont Elec Mag
W-0.8-SXL
55A
RTT-Float Sw
W-0.8-SXL
56_A
Height-RTT Pwr
W-1.0-SXL
10 Height Cntrl-RTT
SPL_A3 Splice A3
SPL_A3
56_B
RTD Pwr
W-1.0-SXL
12F RTD
SPL_A3 Splice A3
SPL_A3
56_C
Prox Switch Pwr
W-1.0-SXL
1 Cab-Frnt Chas
SPL_A3 Splice A3
SPL_A3
56_D
RTD Pwr
W-1.0-SXL
12M RTD
200 RTD
56_E
Detent Switched Pwr
W-0.8-SXL
56_F
Detent Switched Pwr
W-0.8-SXL
56_G
Detent Switched Pwr
W-0.8-SXL
56_H
Detent Switched Pwr
W-0.8-SXL
36F Detent Switch
56_J
Prox Switch Pwr
W-0.8-SXL
1F Cab-Frnt Chas
57_A
Pin Engage Sol Pwr
W-0.8-SXL
40F Pin Engage Sw
1F Cab-Frnt Chas
58A_A
Float Switch Signal
W-1.0-SXL
273F Rollbck Jmpr Diode Module
58H_B
Ride Cntl Sw Pwr VPS2
W-0.8-SXL
19F TECM
86
58S
Ride Cntl Relay Pwr
W-0.8-SXL
30
44F Ride Control Sw
58_A
Ride Cntrl Sol Pwr
W-0.8-SXL
87
1F Cab-Frnt Chas
58_B
Ride Cntrl Sol Pwr
W-0.8-SXL
87
44F Ride Control Sw
58_C
Ride Cntrl Sol Pwr
W-1.0-SXL
5F Ride Control Opt
SPL_A7
58_D
Ride Cntrl Sol Pwr
W-1.0-SXL
202F Diode Module
SPL_A7
58_E
Ride Cntrl Sol Pwr
W-1.0-SXL
229M Diode Module
SPL_A7
58_F
Float Switch Signal
W-1.0-SXL
271M Frt Chs Rollbck Jmpr
61A
AC High Pres Sw
Or-1.0-SXL
94M Engine Trans
98 AC High Pres Sw
61A_A
AC High Pres Sw
Or-1.0-SXL
26
94F Eng-Trans
61A_B
AC Relay Pwr
Or-0.8-SXL
203F Relay AC
30
26
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-29
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
61A_C
AC Relay Pwr
Or-0.8-SXL
203F Relay AC
30
SPL_D3 AC Power
61A_D
AC Thermostat
Or-0.8-SXL
208F Thermostat Switch 1
SPL_D3 AC Power
61A_E
AC Low Pres Sw
Or-0.8-SXL
27M AC Low Pres Sw
SPL_D3 AC Power
61C
AC Comp Clutch
Or-1.0-SXL
94M Engine Trans
99 AC Comp Clutch
61C_A
AC Comp Clutch
Or-1.0-SXL
25
94F Eng-Trans
61C_B
AC Comp Clutch
Or-0.8-SXL
203F Relay AC
87a
25
61C_C
Splice
Or-1.0-SXL
SPL_N1 Splice
265F Diode Module
61C_D
Or-1.0-SXL
267F AC Compressor Clutch
SPL_N1 Splice
61C_E
Or-1.0-SXL
266M AC Compressor Clutch
SPL_N1 Splice
61R
AC High Pres Sw
Or-1.0-SXL
94M Engine Trans
98 AC High Pres Sw
61R_A
AC High Pres Sw
Or-1.0-SXL
27
94F Eng-Trans
61R_B
AC Relay Signal
Or-0.8-SXL
203F Relay AC
87
27
61R_C
AC Relay Signal
Or-0.8-SXL
203F Relay AC
87
203F Relay AC
86
61R_D
AC Relay Signal
Or-0.8-SXL
203F Relay AC
87
SPL_D1
61R_E
AC Low Pres Sw
Or-0.8-SXL
27M AC Low Pres Sw
SPL_D1
61R_F
AC Telltale
Or-0.8-SXL
13F Cab-Pedestal
10
SPL_D1
61R_G AC Telltale
Or-0.8-SXL
10
13M Pedestal-Cab
10
61T
AC Thermostat Pwr
Or-1.0-SXL
30F Blower Switch
62H
Blower High Speed
Or-2.0-SXL
29M Blower Motor
30F Blower Switch
62L
Blower Low Speed
Or-1.0-SXL
29M Blower Motor
30F Blower Switch
62M
Blower Medium Speed
Or-2.0-SXL
29M Blower Motor
30F Blower Switch
63C
Front Wiper Park
Or-0.8-SXL
13M Pedestal-Cab
59
63C_A
Front Wiper Park
Or-0.8-SXL
13F Cab-Pedestal
59
63H
Or-0.8-SXL
13M Pedestal-Cab
57
63H_A
Or-0.8-SXL
13F Cab-Pedestal
57
63H_B
Or-0.8-SXL
140M Diode Module
63L
Or-0.8-SXL
13M Pedestal-Cab
58
63L_A
Or-0.8-SXL
13F Cab-Pedestal
58
63L_B
Or-0.8-SXL
140M Diode Module
Front Washer Pump
Or-1.0-SXL
2 Front Washer
21M Rear-Cab
25
63W_A Front Washer Pump
Or-0.8-SXL
21F Cab-Rear
25
63W
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-30
21C Bk - 1.0
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
1.0 mm
Circuit
5.0 mm
DU = Dark Blue
W = White
Or = Orange
Wire Identification
Wire
2.0 mm
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
64C
Horn Control
Or-0.8-SXL
13M Pedestal-Cab
42
184 Horn Switch
64C_A
Horn Control
Or-0.8-SXL
51F Horn Relay
85
13F Cab-Pedestal
42
Or-0.8-SXL
13M Pedestal-Cab
55
186 High Low Beam
Or-0.8-SXL
59F High/Low Beam
13F Cab-Pedestal
55
64A
Horn
Or-0.8-SXL
51F Horn Relay
87
1F Cab-Frnt Chas
65C
Radio Power
Or-0.8-SXL
114F Radio Radio Adapter
65C_B
Radio Power
Or-0.8-SXL
114M Radio Adapter Radio
113 Radio
14
65L
Left Spkr Signal
Or-0.8-SXL
112M Left Speaker
65L_A
Left Spkr Signal
Or-0.8-SXL
113 Radio
11
65R
Right Spkr Signal
Or-0.8-SXL
111M Right Speaker
65R_A
Right Spkr Signal
Or-0.8-SXL
113 Radio
68C_A
Rear Wiper Park
Or-1.0-SXL
23F Cab-Roof
45F Rear Wiper Sw
68C_B
Rear Wiper Park
Or-1.0-SXL
23M Roof-Cab
81M Rear Wiper Mtr
68L_A
Or-1.0-SXL
23F Cab-Roof
45F Rear Wiper Sw
68L_B
Or-0.8-SXL
45F Rear Wiper Sw
140M Diode Module
68L_C
Or-1.0-SXL
23M Roof-Cab
81M Rear Wiper Mtr
Rear Washer Pump
Or-1.0-SXL
3 Rear Washer
21M Rear-Cab
24
68W_A Rear Washer Pump
Or-1.0-SXL
45F Rear Wiper Sw
21F Cab-Rear
24
64D
64D_A
68W
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-31
UNDERSTANDING THE TROUBLESHOOTING TABLES

1 Alternator
Check Points
Reading
Check the 10 ampere fuse at

location 3 and 4C in the fuse block.
Good
12 volts
Bad fuse.
Check wire 1A between the starter terminal (21) and the

alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter.
5
6
1.
2.
3.
4.
5.
6.
This title is the number and component name on the Electrical Schematic.
This column shows the location of the check point.
This column shows the indication of the check.
This column shows the possible cause of a bad test indication.
The numbers in the parentheses show the number of the component on the Electrical Schematic.
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.
Co mpo ne nts can b e loc ate d o n th e Ele ctrica l
Schematic posters (rear pocket) by item number
using the key at the bottom of the posters. Use the
following index to find the sheet a component is
located on.
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
95
Accessory Relay No. 3
16
87
86
Air Filter Restriction Switch
44
Alternator
Back-up Alarm
37
Back-up Alarm Disable Switch
36
Back-up Alarm Relay No. 7
35
Batteries
Beacon Switch
99
Blower Motor
85
84
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-32
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
Blower Switch
83
32
101
Brake Lamps Relay No. 6
102
Brake Warning Pressure Switch
38
Bucket Control Valves Electromagnetic Detents
60
91
Compressor Clutch
90
Compressor Clutch Lockout Relay No. 14
89
Coolant Level Sender
39
Courtesy Lamp
118
Declutch Switch
31
Detent Switch
59
28
Dome Lamp
117
Engine Coolant Temperature Sender
43
Engine Fuel Solenoid
50
Engine Speed Sensor
20
FNR Switch
34
Fan Reverser Switch
55
56
23
First Fuel Filter Heater
114
Flasher Module
105
64
Float Solenoid
65
76
Front Wiper Motor
74
75
Fuel Filter Heater Relay No. 16
Fuel Level Sender
40
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-33
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
Grid Heater (Option)
11A
Grid Heater Controller (Option)
11C
11
Grid Heater Temperature Sensor (Option)
11B
Hazard Switch
103
63
High/Low Beam Relay No. 13
115
Horn
81
Horn Relay No. 5
80
Hydraulic Filter Restriction Switch
42
Hydraulic Oil Temperature Sender
41
14
15
Ignition Switch
13
Instrument Cluster
47
21
LH Front Combination Lamp
108
LH Front Work Lamp
112
LH Rear Combination Lamp
106
LH Rear Work Lamp
110
Left Speaker (Option
97
License Plate Lamp
116
Neutral Start Relay No. 8
12
Output Speed Sensor
19
Parking Brake Relay No. 9
52
53
46
Pilot Control Relay No. 10
51
48
54
70
69
Power Converter (24 Volts to 12 Volts) (Option)
92
Grid Heater Relay No. 15 (Option)
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-34
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
93
Program/Reset Switch
45
Relay Socket No. 11
58
RH Front Combination Lamp
109
RH Front Work Lamp
113
RH Rear Combination Lamp
107
RH Rear Work Lamp
111
Radio Power Converter (24 Volts to 12 Volts) (Option)
96
78
77
Rear Wiper Motor
79
57
94
62
61
Ride Control Relay No. 4
72
73
Ride Control Switch
71
98
Rotating Beacon
100
Seat Compressor and Switch
82
Secondary Fuel Filter Heater
10
66
68
67
68A
Starter Motor
Starting Relay
Thermostat Switch
88
Time Delay Module
18
Torque Converter Output Temperature Sensor
24
30
26
33
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-35
COMPONENT
COMPONENT
NUMBER
SCHEMATIC
SHEET
Transmission Kick-Down Switch
29
27
Transmission Solenoid Valve and Temperature Sender
25
22
Turn Signal, High/Low Beam, and Horn Switch
104
49
Voltmeter Relay No. 12
17
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-36
TROUBLESHOOTING BATTERIES, ENGINE FUEL SOLENOID, CHARGING,

STARTING, ALTERNATOR, FUEL FILTER HEATER, GRID HEATER,
IGNITION SWITCH AND RELAYS
13
5
6
7
11
11C
12
14
1
11A
11B
8 9 10
BC00N140
1.
2.
3.
4.
5.
6.
BATTERIES
MASTER DISCONNECT SWITCH
ENGINE FUEL SOLENOID
ALTERNATOR
STARTER MOTOR
STARTING RELAY
7. FUEL FILTER HEATER RELAY NO. 16

8. FUEL FILTER HEATER SWITCH
9. FIRST FUEL HEATER
10. SECOND FUEL FILTER HEATER (621D ONLY)
11. GRID HEATER RELAY NO. 15 (OPTION)
11A.GRID HEATER (OPTION)
11B.GRID HEATER TEMPERATURE

SENSOR (OPTION)
11C.GRID HEATER CONTROLLER
(OPTION)
12. NEUTRAL START RELAY NO. 8
13. IGNITION 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.
1 Batteries
NOTE: See Section 4003 and check the batteries.
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-37
2 Master Disconnect Switch

Check Points
Reading
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
disconnect switch
Continuity
If there is no continuity, the master disconnect switch (2) is bad.
NOTE: Put the master disconnect switch in the OFF position.

disconnect switch
Open Circuit
If there is continuity, the master disconnect switch is bad.
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
3 Engine Fuel Solenoid

Check Points
Reading
NOTE: Disconnect connector 133M from fuel solenoid (3).

Between housing of fuel solenoid
and ground
Between terminal 1 of fuel solenoid
and ground
Continuity
12.7 ohms at
20C (68F)
(Nominal)
Bad fuel solenoid.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in the ON position.
24 volts
Check wire 13M and circuits 13C and 13K, also check circuit to
batteries. Bad master disconnect switch (2) or ignition switch
(13).
NOTE: If the readings are good, replace the fuel solenoid (3).
4 Alternator
Check Points
Between housing of alternator and
ground
Reading
Continuity


Between the B+ terminal of
24 volts
Check circuit to positive post of left battery. Bad master

disconnect switch.
Between terminal for wire 30 and

ground
24 volts
Bad wire 30.

Between the B+ terminal of
24 volts
20 volts
Check circuit 14, 75 ohm resistor, and diode module. Bad fuse
R. Check ignition relay No. 1, and 12.5 ampere circuit breaker
A.
NOTE: If the readings are good, see Section 4007 to repair the alternator (4).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-38
5 Starter Motor
Check Points
Between housing of starter and
ground
Reading
Continuity


Starter B+ stud to ground
24 volts
Terminal S to ground
24 volts
Bad starting relay (6). Also check wire 1_F between starter (5)
and starting relay (6).
NOTE: If the readings are good, see Section 4004 and repair the starter (5).
6 Starting Relay
Check Points
Terminal for wire 0_UB to ground
Reading
Continuity

Bad ground circuit.

24 volts
24 volts
24 volts
Bad starting relay (6).
7 Fuel Filter Heater Relay No. 16

Check Points
Reading
NOTE: Make sure engine temperature is below -3 C (27 F).

Terminal for wire 31U_X to ground
Continuity
Bad ground circuit or bad fuel filter heater switch (8).

Terminal for wire 1Y_A to ground
24 volts
Check 40 ampere fuse, also check circuit 1Y and circuit to

batteries.

Terminal for wire 13C_H to ground
24 volts
Check ignition switch (13), also check circuits 13C and 13K.
Terminal for wires 1Y_D and 1Y_E

to ground
24 volts
Bad fuel filter relay (7).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-39
8 Fuel Filter Heater Switch

Check Points
Reading
NOTE: The fuel filter heater switch opens at 13 3 C (55 5 F) and closes at 1.5 4 C (34 8 F).
Terminal for wire 0_BM to ground
Continuity
Bad ground circuit.
NOTE: Disconnect the connector from the fuel filter heater switch (8). Make sure the engine temperature is below
-3 C (27 F).
Between terminals A and B of fuel
filter heater switch (8)
Continuity
Bad fuel filter heater switch (8).
9 First Fuel Filter Heater

Check Points
Terminal for wire 0_BL to ground
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect connector 288 from first fuel filter heater.

Between terminals A and B of first
fuel filter heater
1.9 ohms
Bad first fuel filter heater.
NOTE: If the readings are good, check circuit 1Y between first fuel filter heater connector 288 and fuel filter
heater relay connector 280.
10 Second Fuel Filter Heater (621D Only)

Check Points
Terminal for wire 0_BK to ground
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect connector 287 from second fuel filter heater.

Between terminals A and B of
second fuel filter heater
1.9 ohms
Bad second fuel filter heater.
NOTE: If the readings are good, check circuit 1Y between second fuel filter heater connector 287 and fuel filter
heater relay connector 280.
11 Grid Heater Relay No. 15 (Option)

Check Points
Terminal for wire 0_UC to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
24 volts
Bad 150 ampere fuse. Check wires 1_DA and 1_D.
NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make
sure engine temperature is below -3 C (27 F).
Terminal for wire 28GC_C to ground
24 volts
Bad grid heater controller (11C), also check circuit 28GC.
24 volts
Bad grid heater relay (11).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-40
11A Grid Heater (Option)

Check Points
Grid heater terminal B to ground
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect terminal for wire 1Z from grid heater.

Between terminals of grid heater
Resistance
If an open or short circuit is obtained, replace the grid heater.
11B Grid Heater Temperature Sensor (Option)

Check Points
Terminal for wire 0_BC to ground
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect connector 290 from grid heater temperature sensor.

Between terminals A and B of grid
heater temperature sensor
2.26 to 2.76 K
ohms at 20C
(68F)
Bad grid heater temperature sensor.
NOTE: Resistance of grid heater temperature sensor decreases as temperature increases and increases as
temperature decreases.
11C Grid Heater Controller (Option)

Check Points
Reading
NOTE: Disconnect connector 201 from the grid heater controller.

Continuity
Bad preheater lamp. Also check wires 18L_C, 18L_D, 31Y_B,

and 0_DBA.
110 to 140
ohms
Bad grid heater relay (11). Also check circuit 28GC, and wires
28GP, 0_UC, 0_UA, and 0_U.
110 to 140
ohms
Bad grid heater relay (11). Also check circuit 28GC, and wires
0_UC, 0_UA, and 0_U.
Continuity
Bad ground circuit. Check wire 0_DBB.
2.26 to 2.76 K
ohms at 20C
(68F)
Bad grid heater temperature sensor (11B). Also check circuit

31T and wire 0_BC.
NOTE: Put master disconnect switch in ON position and ignition switch in ON position.
20 volts
Bad fuse R. Check 75 ohms resistor and diode module. Check

ignition relay No. 1 (14) and 12.5 ampere circuit breaker A.
24 volts
Bad fuse E. Check wire 19E. Also check ignition relay (14) and
12.5 ampere circuit breaker A.
NOTE: Have an assistant put transmission in neutral and ignition switch in START position.
24 volts
Bad neutral start relay (12). Also check ignition switch (13) and
wire 21C_G.
NOTE: If all readings are good, replace the grid heater controller.
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-41
12 Neutral Start Relay No. 8

Check Points
Terminal for wire 0_DJ to ground
Reading
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_E to ground
24 volts
Check circuit 25T.
24 volts
Check circuit 21K_A and ignition switch.
Terminal for wire 21C_E to ground
24 volts
Bad neutral start relay (12).
13 Ignition Switch
Check Points
Reading

24 volts
Check circuit 1A to 12.5 ampere circuit breaker A.
NOTE: Disconnect the connector from the ignition switch (13). Turn the switch to ON.
Between Bat and Ign
Continuity
Between Bat and Acc
Continuity
NOTE: Hold the ignition switch (13) in the START position.

Between Bat and Starter
Continuity
Between Bat and Ign
Continuity
NOTE: Put the switch in the Acc position.

Between Bat and Acc
Continuity

Check Points
Terminal for wire 0_DE to ground
Reading
Continuity

Bad ground circuit.
24 volts
24 volts
24 volts
Bad ignition relay No. 1 (14)
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-42
TROUBLESHOOTING IGNITION RELAY, ACCESSORY RELAY, VOLTMETER

RELAY, AND TIME DELAY MODULE
18
15
16
17
BC00N140

16. ACCESSORY RELAY NO. 3
17. VOLTMETER RELAY NO. 12

18. TIME DELAY MODULE

Check Points
Reading
Continuity

Bad ground circuit.
Terminal for wire 1_T to ground
24 volts
24 volts
24 volts
Bad ignition relay No. 2 (15).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-43
16 Accessory Relay No. 3

Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Acc or the ON position.
24 volts
24 volts
24 volts
Bad accessory relay (16).
17 Voltmeter Relay No. 12

Check Points
Reading
Continuity

Bad ground circuit.

24 volts
Check circuit 1 to starter motor B+ stud.
NOTE: Turn ignition switch to the ON position.

24 volts
Terminal for wire 13V to ground
24 volts
Bad voltmeter relay (17).
18 Time Delay Module

Check Points
Terminal for wire 0_DAS to ground
Reading
Continuity

Bad ground circuit.

24 volts
Bad 12.5 ampere circuit breaker A. Check wire 1_l to SPL_D17

and wire 1_J to B+ stud.
NOTE: Put the ignition switch in the ON position. Have another person press and hold the program/reset switch
(45) in RESET position.
24 volts
Bad program/reset switch (45), also check circuit 37R.
Terminal for wire 13K_F to ground
24 volts
Bad ignition switch (13), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 10 seconds time
delay an audible click will be heard.
Within 10 seconds of putting the
ignition switch in the OFF position,
check terminal for wire 13D to
ground
24 volts
Key OFF
0 volt after 10
seconds
After 10 seconds of turning ignition

switch to the OFF position, check
terminal for wire 13D to ground
0 volt
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-44
TROUBLESHOOTING TRANSMISSION SOLENOIDS, SENSORS AND

SWITCHES, CONTROL MODULE, SHIFTER, DIAGNOSTIC CONNECTOR,
AND BACK-UP ALARM
,
27
32
25
24
37
23
20
21
22
26
30
28
31
35
36
29
33
34
19
BC00N140
19.
20.
21.
22.
23.
24.
25.
OUTPUT SPEED SENSOR

ENGINE SPEED SENSOR
INTERMEDIATE SPEED SENSOR
TURBINE SPEED SENSOR
FILTER MAINTENANCE SWITCH
TRANSMISSION SOLENOID VALVE AND TEMPERATURE
SENSORS
26. TRANSMISSION ELECTRONIC CONTROL MODULE
27. TRANSMISSION SHIFTER
28. DIAGNOSTIC CONNECTOR
Bur 6-48930
29.
30.
31.
32.
33.
34.
35.
TRANSMISSION KICK-DOWN SWITCH

TRANSMISSION AUTO SWITCH
DECLUTCH SWITCH
BRAKE DECLUTCH PRESSURE SWITCH
TRANSMISSION ENABLE SWITCH
FNR SWITCH
BACK-UP ALARM RELAY NO. 7
36. BACK-UP ALARM DISABLE SWITCH

37. BACK-UP ALARM
Issued 2-03
Printed in U.S.A.
Copyright
4002-45
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 19 through 34.
19 Output Speed Sensor

20 Engine Speed Sensor
21 Intermediate Speed Sensor
22 Turbine Speed Sensor
23 Filter Maintenance Switch
24 Torque Converter Output Temperature Sender
25 Transmission Solenoid Valve and Temperature Sensors
26 Transmission Electronic Control Module
28 Diagnostic Connector
29 Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick
Option; Next to Hydraulic Levers for Single Axis Controls)
30 Transmission Auto Switch
31 Declutch Switch
32 Brake Declutch Pressure Switch
33 Transmission Enable Switch
34 FNR Switch
35 Back-up Alarm Relay No. 7
Check Points
Reading
NOTE: Disconnect the transmission electronic control module (26) quick disconnect connector.
Terminal for wire 35C to terminal 7 of
quick disconnect connector
Continuity
Bad wire 35C.
Terminal for wire 19A_P to ground
24 volts
Bad fuse A, also check wires 19A_P, 13P_A, and ignition relay
No. 1 (14).
24 volts
Bad fuse H, also check wires 19H and 13R and ignition relay
No. 2 (15).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Bur 6-48930
24 volts
Bad back-up alarm relay (35).
Issued 2-03
Printed in U.S.A.
Copyright
4002-46
36 Back-up Alarm Disable Switch

Check Points
Reading
Continuity

Bad ground circuit.
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
24 volts
Bad back-up alarm relay (35), also check circuit 35A_E.
NOTE: Wires 35A_F and 35R_D are connected together and switch is removed in North American models. The
wires are disconnected and the switch is installed in TUV road approved (Germany) models.
24 volts
Bad back-up alarm disable switch (36). If machine is not a TUV

model, check wires 35A_F and 35R_D.
Reading
37 Back-up Alarm
Check Points
Continuity
Bad ground circuit.
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
24 volts
Bad back-up alarm disable switch (36), also check wires

35R_C and 35R_B. If machine is not a TUV model, check wires
35R_C and 35R_B.
NOTE: If the readings are good, replace the back-up alarm (37).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-47
TROUBLESHOOTING INDICATOR SWITCHES AND SENDERS,

PROGRAM/RESET SWITCH, PARK BRAKE SWITCH, INSTRUMENT
CLUSTER, PILOT CONTROL SWITCH, AND UP/DOWN COUNT SWITCH
44
39
43
45
38
42
41
46
47
48
49
40
BC00N140
38.
39.
40.
41.
42.
43.
Bur 6-48930

COOLANT LEVEL SENDER
FUEL LEVEL SENDER
HYDRAULIC OIL TEMPERATURE SENDER
HYDRAULIC FILTER RESTRICTION SWITCH
ENGINE COOLANT TEMPERATURE
SENDER
44.
45.
46.
47.
48.
49.
AIR FILTER RESTRICTION SWITCH

PROGRAM/RESET SWITCH
PARKING BRAKE SWITCH
INSTRUMENT CLUSTER
PILOT CONTROL SWITCH
UP/DOWN COUNT SWITCH
Issued 2-03
Printed in U.S.A.
Copyright
4002-48
38 Brake Warning Pressure Switch

Check Points
Reading
NOTE: Brake warning pressure switch opens at 117.2 bar (1700 psi).
Continuity
Bad ground circuit.
Approximately
11.5 volts
Check circuit 33P.
Terminal B for wire 0 to ground

NOTE: Disconnect the wires from the brake warning pressure switch (38).
switch
Continuity
Bad brake warning pressure switch (38).
NOTE: Start and run the engine at idle.

switch
Open Circuit
Bad brake warning pressure switch (38) or brake pressure is

below 117.2 bar (1700 psi). Refer to Section 7002 to check
brake pressure.
39 Coolant Level Sender

Check Points
Reading
Continuity

Bad ground circuit.
Terminal A for wire 31D to ground
Approximately
1.6 volts AC
Check circuit 31D, also check the instrument cluster (47).
NOTE: If the readings are correct replace the coolant level sender (39).
40 Fuel Level Sender

Check Points
Reading
Continuity

Bad ground circuit.
Approximately
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
sender
Bur 6-48930
33 to 240
ohms
Bad fuel level sender (40).
Issued 2-03
Printed in U.S.A.
Copyright
4002-49
41 Hydraulic Oil Temperature Sender

Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect the connector from the hydraulic oil temperature sender.
Between terminals of hydraulic oil
temperature sender
130 to 9500
ohms
Replace hydraulic oil temperature sender (41).
Terminal A for wire 36H to ground
Approximately
5 volts
42 Hydraulic Filter Restriction Switch

Check Points
Reading
NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi).
Check between the housing of the
hydraulic filter restriction switch (42)
and ground
Continuity
Bad ground connection between the hydraulic filter restriction

switch (42) and ground.
Terminal A for wire 31H to ground.
Approximately
11.5 volts
NOTE: If the readings are correct replace the hydraulic filter restriction switch (42).
43 Engine Coolant Temperature Sender

Check Points
Terminal for wire 0_BE to ground
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect the connector from the engine coolant temperature sender.
Between terminals of engine coolant
temperature sender
130 to 9500
ohms
Replace engine coolant temperature sender.
Terminal A for wire 36C to ground
Bur 6-48930
Approximately
5 volts
Issued 2-03
Printed in U.S.A.
Copyright
4002-50
44 Air Filter Restriction Switch

Check Points
Reading
NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig).
Terminal for wire 0_BD to ground
Continuity
Bad ground circuit.
Approximately
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch (44).
45 Program/Reset Switch
Check Points
Terminal for wire 0_KM to ground
Reading
Continuity

Bad ground circuit.
24 volts
Check 12.5 ampere circuit breaker A. Also check circuit 1A.
NOTE: Press and hold the program/reset switch in the reset position.
24 volts
Bad program/rest switch.
NOTE: Put the program/reset switch (45) in the program position.

24 volts
Bad program/reset switch.
24 volts
Bad rotary lamp switch. Also check fuse Z and circuit 49 and
19Z.
NOTE: If 24 volts between wire 49 and ground and program/reset switch is not illuminated, replace program/reset
switch.

Check Points
Terminal for wire 0_KJ to ground
Reading
Continuity

Bad ground circuit.
24 volts
24 volts
Bad parking brake switch (46).
NOTE: Apply parking brake switch (46).

24 volts
Bad rotary lamp switch. Also check fuse Z and circuits 49 and
19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-51
Check Points
Reading
NOTE: Disconnect the connector from the instrument cluster.

Continuity
Bad brake warning pressure switch (38). Also check circuit 33P
and ground circuit at brake warning pressure switch.
Continuity
Bad coolant level sender (39). Also check circuit 31D and
ground circuit at coolant level sender.
Continuity
Bad secondary steering pressure switch (67). Also check

circuit 35X and ground circuit at pressure switch.
Open Circuit
Bad air filter restriction switch (44). Also check circuit 31F.
Open Circuit
Bad hydraulic filter restriction switch. Also check circuit 31H.
Continuity
130 to 9500
ohms
Bad engine coolant temperature sender (43). Also check circuit

circuit 36C and ground circuit at sender.
33 to 240 ohms
Bad fuel level sender (40). Also check circuit 36F and ground
circuit at sender.
130 to 9500
ohms
Bad hydraulic oil temperature sender (41). Also check circuit

36H and ground circuit at sender.
Bad ground circuit. Check wires 0_KP, 0_DAV, 0_HC, and

0_BG.
Connector terminal 21 to connector

terminal 33
Continuity
Bad wire 50T.
237 to 243
ohms
Bad engine oil pressure switch (50). Also check circuit 36P and
ground circuit.
Open Circuit
Bad redundant brake switche(s) (57). Also check circuit 33R.
Connector terminal 31 to terminals

26 and 27 on the transmission
electronic control module (26)
Continuity
Bad circuit 50L.
Connector terminal 32 to terminal 25

on the transmission electronic
control module (26)
Continuity
Bad circuit 50H.
Continuity
Check LH and RH stop lamps and circuit 44. Also check ground
circuit at lamps.
Continuity
Bad ground circuit.
Continuity
Bad ground circuit.
Continuity
Bad ground circuit.
24 volts
Bad fuse V. Also check circuit 19V.
24 volts
Bad fuse S. Also check circuit 19S.

Bur 6-48930
24 volts
Bad parking brake switch. Also check fuse A and circuit 19A.
Issued 2-03
Printed in U.S.A.
Copyright
4002-52

NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
24 volts
Check fuse G, blower switch, thermostat switch, and A/C low

pressure switch. Also check circuits 61R, 61A, and 61T.
NOTE: Put the five position rotary lamp switch in position four or five.
24 volts
Check lamp switch and fuse A. Also check circuits18A and

42R.
NOTE: Put the rotating beacon switch in the ON position.

24 volts
Check rotating beacon switch and fuse X. Also check circuit 46.
NOTE: Put the five position rotary lamp switch in position four or five. Put the high/low beam switch in HIGH
BEAM position.
24 volts
Check high/low beam switch, high/low beam relay, five position

rotary lamp switch, and fuse C. Also check circuits 18C and
64D and wires 41H and 41J_A.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and
off every 1-2
seconds

check wire 19B, circuit 45A to flasher module, and circuit 45L
NOTE: Put the turn signal switch in the RIGHT TURN position.
24 volts on and
off every 1-2
seconds

check wire 19B, circuit 45B to flasher module, and circuit 45R
NOTE: Put the program/reset switch in the PROGRAM position.

24 volts
Bad program/reset switch. Also check wire 37P and wire 1A_B
to ignition switch.
NOTE: Press and hold the program/reset switch in the RESET position.
24 volts
Bad program/reset switch. Also check wire 37R_B and wire

1A_B to ignition switch.
NOTE: Press and hold up/down count switch in UP position.
24 volts

Also check wires 37U and wire 13D from time delay module to
NOTE: Press and hold up/down count switch in DOWN position.
Bur 6-48930
24 volts

Also check wire 37D and wire 13D from time delay module to
Issued 2-03
Printed in U.S.A.
Copyright
4002-53

24 volts
Bad pilot control switch or fuse C. Also check wire 31L and
circuit 19C.
24 volts
Bad parking brake relay or fuse D. Also check circuits 52C and
19D.
24 volts
Bad pilot control relay or fuse C. Also check circuits 53C and
19C.

Check Points
Reading
Continuity

Bad ground circuit.
24 volts

24 volts
Bad pilot control switch (48).
24 volts
check circuit 49.
NOTE: If the readings are correct replace the pilot control switch (48).
49 Up/down Count Switch

Check Points
Reading
Continuity

Bad ground circuit.
24 volts
Check fuse S and time delay module. Also check circuits 19S
and 13D from time delay module to fuse S.
NOTE: Press and hold the up/down switch in the DOWN COUNT position.
24 volts
NOTE: Press and hold the up/down switch in the UP COUNT position.
24 volts
Bur 6-48930
24 volts
check circuit 49.
Issued 2-03
Printed in U.S.A.
Copyright
4002-54
TROUBLESHOOTING ENGINE OIL PRESSURE SWITCH, PILOT CONTROL,

PARKING BRAKE, AND REDUNDANT BRAKE SWITCHES
53
57
56
55
54
51
52
58
50
BC00N140
50.
51.
52.
53.
54.
Bur 6-48930
ENGINE OIL PRESSURE SWITCH

PILOT CONTROL RELAY NO. 10
PARKING BRAKE RELAY NO. 9
PILOT PRESSURE SOLENOID
55.
56.
57.
58.
FAN REVERSER SWITCH (OPTION)

FAN REVERSING SOLENOID (OPTION)
REDUNDANT BRAKE SWITCHES
RELAY SOCKET NO. 11
Issued 2-03
Printed in U.S.A.
Copyright
4002-55

Check Points
Reading

(50) terminals C and NC
Continuity

(50) terminals C and NO
Open Circuit

(50) terminal NC and ground
237 to 243
ohms

(50) terminal NO and ground
90 to 92 ohms
NOTE: Disconnect wire 36P from terminal C of engine oil pressure switch. Put master disconnect switch and
ignition switch in ON position.
Approximately
5 volts
Bad instrument cluster (47) or bad circuit 36P.
NOTE: Start engine and operate at idle speed.

terminal C and ground
90 to 92 ohms
Bad engine oil pressure switch.
51 Pilot Control Relay No. 10

Check Points
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch
(48) is OFF.
24 volts
0 volt
24 volts

Bad pilot control relay.
NOTE: Put the pilot control switch in ON position.

24 volts
52 Parking Brake Relay No. 9

Check Points
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (46) is OFF.
Terminal for wire 19D_B to ground
24 volts
0 volt
24 volts
Bad fuse D, also check circuit 19D.

Bad parking brake relay.

Bur 6-48930
24 volts
Bad instrument cluster (47). Also check wire 52C.
Issued 2-03
Printed in U.S.A.
Copyright
4002-56
53 Parking Brake Solenoid

Check Points
Reading
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 (52). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid (53).
54 Pilot Pressure Solenoid

Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control
switch (48) is OFF.
24 volts
Bad pilot control relay (51), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid (54).
55 Fan Reversing Switch (Option)

Check Points
Terminal for wire 0_DAF to ground
Reading
Continuity

Bad ground circuit.
24 volts
Check fuse P, ignition relay No. 1, and wires 19P_A and

13P_B.
NOTE: Put fan reversing switch in ON position (hold rocker in momentary position).
24 volts
Bad fan reversing switch.
NOTE: Put five position rotary lamp switch in position 3 or higher.
Terminal for wire 49_U to ground
Bur 6-48930
24 volts
Check five position rotary lamp switch. If LEDs in fan reversing

switch are not ON with 24 volts at check point, replace fan
reversing switch.
Issued 2-03
Printed in U.S.A.
Copyright
4002-57
56 Fan Reversing Solenoid (Option)

Check Points
Reading
NOTE: Disconnect wiring harness connector 158 from fan reversing solenoid.
Between pins 1and 2 of fan
reversing solenoid
Pin 2 of wiring harness connector
158 to ground
36 to 42 ohms
Continuity
Bad fan reversing solenoid.
Bad ground circuit.
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
158 to ground
24 volts
Bad fan reversing switch. Also check wire 52_A.
57 Redundant Brake Pressure Switches

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

Continuity
Bad ground circuit.
Terminal A for wire 33R to ground
Approximately
11.5 volts
Bad instrument cluster (47), also check circuit 33R.
NOTE: If the readings are good, replace the redundant brake pressure switch(es) (57).
58 Relay Socket No. 11

Check Points
Reading
0 volt
Bad instrument cluster (47). Also check circuit 23C to

instrument cluster.
24 volts
Bad fuse F. Also check circuit 19F to ignition relay No. 2 (15).
Terminal for wire 13K_B to ground
24 volts
Check wire 13K_B to ignition relay No. 2 (15).
24 volts
Check wires 13K_D and 13C_B and connectors 217F and

217M.
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-58
TROUBLESHOOTING BUCKET CONTROLS

63
62
65
64
60
59
61
BC00N140
59. DETENT SWITCH

60. BUCKET CONTROL VALVES ELECTROMAGNETIC DETENTS
61. RETURN TO TRAVEL/FLOAT SWITCH
62. RETURN TO DIG PROXIMITY SWITCH
Bur 6-48930
63. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY

SWITCH
64. FLOAT PRESSURE SWITCH
65. FLOAT SOLENOID
Issued 2-03
Printed in U.S.A.
Copyright
4002-59
59 Detent Switch
Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in
the OFF position.
24 volts
Bad pilot control relay (51), also check circuit 53P_B.
NOTE: Put the detent switch (59) in the ON position.

24 volts
Bad detent switch (59).
Terminal for wire 49_M to ground
24 volts
Bad circuit 49_M. Also check five position rotary lamp switch
(114). If detent switch illumination LED does not turn ON with
24 volts at check point, replace detent switch (59).
60 Bucket Control Valve Electromagnetic Detents

Check Points
Reading
NOTE: Disconnect the wiring harness connector from the control valve electromagnetic detents connector.
65 to 71 ohms
Bad return-to-travel detent electromagnet.

65 to 71 ohms
Bad height control detent electromagnet.

65 to 71 ohms
Bad return-to-dig control detent electromagnet.
to ground
24 volts
Bad detent switch (59). Also check wires 53P_B, 56_G, and
56_H.

to ground
24 volts
Bad detent switch (59). Also check wires 56_E and 56_H.

to ground
24 volts
Bad detent switch (59). Also check wires 56_F and 56_H.
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-60
61 Return-To-Travel/Float Switch
Check Points
Reading
Terminal for wire 0_DAG to ground
Continuity
Bad ground circuit.
Terminal for wire 0_DAH to ground
Continuity
Bad ground circuit.
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch (61). Put the return-totravel/float switch (61) in FLOAT position.
Continuity
NOTE: Put the return-to-travel/float switch (61) in the TRAVEL position.

Continuity
Pin 2 of connector 39F to ground
24 volts
Bad return-to-travel detent electromagnet. Also check circuit

55A.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch (61).
Put ignition switch in ON position. Put five position rotary lamp switch (114) in position 3 or higher.
Terminal for wire 49_K to ground
24 volts
Bad circuit 49_K. Also check five position rotary lamp switch
(114). If return-to-travel/float switch illumination LED is not ON
with 24 volts at check point, replace return-to-travel/float
switch.
62 Return-To-Dig Proximity Switch

Check Points
Reading
NOTE: Disconnect the connector from the return-to-dig proximity switch (62). Put the master disconnect switch
and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position and the detent
switch (59) in the ON position.
Terminal B for wire 0_AM to ground
Continuity
Terminal A for wire 53B_A to ground
24 volts

switch (59). Also check circuit 53B_A.
Terminal C for wire 56_D to ground
24 volts
Bad detent switch (59), also check circuit 56.
Bad ground circuit.
NOTE: If the readings are good, replace the return-to-dig proximity switch (62).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-61
63 Height Control/Return-To-Travel Proximity Switch

Check Points
Reading
NOTE: Disconnect the connector from the height control/return-to-travel proximity switch (63). Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (48) in the OFF position
and the detent switch (59) in the ON position.
Terminal B for wire 0_AA to ground
Continuity
Bad ground circuit.
Terminal A for wire 54B to ground
24 volts

switch (59). Also check circuit 54B.
Terminal C for wire 56_A to ground
24 volts
Bad detent switch (59). Also check circuit 56.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch (63).
64 Float Pressure Switch

Check Points
Reading
NOTE: Disconnect the wiring harness connector 178M from the float pressure switch.
switch
Open Circuit
switch
Continuity
NOTE: Shut down engine. Put ignition switch in ON position. Put pilot control switch in OFF position (switch LED
OFF).
Wiring harness connector 178M, pin
A and ground
24 volts
Bad pilot control relay. Also check wires 53P_C and 53P_D.
65 Float Solenoid
Check Points
Reading
NOTE: Disconnect the wiring harness connector 179F from the float solenoid.
Between terminals of float solenoid
37 to 43 ohms
Bad float solenoid.

to ground
Continuity
Bad ground circuit.
to ground
Bur 6-48930
24 volts
Bad float pressure switch. Also check wires 53S_A and 53S_B.
Issued 2-03
Printed in U.S.A.
Copyright
4002-62
TROUBLESHOOTING SECONDARY STEERING COMPONENTS AND RIDE

CONTROL
71
69
70
67
66
68A
73
72
68
BC00N140
66. SECONDARY STEERING MODULE (OPTION)

67. SECONDARY STEERING PRESSURE SWITCH (OPTION)
68. SECONDARY STEERING MOTOR (OPTION)
68A.SECONDARY STEERING SOLENOID (OPTION)
69. PIN ENGAGE SWITCH (OPTION)
Bur 6-48930
70.
71.
72.
73.
PIN ENGAGE SOLENOID (OPTION)

RIDE CONTROL SWITCH
RIDE CONTROL RELAY NO. 4
RIDE CONTROL SOLENOID
Issued 2-03
Printed in U.S.A.
Copyright
4002-63
66 Secondary Steering Module (Option)

Check Points
Reading
NOTE: Disconnect the wiring harness connector 90M from the secondary steering module.
Continuity
Bad relay on secondary steering motor (68) or bad secondary

steering solenoid (68A). Also Check wires 51_A, 51_B, and
51_C and ground circuit connections (wires 0_ND and 0_CF).
Continuity
Bad ground circuit.
Continuity

35X_D, 35X_C, and 35X_A.
Open Circuit

51P_A and 51P_B.
Continuity
Bad ground circuit.
Continuity
Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
24 volts
Bad wire 1_W to secondary steering motor (68) B+ stud.
24 volts
Bad fuse M or ignition switch. Also check circuits 19M and 12K.
24 volts
Check fuse R, ignition relay No. 1, ignition switch, and diode

module. Also check circuits 19R and 13P_B.

Continuity
11 volts

Check circuit 35X to instrument cluster. If circuit 35X okay,
problem is bad instrument cluster.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector 90M to secondary
steering module. Disconnect wire 51_B from secondary steering motor (68) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector 131F from secondary steering pressure switch (67). Apply a
ground to pin C of connector 131F.
24 volts
Bad secondary steering module.
67 Secondary Steering Pressure Switch (Option)

Check Points
Reading
NOTE: Disconnect wiring harness connector 131F from secondary steering pressure switch (67).
Continuity
Open Circuit
Pressure switch (67) pin A to pin C
Open Circuit

Continuity
Open Circuit
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-64
68 Secondary Steering Motor (Option)

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

ground terminal to ground
Continuity
Bad ground circuit.
Terminal for wire 51_B to ground.
10 to 45 ohms
Bad secondary steering motor (68) relay coil or secondary

steering solenoid (68A). 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
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.
24 volts
Check fuses M and R, secondary steering module (66), and

secondary steering pressure switch (67). If 24 volts is obtained
the secondary steering motor is bad. If fuse M or R was
replaced: if fuse M blows again, secondary steering module is
bad; if fuse R blows again, secondary steering module is bad
or secondary steering motor relay or secondary steering
solenoid is shorted.
68A Secondary Steering Solenoid (Option)

Check Points
Reading
NOTE: Disconnect connector 264M from secondary steering solenoid.

Between pins A and B of secondary
steering solenoid
Between pin B of connector 264M
and ground
36 to 42 ohms
Continuity
Bad secondary steering solenoid.
Bad ground circuit.
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 A of connector 264M
and ground
Bur 6-48930
24 volts
Check secondary steering module (66) and secondary steering

pressure switch (67).
Issued 2-03
Printed in U.S.A.
Copyright
4002-65
69 Pin Engage Switch (Option)

Check Points
Terminal for wire 0_DAL to ground
Reading
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.
24 volts
0 volt
Bad fuse P or ignition relay No. 2. Also check circuits 19P_A

and 13P_B.
NOTE: Put the pin engage switch (69) in the ON position.

24 volts
24 volts
Check the five position rotary lamp switch (114). Also check
circuit 49. If LED in pin engage switch is not ON with 24 volts
at check point, replace pin engage switch.
70 Pin Engage Solenoid (Option)

Check Points
Terminal for wire 0_AB to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(69) in the ON position.
24 volts
Bad pin engage switch (69), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid (70).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-66
71 Ride Control Switch

Check Points
Reading
NOTE: Disconnect connector 44F from ride control switch (71).

Continuity
Bad ground circuit.
Ride control switch terminal 6

(positive) to terminal 7 (negative)
Continuity
NOTE: Connect connector 44F to ride control switch (71). Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
24 volts
0 volt
Check fuse C and ignition relay No. 1. Also check circuits 19C
and 13P_A.
NOTE: Put the ride control switch (71) in the ON position.

24 volts
NOTE: Put the five position rotary light switch (114) in position 3 or higher.
24 volts
49. If LED in ride control switch is not ON with 24 volts at check
point, replace ride control switch.
Reading
72 Ride Control Relay No. 4

Check Points
Terminal 85 for wire 0_DD to
connector 19F pin 57
Continuity
Check wire 44F.
Terminal 86 for wire 58H_B to

connector 19F pin 8
Continuity
Check wire 58H_B.
Terminal 87 for wire 58_B to ride

control switch (71) pin 6
Continuity
Check wire 58_B
NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position.
24 volts
Bad ride control switch. Also check wire 58S.
NOTE: If readings are normal, replace ride control relay (72).
73 Ride Control Solenoid

Check Points
Reading
NOTE: Disconnect connector 5F from ride control solenoid.

Between terminals 1 and 2 of ride
control solenoid
Bur 6-48930
Continuity
20 to 26 ohms
Bad ground circuit.

Bad ride control solenoid.
Issued 2-03
Printed in U.S.A.
Copyright
4002-67
TROUBLESHOOTING WIPER/WASHER
74
79
75
77
78
76
BC00N140
74. FRONT WIPER MOTOR

75. FRONT WIPER AND WASHER SWITCH
76. FRONT WASHER PUMP MOTOR
Bur 6-48930
77. REAR WIPER AND WASHER SWITCH

78. REAR WASHER PUMP MOTOR
79. REAR WIPER MOTOR
Issued 2-03
Printed in U.S.A.
Copyright
4002-68
74 Front Wiper Motor

Check Points
Terminal for wire 0_KN to ground
Reading
Continuity

Bad ground circuit.
NOTE: Make sure the front wiper and washer switch (75) is in the OFF position.
Between terminals B and D for wires
63C and 63L
Continuity
Bad front wiper motor.
24 volts
24 volts
0 volt
washer switch (75).
Bad front wiper and washer switch (75)
24 volts
0 volt
washer switch (75).
24 volts pulse
24 volts pulse
NOTE: If the readings are good, replace the front wiper motor (74).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-69
75 Front Wiper and Washer Switch

Check Points
Terminal for wire 0_DAR to ground
Reading
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 (75) is in the OFF position.
24 volts
24 volts
0 volt
washer switch (75).
Bad front rotary wiper and washer switch (75)
24 volts
0 volt
Check fuse J, also check circuit 19J. Bad front rotary wiper and
washer switch (75).
Bad front rotary wiper and washer switch (75).
24 volts pulse
24 volts pulse
76 Front Washer Pump Motor

Check Points
Reading
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 (75).
24 volts
Bad front wiper and washer switch (75), also check wires 63W
and 63W_A.
NOTE: If the readings are good, replace the front washer pump motor (76).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-70
77 Rear Wiper and Washer Switch

Check Points
Terminal for wire 0_DW to ground
Reading
Continuity

Bad ground circuit.

Terminal for wire 19K_D to ground
24 volts
Terminal for wire 19K_C to ground
24 volts
NOTE: Put the rear wiper and washer switch in the ON position.
24 volts
NOTE: Press and hold the rear wiper and washer switch (77) in the WASH position.
24 volts
NOTE: Put the five position rotary lamp switch in position 3 or higher.
Terminal for wire 49_L to ground
24 volts
Check rotary lamp switch and circuit 49. If LEDs in rear wiper
and washer switch are not ON with 24 volts at check point,
replace rear wiper and washer switch.
78 Rear Washer Pump Motor

Check Points
Reading
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (77) in WASH position.
24 volts
Bad rear wiper and washer switch (77) Also check wires
68W_A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor (78).
79 Rear Wiper Motor

Check Points
Terminal for wire 0_MA to ground
Reading
Continuity

Bad ground circuit.
NOTE: Make sure the rear wiper and washer switch (77) is in the OFF position.
Between terminals for wires 68C_B
and 68L_C
Continuity
24 volts
Check fuse K, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (77) in the ON position.
Terminal for wire 68L_C to ground
24 volts
0 volt
NOTE: If the readings are good, replace the rear wiper motor (79).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-71
TROUBLESHOOTING HORN, BLOWER, AND AIR CONDITIONING
86
81
87
90
83
80
89
88
82
84
85
BC00N140
80.
81.
82.
83.
84.
85.
HORN RELAY NO. 5

HORN
SEAT COMPRESSOR
BLOWER SWITCH
SPEED RESISTOR
BLOWER MOTOR
86.
87.
88.
89.
90.
A/C LOW PRESSURE SWITCH (IN CAB)

A/C HIGH PRESSURE SWITCH (IN REAR CHASSIS)
THERMOSTAT SWITCH
COMPRESSOR CLUTCH LOCKOUT RELAY NO. 14
COMPRESSOR CLUTCH
80 Horn Relay No. 5

Check Points
Reading
Terminal for wire 19U_B to ground
24 volts
Check fuse U, also check wire 19U_B.
Terminal for wire 19U_C to ground
24 volts
Check wire 19U_C.
24 volts
NOTE: Have another person push and hold the horn switch.
Bur 6-48930
0 volt
24 volts
Bad horn switch.

Issued 2-03
Printed in U.S.A.
Copyright
4002-72
81 Horn
Check Points
Terminal for wire 0_AD to ground
Reading
Continuity

Bad ground circuit.
NOTE: Disconnect the wire 64 from the horn (81). Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground.
24 volts
Check the horn relay (80). Also check wires 64 and 64_A.
NOTE: If the readings are good replace the horn (81).
82 Seat Compressor and Switch (Option)

Check Points
Terminal for wire 0_DY to ground
Reading
Continuity

Bad ground circuit.
Terminal for wire 19N_A at seat
switch
24 volts
Check fuse N and accessory relay (16). Also check wire 19N_A
and circuit 12P.
NOTE: Put the seat compressor (82) switch in the ON position.

Terminal for wire from seat switch at
compressor
24 volts
Bad seat switch, also check circuit from seat switch to

compressor.
NOTE: If the readings are good replace the seat compressor.
83 Blower Switch
Check Points
Reading
24 volts
Check fuse G and ignition relay No. 2 (15). Also check circuits
19G and 13R.
24 volts
24 volts

NOTE: Turn the blower switch to LOW.
NOTE: Turn the blower switch to MEDIUM.

24 volts
24 volts
24 volts
24 volts
NOTE: Turn the blower switch to HIGH.
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-73
84 Blower Motor Speed Resistors with Thermal Fuse

Check Points
Reading
NOTE: Disconnect the wiring harness connector 29M from the blower motor (85).
motor connector
Approximately
4.5 ohms

motor connector
Approximately
1.5 ohms
85 Blower Motor
Check Points
Terminals for wire 0_DZ to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (83) to
HIGH.
24 volts
Check the blower switch (83).
NOTE: If the readings are correct and the blower motor (85) does not run, replace the blower motor (85). Turn
the blower switch (83) to LOW. If the blower motor (85) ran in HIGH but not in LOW or MEDIUM, check the blower
motor resistor (84).
86 A/C Low Pressure Switch (In Cab)

Check Points
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (83) to HIGH and
the thermostat switch (88) to COLD.
Terminal B for wire 61A_E to ground
24 volts
NOTE: Disconnect the wiring harness connector 27M from the A/C low pressure switch (86).
Between terminals of low pressure
switch (86)
Open Circuit
Bad A/C low pressure switch (86), also check refrigerant

charge level. (Pressure must be above 1.4 bar (20 psi) for
switch to open.)
87 A/C High Pressure Switch (In Rear Chassis)

Check Points
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH and the
24 volts
NOTE: Disconnect wiring harness connector 98 from A/C high pressure switch (87).
Between terminals of A/C high
pressure switch (87)
Bur 6-48930
Open Circuit
Bad A/C high pressure switch (87), also check for excessive
refrigerant pressure. (Switch closes at or above 27.6 bar (400
psi)).
Issued 2-03
Printed in U.S.A.
Copyright
4002-74
88 Thermostat Switch
Check Points
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (83) to HIGH.
24 volts
Check the blower switch (83), also check wire 61T.
NOTE: Turn the thermostat switch (88) all the way to COLD.
24 volts
Bad thermostat switch (88).
89 Compressor Clutch Lockout Relay No. 14

Check Points
Reading
Continuity

Bad ground circuit.
24 volts
0 volt
24 volts
Check thermostat switch (88), also check wire 61A_C.

Check A/C low pressure switch (86) and A/C high pressure
switch (87).
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector 98 from A/C high pressure
switch. Connect a jumper wire between pins A and B of connector 98. Put ignition switch in ON position.
24 volts
0 volt
Check wires 61R_C and 61R_D. If air conditioning indicator on

instrument cluster (47) is not ON, check wires 61R_F and
61R_G to instrument cluster.
90 Compressor Clutch
Check Points
Reading
Terminals for wire 61C to ground
Bur 6-48930
24 volts
Check the compressor clutch lockout relay (89), also check

circuit 61C.
Issued 2-03
Printed in U.S.A.
Copyright
4002-75
TROUBLESHOOTING CIGAR LIGHTER, POWER COVERTER, POWER

OUTLET, RADIOS AND SPEAKERS
97
98
94
95
96
92
93
91
BC00N140
91. CIGAR LIGHTER

92. POWER CONVERTER
93. POWER OUTLET
94. REMOTE OR 24 VOLT RADIO

95. 12 VOLT RADIO
96. RADIO POWER CONVERTER
97. LEFT SPEAKER

98. RIGHT SPEAKER
91 Cigar Lighter (Option)

Check Points
Reading
24 volts
Continuity

Check fuse W, also check circuit 19W.
Bad ground circuit.
NOTE: If the readings are good replace the cigar lighter (91).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-76
92 Power Converter 24 volts to 12 volts (Option)

Check Points
Terminal for wire 0_RA to ground
Reading
Continuity
24 volts

Bad ground circuit.
Check wire 1_V to cab power stud.

Terminal for wire 19L_B to ground
24 volts
Bad fuse L, also check circuit 19L.
Terminal for wire 12V_B to ground
12 volts
Bad power converter (92).
93 Power Outlet (Option)

Check Points
Reading
Terminal for wire 0_RB to ground
Continuity
Terminal for wire 12V_A to ground
12 volts

Bad ground circuit.
Bad power converter (92), also check wire 12V_A.
NOTE: If the readings are good replace the power outlet (93).
94 Remote Radio or 24 Volt Radio (Option)

Check Points
Reading

0_QC to ground
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on. Put balance control for RH
and LH speakers to center position.
65C_A to ground
24 volts
Check fuse L, also check circuits 19L and 65C.
NOTE: Keep the ignition switch and radio ON. Disconnect wiring harness connectors at LH and RH speakers (97
and 98).
111M to ground
Voltage
(94).

112M to ground
Voltage
(94).
95 12 Volt Radio Ready (Option)

Check Points
Reading

0_QC to ground
Continuity

Bad ground circuit.

65C_A to ground
Bur 6-48930
12 volts
Check fuse L, also check circuit 19L and 65C. Also check the
radio power converter (96).
Issued 2-03
Printed in U.S.A.
Copyright
4002-77
96 Radio Power Converter (24 volts to 12 volts) (Option)

Check Points
Terminal for wire 0_PD to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Turn radio on.
12 volts
Check fuse L and circuit 19L. Bad radio power converter (96).
Reading
97 Left Speaker (Option)

Check Points
NOTE: Disconnect connector from left speaker (97). Put master disconnect switch and ignition switch in ON
112M to ground
Voltage

112M to ground
Continuity
Bad circuit between the left speaker (97) and the radio or a bad
radio (94).
Bad circuit between the left speaker (97) and the radio (94).
NOTE: If the readings are good, replace the left speaker (97).
98 Right Speaker (Option)

Check Points
Reading
NOTE: Disconnect connector from right speaker (98). Put master disconnect switch and ignition switch in ON
111M to ground
Voltage
Bad circuit between the right speaker (98) and the radio or a
bad radio (94).

111M to ground
Continuity
Bad circuit between the right speaker (98) and the radio (94).
NOTE: If the readings are good, replace the right speaker (98).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-78
TROUBLESHOOTING ROTATING BEACON, STOP SWITCH, HAZARD

SWITCH, TURN SIGNAL/HI/LOW BEAM/HORN SWITCH, AND FLASHER
MODULE
100
103
101
99
104
102
105
BC00N140
99. BEACON SWITCH

100. ROTATING BEACON
101. BRAKE LAMP PRESSURE
SWITCH
102. BRAKE LAMPS RELAY NO. 6

103. HAZARD SWITCH
104. TURN SIGNAL, HI/LOW BEAM, AND HORN SWITCH

105. FLASHER MODULE
99 Beacon Switch
Check Points
Terminal for wire 0_DAP to ground
Reading
Continuity

Bad ground circuit.
NOTE: Put master disconnect switch in ON position and five position rotary lamp switch (114) in position 3 or
higher.
Terminal for wire 49_R to ground
24 volts
Check the five position rotary lamp switch (114), also check
circuit 49. If LED in beacon switch is not ON with 24 volts at
check point, replace beacon switch.
Terminal for wire 19X to ground
24 volts
Check fuse X, also check wire 19X.
NOTE: Put the beacon switch (99) in the ON position.

Bur 6-48930
24 volts
Bad beacon switch (99).

Issued 2-03
Printed in U.S.A.
Copyright
4002-79
100 Rotating Beacon

Check Points
Reading
Bulb
Continuity
Bad bulb.
Terminal for wire 0_MC to ground
Continuity
Bad ground circuit.
NOTE: Put master disconnect switch and beacon switch (99) in ON position.
24 volts
Bad circuit between the beacon (100) and the beacon switch
(99). Also check the beacon switch (99).
NOTE: If readings are good replace the rotating beacon (100).
101 Brake Lamp Pressure Switch

Check Points
Reading

24 volts
0 volt
Check circuit breaker B, also check wires 1B_A and 1B_D.

24 volts
102 Brake Lamps Relay No. 6

Check Points
Terminal for wire 0_DC to ground
Reading
Continuity

Bad ground circuit.

Terminal for wire 1B_E to ground
24 volts
0 volt
0 volt
Check circuit breaker B and wires 1B_E and 1B_F.
24 volts
24 volts
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-80
103 Hazard Switch

Check Points
Terminal for wire 0_KH to ground
Reading
Continuity
Bad ground circuit.

24 volts
Check circuit breaker B. Also check wires 1B and 1B_F.
NOTE: Put hazard switch in ON position.

Bad hazard switch (103). If hazard switch LED is not ON with

24 volts at check point, replace hazard switch.
24 volts
NOTE: Put five position rotary lamp switch (114) in position 3 or higher.
49 to lamp switch (114). If hazard switch LED is not ON with 24
volts at check point, replace hazard switch.
24 volts
104 Turn Signal, Hi/Low Beam, and Horn Switch

Check Points
Reading

HORN SWITCH
Terminal for wire 0_KG to ground
Continuity
Bad ground circuit.

Check fuse U and horn relay (80). Also check wires 64C,
64C_A, and 19U_C.
24 volts
NOTE: If readings are good, replace the switch (104).

TURN SIGNAL
24 volts
Check fuse B and ignition relay No. 1 (14). Also check wires
19B and 19B_A.
NOTE: Move turn signal lever to RIGHT turn position.

24 volts
NOTE: Move turn signal lever to LEFT turn position.

24 volts
HI/LOW BEAM SWITCH

Terminal for wire 0_KF to ground
Continuity
Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in OFF position. Hold Hi/Low beam lever in HIGH beam
position.
Bur 6-48930
Continuity
Bad hi/low beam switch (104).
Issued 2-03
Printed in U.S.A.
Copyright
4002-81
105 Flasher Module

Check Points
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_DAN to ground
Continuity
Bad ground circuit.
Terminal for wire 0_DAQ to ground
Continuity
Bad ground circuit.
Terminal for wire 45N_A to terminal

for wire 45N_B (North American
machines only)
Continuity
Bad 45N circuit.

Terminal for wire 1B_B to ground
24 volts
Check flasher circuit breaker B. Also check wires 1B_B and

1B_F.
NOTE: Put ignition switch in the ON position. Put the hazard switch (103) ON.
Terminal for wire 45H_A to ground
24 volts
Intermittent 24
volts
Intermittent 24
volts
Bad hazard switch (103). Also check wires 45H_A and 45H.
NOTE: Put hazard switch (103) in OFF position. Put turn signal switch (104) in RIGHT turn position.
24 volts
Intermittent 24
volts
Bad turn signal switch (104) or fuse B. Also check wires 45B_A
and 45B.
NOTE: Put turn signal switch (104) in LEFT turn position.

24 volts
Intermittent 24
volts
Bur 6-48930
Bad turn signal switch (104) or fuse B. Also check wires 45A_A
and 45A.
Issued 2-03
Printed in U.S.A.
Copyright
4002-82
TROUBLESHOOTING EXTERNAL LIGHTS AND SIGNALS, ROTARY LAMP

SWITCH, AND CAB LIGHTS
117
112
113
118
110
108
115
114
109
111
106
116
107
BC00N140
106. LH REAR COMBINATION LAMP

107. RH REAR COMBINATION LAMP
108. LH FRONT COMBINATION LAMP
109. RH FRONT COMBINATION LAMP
110. LH REAR WORK LAMP
111. RH REAR WORK LAMP
112. LH FRONT WORK LAMP
Bur 6-48930
113.
114.
115.
116.
117.
118.
RH FRONT WORK LAMP

FIVE POSITION ROTARY LAMP SWITCH
HIGH/LOW BEAM RELAY NO. 13
LICENSE PLATE LAMP
DOME LAMP
COURTESY LAMP
Issued 2-03
Printed in U.S.A.
Copyright
4002-83
106 LH Rear Combination Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 125 from LH rear combination lamp connector.
pin 5
Continuity
Bad stop lamp bulb.

pin 5
Continuity
Bad turn lamp bulb.

pin 5
Continuity
Bad tail lamp bulb.

pin 5
Continuity
NOTE: Connect wiring harness connector 125 to LH rear combination lamp connector.
Continuity
Bad ground circuit.
24 volts

lamps relay (102).

24 volts

NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.
Intermittent 24
volts
24 volts
Check fuse F and lamp switch (114). Also check wires 18F_A
and 18F_D to fuse F, and wire 41T_A from fuse F to lamp
switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp (106).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-84
107 RH Rear Combination Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 127 from RH rear combination lamp connector.
pin 5
Continuity
Bad stop lamp bulb.

pin 5
Continuity
Bad turn lamp bulb.

pin 5
Continuity
Bad tail lamp bulb.

pin 5
Continuity
NOTE: Connect wiring harness connector 127 to RH rear combination lamp connector.
Continuity
Bad ground circuit.
24 volts

lamps relay (102).

24 volts

NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R_A to ground
Intermittent 24
volts
Terminal for wire 18G_A to ground
24 volts
Check fuse G and lamp switch (114). Also check wires 18G_A,
18G_D, and 18G_F to fuse G, and wire 41T_A from fuse G to
lamp switch (114).
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp (107).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-85
108 LH Front Combination Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 6 from LH front combination lamp connector.
pin 1
Continuity

pin 1
Continuity

pin 1
Continuity

pin 1
Continuity
NOTE: Connect wiring harness connector 6 to LH front combination lamp connector.

Terminal for wire 0_AL to ground
Continuity
Bad ground circuit.
24 volts
Check fuse F and five position rotary lamp switch (114). Also
check circuit 18F and wires 41T_A and 41T_B.
24 volts
Check fuse B, high/low beam relay (115), five position rotary

circuit 18B and wire 41H.
24 volts
Check fuse D, high/low beam relay (115), five position rotary

circuit 18D and wire 41L_A.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Intermittent 24
volts
NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp (108).
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-86
109 RH Front Combination Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 8 from RH front combination lamp connector.
pin 1
Continuity

pin 1
Continuity

pin 1
Continuity

pin 1
Continuity
NOTE: Connect wiring harness connector 8 to RH front combination lamp connector.

Terminal for wire 0_AG to ground
Continuity
Bad ground circuit.
24 volts
Check fuse G and five position rotary lamp switch (114). Also
check circuit 18G and wires 41T_A and 41T_B.
24 volts
Check fuse C, high/low beam relay (115), five position rotary

circuit 18C and wire 41H.
24 volts
Check fuse E, high/low beam relay (115), five position rotary

circuit 18E and wire 41L_A.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Intermittent 24
volts
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp (109).
110 LH Rear Work Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 83F from LH rear work lamp connector.
Continuity
Bad lamp bulb.
NOTE: Connect wiring harness connector 83F to LH rear work lamp connector.
Terminal for wire 0_ME to ground
Continuity
Bad ground circuit.
Bur 6-48930
24 volts
18A to fuse A.
Issued 2-03
Printed in U.S.A.
Copyright
4002-87
111 RH Rear Work Lamp

Check Points
Reading
NOTE: Disconnect wiring harness connector 80F from RH rear work lamp connector.
Continuity
Bad lamp bulb.
NOTE: Connect wiring harness connector 80F to RH rear work lamp connector.
Terminal for wire 0_MF to ground
Continuity
Bad ground circuit.
24 volts
18A to fuse A.
Reading
112 LH Front Work Lamp

Check Points
NOTE: Disconnect wiring harness connector 79F from LH front work lamp connector.
Continuity
Bad lamp bulb.
NOTE: Connect wiring harness connector 79F to LH front work lamp connector.
Terminal for wire 0_MH to ground
Continuity
Bad ground circuit.
24 volts
19Z to fuse Z.
Reading
113 RH Front Work Lamp

Check Points
NOTE: Disconnect wiring harness connector 78F from RH front work lamp connector.
Continuity
Bad lamp bulb.
NOTE: Connect wiring harness connector 78F to RH front work lamp connector.
Terminal for wire 0_MJ to ground
Continuity
Bad ground circuit.
Terminal for wire 42C_C to ground
Bur 6-48930
24 volts
19Z to fuse Z.
Issued 2-03
Printed in U.S.A.
Copyright
4002-88
114 Five Position Rotary Lamp Switch

Check Points
Reading

Terminal for wire 1_N to ground
24 volts
Check wire 1_N.
24 volts
Check fuse Z, also check circuit 19Z.
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
24 volts
115 High/Low Beam Relay No. 13

Check Points
Reading

Terminal for wire 64D_A to ground
Continuity
Check high/low beam switch (104). Also check circuits 64D and
0_KF to and through the high/low beam switch.

24 volts
Check circuit 1_H.
NOTE: Put the 5 position rotary lamp switch (114) in position 3 or 4.

24 volts
Bad five position rotary lamp switch (114). Also check wire
41J_A.
NOTE: Put high/low beam lever in LOW beam position.

24 volts

Bur 6-48930
24 volts

Issued 2-03
Printed in U.S.A.
Copyright
4002-89
116 License Plate Lamp

Check Points
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 five position rotary lamp switch (114) in position 2.
Terminal for wire 18G_E to ground
24 volts
Check fuse G and five 5 position rotary lamp switch (114). Also
check circuit 18G.
Reading
117 Dome Lamp

Check Points
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 (118) switch in ON position.
Terminal for wire 19U_D to ground
24 volts
Check fuse U, also check circuit 19U.
NOTE: If readings are good, replace dome lamp (118).
118 Courtesy Lamp

Check Points
Reading
Bulb
Continuity
Bad bulb.
Terminal for wire 0_ML to ground
Continuity
Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put five position rotary lamp switch (114) in position 2 or
higher.
Bur 6-48930
24 volts
Check circuit 49, also check five position rotary lamp switch
(114).
Issued 2-03
Printed in U.S.A.
Copyright
4002-90
CONNECTORS
CONNECTOR 1 - FRONT CHASSIS HARNESS TO
MAIN CAB HARNESS

291660A1
319148A1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
45L N-1.0
Left Turn Signal
53P_D W-1.0
53P_C W-0.8
45R N-1.0
Right Turn Signal
45R_D N-0.8
Right Turn Signal
None
D
18G_G Or-0.8
Position RH
45L_C N-0.8
Left Turn Signal
None
18G Or-1.0
Position RH
18F Or-1.0
Position LH
18F_E Or-0.8
Left Tail Position
18B Or-1.0
High Beam LH
18B_A Or-0.8
High Beam LH
19M_B Or-1.0
19M_A Or-0.8
19R_A Or-0.8
19R_B Or-1.0
35X_B Y-1.0
35X_E Y-0.8
54B W-1.0
Height-RTT Signal
54B_A W-0.8
Height-RTT Signal
53B W-1.0
RTD Signal
53B_B W-0.8
RTD Signal
64A Or-0.8
Horn
64 Or-1.0
Horn
18D Or-1.0
Low Beam LH
18D_A Or-0.8
Low Beam LH
18E Or-1.0
Low Beam RH
18E_A Or-0.8
Low Beam RH
18C Or-1.0
High Beam RH
18C_A Or-0.8
High Beam Fused Pwr
None
None
None
None
56_C W-1.0
Prox Switch Pwr
56_J W-0.8
Prox Switch Pwr
57 W-1.0
Pin Engage Sol Pwr
57_A W-0.8
Pin Engage Sol Pwr
Ride Cntrl Sol Pwr
58_A W-0.8
Ride Cntrl Sol Pwr
None
None
None
None
58 W-1.0
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-91
CONNECTOR 2 - FRONT WASHER PUMP MOTOR
CONNECTOR 5F - RIDE CONTROL SOLENOID TO

3227856R1
CAV
WIRE IDENT
CIRCUIT
291718A1
CAV
WIRE IDENT
CIRCUIT
63W Or-1.0
Front Washer Pump
58_C W-1.0
0_G Bk-1.0
0_AC Bk-1.0
Ride Control Ground
CONNECTOR 3 - REAR WASHER PUMP MOTOR

CONNECTOR 6 - LH FRONT COMBINATION

225351C1
3227856R1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
0_AL Bk-1.0
Lights Ground LH
18D Or-1.0
Low Beam LH
68W Or-1.0
Rear Washer Pump
0_F Bk-1.0
18B Or-1.0
High Beam LH
18F Or-1.0
Position LH
45L N-1.0
Left Turn Signal
CONNECTOR 4 - BRAKE DECLUTCH PRESSURE

None
245482C1
CAV
WIRE IDENT
CIRCUIT
19A_A Or-1.0
Declutch Switch
25G LU-1.0
Declutch Switch
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-92
CONNECTOR 8 - RH FRONT COMBINATION
CONNECTOR 12F - RTD HARNESS FOR XT

245485C1
225351C1
CAV
WIRE IDENT
CIRCUIT
0_AG Bk-1.0
Lights Ground RH
18E Or-1.0
Low Beam RH
18C Or-1.0
High Beam RH
18G Or-1.0
Position RH
45R N-1.0
Right Turn Signal
CAV
WIRE IDENT
CIRCUIT
53B W-1.0
RTD Signal
0_AF Bk-1.0
RTD Ground
56_B W-1.0
RTD Power
CONNECTOR 12M - RTD HARNESS FOR XT

None
CONNECTOR 10 - HEIGHT CONTROL/RTT

PROXIMITY SWITCH TO FRONT CHASSIS
HARNESS
245484C1
CAV
WIRE IDENT
CIRCUIT
53B_A W-1.0
RTD Signal
0_AM Bk-1.0
RTD Ground
56_D W-1.0
RTD Power
245484C1
CAV
WIRE IDENT
CIRCUIT
54B W-1.0
Height/RTT Signal
0_AA Bk-1.0
Height/RTT Ground
56_A W-1.0
Height/RTT Power
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-93
PEDESTAL HARNESS
CAV
WIRE IDENT
33
None
34
50G_D Bk-0.8
CAN Ground
35
44_F T-0.8
Brake Light Signal
36
53C_A W-0.8
37
374972A1
CAV
WIRE IDENT
CIRCUIT
CIRCUIT
None
38
0_DAB Bk-0.8
Signal Ground
39
0_DL Bk-0.8
Signal Ground
40
0_DAA Bk-0.8
None
41
0_DX Bk-0.8
Horn Ground
42
64C_A Or-0.8
Horn Control
43
19A_S Or-0.8
Cab Switched Pwr
44
25F_A LU-0.8
Forward Signal
45
25R_A LU-0.8
Reverse Signal
19V Or-0.8
46
25T_C LU-0.8
Neutral Signal
19S Or-0.8
47
33P_A Y-0.8
48
25W_A LU-0.8
31D_A Y-0.8
49
25Z_A LU-0.8
35X_E Y-0.8
50
25Y_A LU-0.8
31F_B Y-0.8
51
49_F S-0.8
Pilot Light Power
31H_A Y-0.8
52
28C_A W-0.8
None
0_DAU Bk-0.8
Analog Ground
53
0_DAC Bk-0.8
Relay Ground
18L_C Or-0.8
Grid Heater Lamp
54
10
61R_F Or-0.8
A/C Telltale
55
64D_A Or-0.8
11
0_DBA Bk-0.8
56
13K_G Or-0.8
Ignition Switch Pwr
12
42R_C DU 0.8
Rear Work Light Pwr
57
63H_A Or-0.8
13
46_A K-0.8
Beacon Switched Pwr
58
63L_A Or-0.8
None
14
None
None
59
63C_A Or-0.8
Front Wiper Park
15
18C_B Or-0.8
High Beam Fused Pwr
60
19J_B Or-0.8
16
45L_E N-0.8
Left Turn Signal
61
0_DV Bk-0.8
Beacon Wpr Diode Ground
17
45R_C N-0.8
Right Turn Signal
62
1A_C R-0.8
18
36C_B P-0.8
ECT Signal
63
12K_B Or-0.8
ACC Power
19
36F_A P-0.8
Fuel Level Signal
64
21K_A W-0.8
20
36H_A P-0.8
Hot Signal
65
1B_C R-0.8
Hazard Switch Power
None
66
19B-A Or-0.8
Turn Signal Power
21
22
36P_B P-0.8
EOP Signal
67
45H_A N-0.8
Hazard Switch Power
23
23C_A W-0.8
68
19C_C Or-0.8
Ride Control Fused Power
None
69
45A_A N-0.8
Reset Signal
70
45B_A N-0.8
24
25
37R_C P-0.8
26
None
27
28
None
33R_D Y-0.8
29
Red Brake Sw Signal

None
30
52C_A W-0.8
31
50L_A G-0.5
CAN L
32
50H_A Y-0.5
CAN H
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-94
CONNECTOR 13M - PEDESTAL HARNESS TO
MAIN CAB HARNESS
CAV
WIRE IDENT
34
50G_A Bk-0.8
CAN Ground
35
44_G T-0.8
Brake Light Signal
36
53C W-0.8
37
374971A1
WIRE IDENT
CIRCUIT

None
38
0_KR Bk-0.8
Signal Ground
39
0_KD Bk-0.8
Signal Ground
41
0_KG Bk-0.8
Horn Hi Lo Beam Ground
42
64C Or-0.8
Horn Control
43
19A_G Or-0.8
Trans Control Pwr
40
CAV
CIRCUIT
None
44
25F LU-0.8
Forward Signal
45
25R LU-0.8
Reverse Signal
25T_B LU-0.8
Neutral Signal
19V_A Or-0.8
46
19S_A Or-0.8
47
None
33P_B Y-0.8
48
25W LU-0.8
31D_B Y-0.8
49
25Z LU-0.8
35X_F Y-0.8
50
25Y LU-0.8
31F_C Y-0.8
51
49_A S-0.8
Pilot Light
31H_B Y-0.8
52
0_KP Bk-0.8
Analog Ground
53
18L_D Bk-0.8
Grid Heater Lamp
54
10
61R_G Or-0.8
A/C Telltale
55
64D Or-0.8
11
31Y_B Y-0.8
56
13K Or-0.8
Ignition Switch Pwr
12
42R_A Y-0.8
57
63H Or-0.8
13
46_B K-0.8
Beacon Telltale
58
63L Or-0.8
None
59
63C Or-0.8
Front Wiper Park
14
None
0_KM Bk-0.8
Pilot Light Ground

None
15
18C_C Or-0.8
High Beam Telltale
60
19J Or-0.8
16
45L_F N-0.8
Left Turn Signal
61
0_KN Bk-0.8
Front Wiper Ground
17
45R_F N-0.8
Right Turn Signal
62
1A_A R-0.8
18
36C_C P-0.8
ECT Signal
63
12K_C Or-0.8
Ign Switch ACC Power
19
36F_B P-0.8
Fuel Level Signal
64
21K W-0.8
20
36H_B P-0.8
Hot Signal
65
1B R-0.8
Hazard Switch Power
None
66
19B Or-0.8
Turn Signal Power
45H N-0.8
Hazard Switch Power
21
22
36P_C P-0.8
EOP Signal
67
23
23C W-0.8
68
19C Or-0.8
None
69
45A N-0.8
Reset Signal
70
45B N-0.8
24
25
37R_A P-0.8
26
None
27
28
None
33R_E Y-0.8
29
Red Brake Sw Signal

None
30
52C W-0.8
31
50L G-0.5
CAN L
32
50H Y-0.5
CAN H
33
Bur 6-48930
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-95
CONNECTOR 17M - BUCKET CONTROL VALVE
ELECTROMAGNETIC DETENTS TO MAIN CAB
HARNESS
225351C1
CAV
WIRE IDENT
CIRCUIT
55A W-0.8
RTT Float Switch
54B_C W-0.8
Height Control Elec Mag
53B_B W-0.8
RTD Signal
56_G W-0.8
56_F W-0.8
56_E W-0.8
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-96
FUSE BLOCK 18F TO MAIN CAB HARNESS
232118A1
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-97
CAV
A1
WIRE IDENT
13P_A Or-1.0
CIRCUIT
B1
Ign Relay 1 (5 Way)
C1
Ign Relay 1 (5 Way)
D1
Ign Relay 1 (5 Way)
E1
Ign Relay 1 (5 Way)
F1
13R Or-1.0
G1
Ign Relay 2 (5 Way)
H1
Ign Relay 2 (5 Way)
J1
Ign Relay 2 (5 Way)
K1
Ign Relay 2 (5 Way)
CAV
WIRE IDENT
CIRCUIT
N2
19N_B Or-1.0
19N_A Or-1.0
P2
19P_A Or-1.0
R2
19R_A Or-0.8
Sec Str Ignition
S2
19S Or-0.8
T2
19T_A Or-0.8
19T_B Or-0.8
U2
19U_A Or-1.0
19U_B Or-1.0
Dome Lt Horn Fused Power
V2
19V Or-0.8
W2
19W Or-1.0
X2
19X Or-1.0
Beacon Sw Fused Power
L1
12P_A Or-1.0
12P_B Or-1.0
ACC Relay
M1
12K_A Or-1.0
ACC Power
Z2
19Z Or-1.0
Frnt Flood Illum Fused Power
N1
12P_B Or-1.0
ACC Relay
A2
18A Or-2.0
Rear Fld Lts Fuse Power
P1
13P_B Or-1.0
B2
18B_A Or-0.8
High Beam LH
C2
18C_A Or-0.8
18C_B Or-0.8
High Beam Fused Power
D2
18D_A Or-0.8
Low Beam LH
18E_A Or-0.8
Low Beam RH
R1
S1
Ign Relay 1 (2 Way)

13D Or-1.0
T1
Y2
Delay Power (2 Way)*

Time Delay Module (2 Way)
None
U1
1_Q R-1.0
Dome Light Horn Power
E2
V1
13V Or-1.0
Voltmeter Relay Out
F2
18F_D Or-0.8
18F_E Or-0.8
Left Tail Pos
W1
1_R R-3.0
Cigar Lighter Power

G2
18G_F Or-0.8
18G_G Or-0.8
Right Tail Pos Lic
19N_B Or-1.0
X1
Power (4 Way)
Y1
Power (4 Way)
B+ Power (4 Way)*
None
Power (4 Way)
None
None
High Beam Signal (2 Way)*
None
41L_A K-2.0
Low Beam Signal (2 Way)*
Rotary Lamp Switch (2 Way)
None
G1
41T_A K-1.0
Tail Light Sw Power (2 Way)*
None
A2
19A_N Or-0.8
19A_P Or-0.8
Cab Switched Power
10
None
11
B2
19B_A Or-0.8
Turn Signal Power
12
None
C2
19C_A Or-1.0
19C_D Or-1.0
Pilot Ride Cntrl Fused Power
13
14
None
15
None
Z1
1_U R-3.0
A1
B1
C1
41H K-2.0
D1
E1
F1
D2
19D_A Or-1.0
Park Brake Rel Fused Power
E2
19E Or-1.0
Ether Start Rel Fused Power
F2
19F Or-1.0
Eng Shutdown Rel Fused Pwr
G2
19G Or-2.0
H2
19H Or-1.0
Backup Alarm Rel Fuse Power
J2
19J_A Or-1.0
K2
19K_A Or-1.0
L2
19L Or-1.0
M2
19M_A Or-0.8
Sec Str Accessory
Bur 6-48930
16
19L Or-1.0
19W Or-1.0
17
18
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-98
CONNECTOR 19F - TRANSMISSION
ELECTRONIC CONTROL MODULE TO MAIN CAB
HARNESS
CAV
WIRE IDENT
CIRCUIT
0_DP Bk-0.8
Diag TECM Ground
0_DQ Bk-0.8
Diag TECM Ground
0_DM Bk-0.8
Speed Sensor Ground
0_DN Bk-0.8
32J_C Y-0.8
Trans Enable Lt Signal
None
35C Y-0.8
58H_B W-0.8
Ride Cntl Sw Power VPS2
25P_A LU-0.8
Trans Sol Valve Y5
10
25L_A LU-0.8
Trans Sol Valve Y2
11
None
12
25S_B LU-0.8
13
25S_C LU-0.8
14
15
None
37D_A P-0.8
16
Diagnostic Signal
None
17
32F_A Y-0.8
18
37E P-0.8
Diagnostic Signal
19
25A_A LU-0.8
Engine Speed Signal
20
26F_B LU-0.8
FNR Forward Signal
21
52P_A W-0.8
22
25Y_B LU-0.8
23
19T_A Or-0.8
24
WIRE IDENT
CIRCUIT
43
25F_A LU-0.8
Forward Signal
44
26N_B LU-0.8
FNR Neutral Signal
45
19A_K Or-0.8
Cab Switched Power
46
36R_E P-0.8
Valve Body Temp Return
47
None
48
None
49
36G_A P-1.0
50
51
TCO Temp Signal

None
25J_A LU-0.8
Trans Sol Valve Y6
52
None
53
None
54
None
55
25N_A LU-0.8
Trans Sol Valve Y4
56
25K_A LU-0.8
Trans Sol Valve Y1
57
0_DD Bk-0.8
Ride Control Relay Sink
58
None
59
None
60
None
61
None
62
25D_A LU-0.8
Output Speed Signal
63
25Z_A LU-0.8
64
25R_A LU-0.8
Reverse Signal
65
25W_A LU-0.8
66
25G_B LU-0.8
Declutch Signal
67
25T_D LU-0.8
Neutral Signal
68
19T_B Or-0.8
None
25
50H_A Y-0.5
CAN H
26
50L_B G-0.5
CAN L
27
50L_C G-0.5
CAN L
28
CONNECTOR 20M - TRANSMISSION KICK-DOWN

SWITCH TO MAIN CAB HARNESS
None
29
25H LU-0.8
Trans Auto Signal
30
26R_B LU-0.8
FNR Reverse Signal
31
26E LU-0.8
Trans Enable Signal
32
25M_A LU-0.8
Trans Sol Valve Y3
33
None
34
None
35
None
36
None
37
None
38
None
39
CAV
36T_A P-0.8
40
222136A1
CAV
WIRE IDENT
CIRCUIT
19A_U Or-0.8
Cab Switched Power
25Y_C LU-0.8
None
41
25B_A LU-0.8
Turb Speed Signal
42
25C_A LU-0.8
Int Speed Signal
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-99
CONNECTOR 21M - REAR CHASSIS HARNESS

TO CAB MAIN HARNESS
291661A1
CAV
WIRE IDENT
374973A1
CIRCUIT
None
CAV
WIRE IDENT
CIRCUIT
None
None
None
31D_A Y-0.8
33P_A Y-0.8
31D Y-1.0
33P Y-1.0
18F_D Or-0.8
Left Tail Pos
35R_C Y-0.8
Backup Alarm Switch
18F_A Or-1.0
Left Tail
35A_D Y-0.8
35R_B Y-1.0
Backup Alarm Switch
44_D T-0.8
Brake Light Signal
35A_C K-1.0
Reverse Lights
44_C T-1.0
Brake Light Signal
18G_F Or-0.8
RH Tail Lic Lights
10
45L_B N-0.8
Left Turn Signal
18G_D Or-1.0
RH Tail Lic Lights
11
21C_E W-0.8
10
45L_A N-1.0
Left Turn Signal
12
45R_B N-0.8
Right Turn Signal
11
21C_D W-1.0
45R_A N-1.0
Right Turn Signal
13
36H_A P-0.8
Hot Signal
12
14
31H_A Y-0.8
13
36H P-1.0
Hot Signal
15
33R_D Y-0.8
Red Brake Sw Signal
14
31H Y-1.0
16
36F_A P-0.8
Fuel Level Signal
15
33R_C Y-1.0
Red Brake Sw Signal
None
16
36F P-1.0
Fuel Level Signal
17
None
18
Grid Heater Signal
19
28GC_B W-1.0
Grid Heater Signal
17
18
52P_B W-0.8
19
20
28GC_A W-0.8
None
52P W-1.0

None
21
1_P R-0.8
20
22
31T Y-0.8
Grid Heater Temp Sndr Signal
21
1_A R-1.0
B+
None
22
31T_A Y-1.0
Rear Washer Pump
23
Front Washer Pump
24
68W Or-1.0
Rear Washer Pump
None
25
63W Or-1.0
Front Washer Pump
23
24
25
68W_A Or-1.0
63W_A Or-0.8
26
None
27
52_A W-0.8
26
None
28
1B_D R-0.8
CB B Load
27
52 W-1.0
1B_A R-1.0
Brake Lt Sw Power
29
44A_B T-0.8
28
30
19A_T Or-0.8
Cab Switched Power
29
44 T-1.0
31
25G_A LU-0.8
Declutch Switch
30
19A_A Or-1.0
Declutch Switch
31
25G LU-1.0
Declutch Switch
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-100
CONNECTOR 22M - TRANSMISSION HARNESS

TO CAB MAIN HARNESS
291661A1
CAV
WIRE IDENT
373358A1
CIRCUIT
13C_D Or-0.8
Fuel Solenoid Power
CAV
WIRE IDENT
CIRCUIT
14_B LG-0.8
Alternator D+
13C_A Or-1.0
Fuel Solenoid
31F_B Y-0.8
14_A LG-1.0
Alternator D+
36C_B P-0.8
ECT Signal
31F_A Y-1.0
36C_A P-1.0
ECT Signal
36T_A P-0.8
36P_B P-0.8
EOP Signal
36T P-0.8
25A_A LU-0.8
Engine Speed Signal
36P_A P-1.0
EOP Signal
25B_A LU-0.8
Turb Speed Signal
25A W-0.8
Engine Speed Signal
25B W-0.8
Turb Speed Signal
25C_A LU-0.8
Int Speed Signal
10
25D_A LU-0.8
Output Speed Signal
25C W-0.8
Int Speed Signal
11
0_DM Bk-0.8
Speed Sensor Ground
10
25D LU-1.0
Output Speed Signal
12
36R_E P-0.8
Valve Body Temp Ret
11
0_HD Bk-1.0
Speed Sensor Ground
TCO Temp Signal
12
36R_A P-1.0
Valve Body Temp Ret
None
13
36G P-1.0
TCO Temp Signal
13
36G_A P-1.0
14
15
0_DAB Bk-0.8
Signal Ground
14
None
16
25K_A LU-0.8
15
0_HB Bk-1.0
Signal Ground
25K LU-0.8
17
25L_A LU-0.8
16
18
25M_A LU-0.8
17
25L LU-0.8
19
25N_A LU-0.8
18
25M LU-0.8
20
25P_A LU-0.8
19
25N LU-0.8
25P LU-0.8
21
25J_A LU-0.8
20
22
25S_A LU-0.8
21
25J LU-0.8
23
0_DL Bk-0.8
Signal Ground
22
25S LU-0.8
None
23
0_HA Bk-1.0
24
Signal Ground
25
61C_B Or-0.8
AC Comp Clutch
24
None
26
61A_B Or-0.8
AC Relay Power
25
61C_A Or-1.0
AC Comp Clutch
27
61R_B Or-0.8
AC Relay Signal
26
61A_A Or-1.0
28
0_DN Bk-0.8
27
61R_A Or-1.0
0_HE Bk-1.0
Out Speed Ground
29
19A_M Or-0.8
Cab Switched Power
28
30
0_DAU Bk-0.8
Analog Ground
29
19A Or-1.0
Out Speed Power
31
32F_A Y-0.8
30
0_HC Bk-1.0
Analog Ground
31
32F Y-1.0
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-101
CAB ROOF HARNESS
CONNECTOR 24F - CAB ROOF HARNESS TO

CAB MAIN HARNESS
3195530R1
3195530R1
CAV
WIRE IDENT
CAV
CIRCUIT
WIRE IDENT
CIRCUIT
68C_A Or-1.0
Rear Wiper Park
None
0_DT Bk-1.0
None
None
None
0_DU Bk-1.0
19U_A Or-1.0
46_A K-0.8
46_C K-1.0
19K_B Or-1.0
68L_A Or-1.0
42R_B DU-0.8
CONNECTOR 23M - CAB ROOF HARNESS TO

CAB MAIN HARNESS
0_MN Bk-0.8
Dome Courtesy Light Ground
49_V S-0.8
0_MK Bk-1.0
Front Work Light Ground
42C_D DU-1.0
Front Work Lights Power
CONNECTOR 24M - CAB MAIN HARNESS TO

CAB ROOF HARNESS
245430C1
245430C1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
None
68C_B Or-1.0
Rear Wiper Park
None
0_MG Bk-1.0
Rear Work Light Ground
None
0_MD Bk-1.0
Beacon Rear Wiper Ground
None
19U_D Or-1.0
Dome Light Fused Power
0_DR Bk-1.0
46_D K-1.0
49_S S-1.0
19K_E Or-1.0
0_DS Bk-1.0
42C_A DU-1.0
Front Flood Lights
68L_C Or-1.0
42R_F DU-1.0
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-102
CONNECTOR 29M - BLOWER MOTOR TO CAB

MAIN HARNESS
255058C1
631801C1
CAV
A
WIRE IDENT
41J_B K-2.0
CAV
CIRCUIT
CONNECTOR 27M - AC LOW PRESSURE

WIRE IDENT
CIRCUIT
62L Or-1.0
Blower Low Speed
62M Or-2.0
Blower Medium Speed
62H Or-2.0
Blower High Speed
0_DZ Bk-2.0
Blwr Wpr Seat Ground
CONNECTOR 30F - BLOWER SWITCH TO CAB

MAIN HARNESS
245482C1
CAV
WIRE IDENT
CIRCUIT
61R_E Or-0.8
61A_E Or-0.8

449797C1
CAV
CONNECTOR 28M - SEAT COMPRESSOR

MOTOR TO CAB MAIN HARNESS
WIRE IDENT
CIRCUIT
None
19G Or-2.0
62H Or-2.0
Blower High Speed
62M Or-2.0
Blower Medium Speed
62L Or-1.0
Blower Low Speed
61T Or-1.0
AC Thermostat Power
245482C1
CAV
WIRE IDENT
CIRCUIT
19N_A Or-1.0
Access Seat Fused Pwr (3 Way)
0_DY Bk-1.0
Blower Wpr Seat Ground
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-103
CONNECTOR 31 - FILTER MAINTENANCE
SWITCH TO TRANSMISSION HARNESS

266516C1
371614A1
CAV
WIRE IDENT
CAV
CIRCUIT
32F Y-1.0
Trans Filt Maint Sw
36R_B P-1.0
Valve Body Temp Ret
WIRE IDENT
CIRCUIT
41J_A K-2.0
41J_B K-2.0
41T_B K-1.0
1_N R-3.0
Light Switch Power

225287C1
CAV
WIRE IDENT
CIRCUIT
245423C1
42R_B DU-0.8
42R_C DU-0.8
18A Or-2.0
Rear Fld Lts Fused Power
42C_A DU-1.0
Front Flood Lights
41T_A K-1.0
41T_B K-1.0
49_J S-0.8
49_K S-1.0
Pilot Light
19Z Or-1.0
Front Flood Illum Fused Power
Bur 6-48930
CAV
WIRE IDENT
CIRCUIT
Issued 2-03
Printed in U.S.A.
Copyright
4002-104
CONNECTOR 35F - WIPER AND WASHER
CONNECTOR 37 - PILOT CONTROL SWITCH TO

PEDESTAL HARNESS
892136C1
382391A1
CAV
WIRE IDENT
CIRCUIT
CAV
0_DAR Bk-1.0
Blower Wiper Seat Ground
19J_A Or-1.0
19J_B Or-0.8
63W_A Or-0.8
Front Washer Pump
63C_A Or-0.8
Front Wiper Park
63H_A Or-0.8
63H_B Or-0.8
63L_A Or-0.8
63L_B Or-0.8
CONNECTOR 36F - DETENT SWITCH TO CAB

MAIN HARNESS
WIRE IDENT
CIRCUIT
None
19C Or-0.8
31L Y-0.8
None
None
None
0_KH Bk-0.8
0_KJ Bk-0.8
Pilot Light Ground
49_B S-0.8
49_C S-0.8
Pilot Light
None
10
None
382391A1
CAV
WIRE IDENT
CIRCUIT
None
53P_B W-0.8
56_H W-0.8

None
None
None
0_DAJ Bk-1.0
0_DAK Bk-1.0
Switch Ground
49_M S-1.0
49_N S-1.0
Pilot Light
None
10
None
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-105
CONNECTOR 38F - DECLUTCH SWITCH TO CAB
MAIN HARNESS
CAV
8
WIRE IDENT
49_K S-1.0
49_M S-1.0
CIRCUIT
Pilot Light
None
10
None
CONNECTOR 40F - PIN ENGAGE SWITCH TO

CAB MAIN HARNESS
382391A1
CAV
WIRE IDENT
25G_A LU-0.8
25G_B LU-0.8
19A_R Or-0.8
CIRCUIT
Declutch Switch
Cab Switched Power
None
None
None
None
382391A1
CAV
0_DAK Bk-1.0
Switch Ground
49_N S-1.0
Pilot Light
None
10
None
CONNECTOR 39F - RETURN-TO-TRAVEL

WIRE IDENT
CIRCUIT
57_A W-0.8
19P_A Or-1.0
19P_B Or-1.0
None
None
None
None
None
None
0_DAF Bk-1.0
0_DAL Bk-1.0
Switch Ground
10
49_H S-0.8
49_P S-1.0
Pilot Light
382391A1
CAV
WIRE IDENT
CIRCUIT
0_DAH Bk-1.0
0_DAJ Bk-1.0
Switch Ground
55A W-0.8
RTT Float Switch
54B_B W-0.8
RTT Float Switch Load
None
None
None
0_DAG Bk-1.0
0_DAH Bk-1.0
Bur 6-48930
Switch Ground
Issued 2-03
Printed in U.S.A.
Copyright
4002-106
CONNECTOR 41F - TRANSMISSION AUTO
CAV
8
WIRE IDENT
49_R S-1.0
49_T S-1.0
CIRCUIT
Pilot Light
None
10
None
CONNECTOR 44F - RIDE CONTROL SWITCH TO

CAB MAIN HARNESS
382391A1
CAV
WIRE IDENT
CIRCUIT
None
19A_Q Or-0.8
Cab Switched Power
25H LU-0.8
Trans Auto Signal
None
None
382391A1
None
CAV
0_DAM Bk-1.0
Switch Ground
49_Q S-1.0
Pilot Light
19C_B Or-1.0
Ride Ctrl Fused Power
None
58S W-0.8
10
None
None
None
CONNECTOR 42F - BEACON SWITCH TO CAB

MAIN HARNESS
WIRE IDENT
CIRCUIT
None
58_B W-0.8
Ride Cntrl Sol Power
0_DAL Bk-1.0
0_DAM Bk-1.0
Switch Ground
49_P S-1.0
49_Q S-1.0
Pilot Light
None
10
None
382391A1
CAV
WIRE IDENT
CIRCUIT
None
19X Or-1.0
Beacon Switch Fused Power
46_C K-1.0
None
None
None
0_DAP Bk-1.0
0_DAW Bk-1.0
Bur 6-48930
Ground
Issued 2-03
Printed in U.S.A.
Copyright
4002-107
CONNECTOR 45F - REAR WIPER AND WASHER

CAB MAIN HARNESS
382391A1
245731C1
CAV
WIRE IDENT
CIRCUIT
CAV
68C_A Or-1.0
Rear Wiper Park
68L_A Or-1.0
68L_B Or-0.8
19K_C Or-1.0
WIRE IDENT
CIRCUIT
30
1_T R-3.0
85
0_DE Bk-0.8
0_DF Bk-0.8
Relay Ground
None
86
13K_A Or-1.0
13K_B Or-1.0
13R Or-1.0
Ignition Relay 2 Out (5 Way)
19K_D Or-0.8
87
68W_A Or-1.0
Rear Washer Pump
87A
0_DW Bk-0.8
Ground
49_L S-0.8
Pilot Light
None
10
None
None
CONNECTOR 49F - ACCESSORY RELAY TO CAB

MAIN HARNESS

CAB MAIN HARNESS
245731C1
CAV
245731C1
CAV
WIRE IDENT
CIRCUIT
30
1_S R-3.0
85
0_DE Bk-0.8
Relay Ground
86
13K_A Or-1.0
87
13P_A Or-1.0
13P_B Or-1.0
Ignition Relay 1 Out
87A
Bur 6-48930
WIRE IDENT
CIRCUIT
30
1_G R-3.0
ACC Relay Power
85
0_DF Bk-0.8
0_DC Bk-0.8
Relay Ground
86
12K_A Or-1.0
12K_B Or-0.8
ACC Power
87
12P_A Or-1.0
ACC Relay
87A
None
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-108
CONNECTOR 50F - RIDE CONTROL RELAY TO
CAB MAIN HARNESS
CONNECTOR 53F - BACKUP ALARM RELAY TO

CAB MAIN HARNESS
245731C1
CAV
WIRE IDENT
CIRCUIT
245731C1
CAV
WIRE IDENT
CIRCUIT
30
58S W-0.8
30
19H Or-1.0
Backup Alrm Rly Fuse Power
85
0_DD Bk-0.8
Ride Control Relay Ground
85
35C Y-0.8
86
58H_B W-0.8
Ride Control Signal
86
19A_P Or-0.8
Cab Switched Power
87
58_A W-0.8
58_B W-0.8
87
35A_E Y-0.8
35A_D Y-0.8
None
87A
87A
CONNECTOR 51F - HORN RELAY TO CAB MAIN

HARNESS
None
CONNECTOR 54F - NEUTRAL START RELAY TO

CAB MAIN HARNESS
245731C1
CAV
WIRE IDENT
30
19U_B Or-1.0
19U_C Or-0.8
85
CIRCUIT
245731C1
CAV
WIRE IDENT
CIRCUIT
30
21K_A W-0.8
64C_A Or-0.8
Horn Control
85
0_DH Bk-0.8
0_DJ Bk-0.8
Relay Ground
86
19U_C Or-0.8
86
25T_E LU-0.8
Neutral Signal
87
64_A Or-0.8
Horn
87
21C_E W-0.8
21C_F W-0.8
21C_G W-0.8
87A
None
87A
Bur 6-48930
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-109
CONNECTOR 55F - PARKING BRAKE RELAY TO
CAB MAIN HARNESS
CONNECTOR 57F - RELAY SOCKET N0. 11 TO

CAB MAIN HARNESS
245731C1
245731C1
CAV
WIRE IDENT
CAV
CIRCUIT
30
19D_A Or-1.0
19D_B Or-1.0
85
52C_A W-0.8
86
19D_B Or-1.0
87
52P_B W-0.8
52P_A W-0.8
87A
WIRE IDENT
30
13K_B Or-1.0
13K_C Or-1.0
13K_D Or-0.8
85
23C_A W-0.8
86
19F Or-1.0
Engine Shtdwn Rly Fused Pwr
87
13C_B Or-0.8
13C_C Or-0.8
13C_D Or-0.8
Fuel Solenoid Power
None
87A
CONNECTOR 56F - PILOT CONTROL RELAY TO

CAB MAIN HARNESS
CIRCUIT
None
CONNECTOR 58F - VOLTMETER RELAY TO CAB

MAIN HARNESS
245731C1
CAV
30
WIRE IDENT
19C_D Or-1.0
19C_E Or-1.0
CIRCUIT
85
53C_A W-0.8
86
19C_E Or-1.0
87
53P_A W-0.8
53P_B W-0.8
53P_C W-0.8
87A
Bur 6-48930
None
245731C1
CAV
WIRE IDENT
CIRCUIT
30
1_P R-0.8
85
0_DG Bk-0.8
0_DH Bk-0.8
Relay Ground
86
13K_C Or-1.0
13K_E Or-0.8
87
13V Or-1.0
Voltmeter Relay Out
87A
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-110
CONNECTOR 59F - HIGH/LOW BEAM RELAY TO
CAB MAIN HARNESS

PEDESTAL HARNESS
194791A1
CAV
WIRE IDENT
CIRCUIT
245715C1
41J_A K-2.0
41L_A K-2.0
Low Beam Power
41H K-2.0
Hi/Low Beam Relay Power
64D_A Or-0.8
1_H R-3.0
CAV

PEDESTAL HARNESS
WIRE IDENT
CIRCUIT
63H Or-0.8
63L Or-0.8
19J Or-0.8
Front Wiper Wash Fused Power
63C Or-0.8
Front Wiper Park

MAIN HARNESS
245480C1
CAV
1
WIRE IDENT
0_KN Bk-0.8
CIRCUIT
Front Wiper Ground
225389C1
CAV
CIRCUIT
1B_B R-0.8
Flasher Module Power
45N_A N-0.8
0_DAN Bk-0.8
0_DAQ Bk-0.8
None
None
Bur 6-48930
WIRE IDENT
45R_E N-0.8
Right Turn Signal
45L_D N-0.8
Left Turn Signal
45B_A N-0.8
10
45A_A N-0.8
11
45H_A N-0.8
Hazard Switch Power
12
45N_B N-0.8
Issued 2-03
Printed in U.S.A.
Copyright
4002-111
CONNECTOR 63M - TIME DELAY MODULE TO
CAB MAIN HARNESS

MAIN HARNESS
225351C1
CAV
WIRE IDENT
631801C1
CIRCUIT
13D Or-1.0
Delay Power (2 Way)
CAV
1A_E R-0.8
Time Delay Power
0_DAS Bk 0.8
Time Delay Module Ground
37R_C P-0.8
Reset Signal
13K_F Or-0.8
WIRE IDENT
45N_B N-0.8
CIRCUIT

PEDESTAL HARNESS
None
CONNECTOR 64F - FLASHER MODULE TO CAB

MAIN HARNESS
1964527C1
CAV
1
739070C1
CAV
1
WIRE IDENT
45N_A N-0.8
WIRE IDENT
45A N-0.8
CIRCUIT

PEDESTAL HARNESS
CIRCUIT
1964527C1
CAV
1
Bur 6-48930
WIRE IDENT
19B Or-0.8
CIRCUIT
Turn Signal Power
Issued 2-03
Printed in U.S.A.
Copyright
4002-112
PEDESTAL HARNESS

PEDESTAL HARNESS
1964527C1
CAV
1
WIRE IDENT
45B N-0.8
CIRCUIT
245486C1
CAV
CONNECTOR 69 - IGNITION SWITCH TO

PEDESTAL HARNESS
WIRE IDENT
CIRCUIT
19A_H Or-0.8
Trans Control Power
25F LU-0.8
Forward Signal
25R LU-0.8
Reverse Signal
25T_A LU-0.8
Neutral Signal
CONNECTOR 71 - HAZARD SWITCH TO

PEDESTAL HARNESS
225253C1
CAV
WIRE IDENT
CIRCUIT
1A_A R-0.8
1A_B R-0.8
21K W-0.8
13K Or-0.8
12K_C Or-0.8
Ign Switch Acc Power
Ign Prog Reset Sw Power
None
None
Bur 6-48930
382391A1
CAV
WIRE IDENT
CIRCUIT
None
1B R-0.8
Hazard Switch Power
45H N-0.8
Hazard Switch Power
None
None
None
0_KH Bk-0.8
Pilot Light Ground
49_A S-0.8
49_B S-0.8
Pilot Light
None
10
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-113
CONNECTOR 72 - PARKING BRAKE SWITCH TO
PEDESTAL HARNESS
CONNECTOR 74 - UP/DOWN COUNT SWITCH TO

PEDESTAL HARNESS
382391A1
CAV
WIRE IDENT
CIRCUIT
None
382391A1
CAV
WIRE IDENT
CIRCUIT
37D P-0.8
Down Count Signal
Trans Control Power
19S_A Or-0.8
19S_B Or-0.8
Park Brake Signal
37U P-0.8
None
None
None
None
None
None
0_KJ Bk-0.8
0_KK Bk-0.8
Pilot Light Ground
0_KK Bk-0.8
0_KL Bk-0.8
Pilot Light Ground
49_C S-0.8
49_D S-0.8
Pilot Light
49_D S-0.8
49_E S-0.8
Pilot Light
None
None
10
None
10
None
19A_H Or-0.8
19A_G Or-0.8
33U Y-0.8
Bur 6-48930
Up Count Signal
Issued 2-03
Printed in U.S.A.
Copyright
4002-114
CONNECTOR 75 - PROGRAM/RESET SWITCH TO
PEDESTAL HARNESS
CAV
WIRE IDENT
0_KP Bk-0.8
Analog Ground
33U Y-0.8
Park Brake Signal
10
61R_G Or-0.8
11
CAV
WIRE IDENT
CIRCUIT
A/C Telltale
None
12
42R_A Y-0.8
13
46_B K-0.8
Beacon Telltale
14
382391A1
CIRCUIT
None
15
18C_C Or-0.8
High Beam Telltale
16
45L_F N-0.8
Left Turn Signal
17
45R_F N-0.8
Right Turn Signal
18
36C_C P-0.8
ECT Signal
19
36F_B P-0.8
Fuel Level Signal
37R_A P-0.8
37R_B P-0.8
Reset Signal
20
36H_B P-0.8
Hot Signal
1A_B R-0.8
21
50T Bk-0.8
CAN T
37P P-0.8
Program Signal
22
36P_C P-0.8
EOP Signal
None
23
23C W-0.8
None
24
37P P-0.8
Program Signal
None
25
37R_B P-0.8
Reset Signal
0_KL Bk-0.8
0_KM Bk-0.8
Pilot Light Ground
26
37U P-0.8
Up Count Signal
27
37D P-0.8
Down Count Signal
49_E S-0.8
Pilot Light
28
33R_E Y-0.8
Red Brake Sw Signal
29
31L Y-0.8
30
52C W-0.8
31
50L G-0.5
CAN L
32
50H Y-0.5
CAN H
33
50T Bk-0.8
CAN T
35
44_G T-0.8
Brake Light Signal
36
53C W-0.8
37
0_KQ Bk -0.8
Signal Ground
38
0_KE Bk-0.8
Signal Ground
39
0_KD Bk-0.8
Signal Ground
7
8
9
None
10
None
CONNECTOR 76 - INSTRUMENT CLUSTER TO

PEDESTAL HARNESS
34
40
None
None
282763A1
CAV
WIRE IDENT
CIRCUIT
19V_A Or-0.8
19S_B Or-0.8
33P_B Y-0.8
31D_B Y-0.8
35X_F Y-0.8
31F_C Y-0.8
31H_B Y-0.8
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-115
CONNECTOR 77F - COURTESY LAMP TO CAB
MAIN HARNESS
CONNECTOR 80F - RH REAR WORK LAMP TO

CAB MAIN HARNESS
245483C1
CAV
291729A1
CAV
WIRE IDENT
CIRCUIT
49_V S-0.8
Courtesy Pilot Lamp
0_ML Bk-0.8
Courtesy Lamp Ground
WIRE IDENT
CIRCUIT
42R_E DU-1.0
RH Rear Work Lamp Power
0_MF Bk-1.0
RH Rear Work Lamp Ground

CAB MAIN HARNESS
CONNECTOR 78F - RH FRONT WORK LAMP TO

CAB MAIN HARNESS
245715C1
245483C1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
42C_C DU-1.0
RH Front Work Lamp Power
0_MJ Bk-1.0
RH Front Work Lamp Ground
CONNECTOR 79F - LH FRONT WORK LAMP TO

CAB MAIN HARNESS
CIRCUIT
None
68L_C Or-1.0
19K_E Or-1.0
Rear Wpr Wash Fused Power
68C_B Or-1.0
Rear Wiper Park

CAB MAIN HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
42C_B DU-1.0
LH Front Work Lamp Power
0_MH Bk-1.0
LH Front Work Lamp Ground
245480C1
CAV
1
Bur 6-48930
WIRE IDENT
0_MA Bk-1.0
CIRCUIT
Rear Wiper Motor Ground
Issued 2-03
Printed in U.S.A.
Copyright
4002-116
CONNECTOR 83F - LH REAR WORK LAMP TO
CAB MAIN HARNESS
CONNECTOR 85F - BEACON LAMP TO CAB

MAIN HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
245426C1
42R_D DU-1.0
LH Rear Work Lamp Power
CAV
0_ME Bk-1.0
LH Rear Work Lamp Ground
46_D K-1.0
0_MC Bk-1.0
Beacon Lamp Ground
CONNECTOR 84F - DOME LAMP TO CAB MAIN

HARNESS
WIRE IDENT
CIRCUIT
CONNECTOR 86 - REDUNDANT BRAKE SWITCH

245483C1
266516C1
CAV
WIRE IDENT
CIRCUIT
19U_D Or-1.0
Dome Lamp Fused Power
0_MB Bk-0.8
0_MM Bk-0.8
Dome Lamp Ground
0_MM Bk-0.8
Dome Lamp Ground
CAV
WIRE IDENT
CIRCUIT
33R_B Y-1.0
Redundant Brake Switch Sig
0_M Bk-1.0
Ground
CONNECTOR 87 - PARKING BRAKE SOLENOID

291718A1
CAV
Bur 6-48930
WIRE IDENT
CIRCUIT
52P W-1.0
Parking Brake Relay Out
0_Q Bk-1.0
Park Str Fuel Relay Ground
Issued 2-03
Printed in U.S.A.
Copyright
4002-117
CONNECTOR 88 - BRAKE PRESSURE WARNING

MODULE TO SECONDARY STEERING HARNESS
225389C1
222135A1
CAV
WIRE IDENT
CIRCUIT
33P Y-1.0
Low Brake Press Warning
0_N Bk-1.0
Brake Press Warning Switch
CONNECTOR 89M - PILOT PRESSURE

SOLENOID TO CAB MAIN HARNESS
CAV
WIRE IDENT
19R_C Or-1.0
51_A W-1.0
Secondary Steer Mtr Rel
1_W R-1.0
Secondary Steer Module B+
0_CE Bk-1.0
Secondary Steer Chassis Grnd
None
None
19M_C Or-1.0
35X_D Y-1.0
51P_A W-1.0
Secondary Steer High Press
10
245482C1
CAV
WIRE IDENT
CIRCUIT
53P_A W-0.8
0_DB Bk-0.8
CAN Pilot Solenoid Ground
CIRCUIT
None
11
0_CA Bk-1.0
12
0_CB Bk-1.0

PEDESTAL HARNESS
739070C1
CAV
1
Bur 6-48930
WIRE IDENT
25T_A LU-0.8
25T_B LU-0.8
CIRCUIT
Neutral Signal
Issued 2-03
Printed in U.S.A.
Copyright
4002-118
CONNECTOR 94F - TRANSMISSION HARNESS
TO ENGINE HARNESS

291659A1
CAV
WIRE IDENT
373356A1
CIRCUIT
13C_A Or-1.0
Fuel Solenoid
CAV
WIRE IDENT
CIRCUIT
61A_A Or-1.0
13C Or-1.0
Fuel Solenoid
61R-A Or-1.0
61A Or-1.0
61C_A Or-1.0
AC Comp Clutch
61R Or-1.0
61C Or-1.0
AC Comp Clutch
14_A LG-1.0
Alternator D+
36P_A P-1.0
EOP Sender
14 LG-1.0
Alternator D+
31F_A Y-1.0
36P P-1.0
EOP Sender
None
31F Y-1.0
Signal Ground
None
Signal Ground
10
None
11
ECT Sender
12
None
13
Analog Ground
14
None
15
17
None
16
None
18
None
17
None
19
None
18
None
19
None
8
9
0_HA Bk-1.0
10
11
0_HB Bk-1.0
12
13
36C_A P-1.0
14
15
0_HC Bk-1.0
16
Bur 6-48930
None
0_BF Bk-1.0
Signal Ground
None
0_BH Bk-1.0
Signal Ground
None
36C P-1.0
ECT Sender
None
0_BG Bk-1.0
Analog Ground
Issued 2-03
Printed in U.S.A.
Copyright
4002-119
CONNECTOR 95 - INTERMEDIATE SPEED
SENSOR TO TRANSMISSION HARNESS
CONNECTOR 97 - PREHEATER LIGHT TO

PEDESTAL HARNESS
245781C1
291718A1
CAV
1
2
WIRE IDENT
25C W-0.8
0_HG Bk-0.8
CAV
CIRCUIT
CONNECTOR 96 - TURBINE SPEED SENSOR TO

WIRE IDENT
CIRCUIT
None
None
None
31Y_B Y-0.8
Lamp Signal
18L_D Bk-0.8
Lamp Ground
None
CONNECTOR 98 - AC HIGH PRESSURE SWITCH

TO ENGINE HARNESS
291718A1
CAV
WIRE IDENT
CIRCUIT
25B W-0.8
Turbine Speed Signal
0_HH Bk-0.8
Turbine Speed Ground
Bur 6-48930
245482C1
CAV
WIRE IDENT
CIRCUIT
61A Or-1.0
61R Or-1.0
Issued 2-03
Printed in U.S.A.
Copyright
4002-120
CONNECTOR 99 - AC COMPRESSOR CLUTCH
TO ENGINE HARNESS
CONNECTOR 101 - ENGINE SPEED SENSOR TO

245480C1
CAV
1
WIRE IDENT
61C Or-1.0
CIRCUIT
291718A1
CAV
CONNECTOR 100 - OUTPUT SPEED SENSOR TO

WIRE IDENT
CIRCUIT
25A W-0.8
Engine Speed Signal
0_HF Bk-0.8
Engine Speed Ground
CONNECTOR 102 - TRANSMISSION CONTROL

VALVE TO TRANSMISSION HARNESS
291719A1
CAV
WIRE IDENT
CIRCUIT
0_HE Bk-1.0
Output Speed Ground
25D LU-1.0
Output Speed Signal
CAV
19A Or-1.0
Output Speed Power
25K LU-0.8
25L LU-0.8
25M LU-0.8
25N LU-0.8
25P LU-0.8
25J LU-0.8
25S LU-0.8
36T P-0.8
36R_C P-0.8
Bur 6-48930
371566A1
WIRE IDENT
CIRCUIT
Valve Body Temp Ret
10
None
11
None
12
None
13
None
14
None
15
None
16
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-121
CONNECTOR 104 - COOLANT LEVEL SENDER
CAV
4
WIRE IDENT
37E P-0.8
CIRCUIT
Diagnostic Signal
None
None
CONNECTOR 109M - RADIO POWER

194788A1
CAV
WIRE IDENT
CIRCUIT
31D Y-1.0
0_V Bk-1.0
Fuel Rdndnt Brake Cool Ground
CONNECTOR 107M - PIN ENGAGE SOLENOID TO

291730A1
CAV
WIRE IDENT
CIRCUIT
19L_A Or-1.0
Radio Power
0_PD Bk-1.0
Radio Ground
CONNECTOR 110F - RADIO POWER

245482C1
CAV
WIRE IDENT
CIRCUIT
57 W-1.0
0_AB Bk-1.0
Pin Engage Ground
CONNECTOR 108F - DIAGNOSTIC CONNECTOR

TO CAB MAIN HARNESS
245426C1
CAV
WIRE IDENT
CIRCUIT
65C Or-0.8
Radio Power
0_PC Bk-0.8
Radio Ground
291663A1
CAV
WIRE IDENT
CIRCUIT
19A_L Or-0.8
Cab Switched Power
37D_A P-0.8
Diagnostic Signal
0_DAV Bk-0.8
Diagnostic TECM Ground
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-122
CONNECTOR 111M - RIGHT SPEAKER TO RADIO
HARNESS
CONNECTOR 114F - RADIO ADAPTOR TO RADIO

HARNESS
195552A1
CAV
WIRE IDENT
CIRCUIT
892136C1
65R Or-0.8
CAV
0_PB Bk-0.8
CONNECTOR 112M - LEFT SPEAKER TO RADIO

HARNESS
WIRE IDENT
65L Or-0.8
CIRCUIT
Left Speaker Signal
0_PA Bk-0.8
Left Speaker Ground
0_PC Bk-0.8
Radio Ground
0_PB Bk-0.8
65R Or-0.8
65C Or-0.8
Radio Power
CONNECTOR 114M - RADIO ADAPTOR TO

REMOTE RADIO ADAPTOR HARNESS
195552A1
CAV
WIRE IDENT
CIRCUIT
65L Or-0.8
Left Speaker Signal
0_PA Bk-0.8
Left Speaker Ground
CONNECTOR 113 - RADIO TO REMOTE RADIO

ADAPTOR HARNESS
CAV
WIRE IDENT
1
2
0_QB Bk-0.8
CIRCUIT
449797C1
None
CAV
WIRE IDENT
None
0_QA Bk-0.8
Left Speaker Ground
0_QC Bk-0.8
Radio Ground
65L_A Or-0.8
CIRCUIT
Left Speaker Signal
0_QA Bk-0.8
Left Speaker Ground
0_QC Bk-0.8
Radio Ground
0_QB Bk-0.8
18_ H Or-0.8
Radio Power
65R_A Or-0.8
None
65C_B Or-0.8
Radio Power
7
8
9
None
65R_A Or-0.8
10
11

None
65L_A Or-0.8
Left Speaker Signal
12
None
13
None
14
65C_B Or-0.8
Bur 6-48930
Radio Power
Issued 2-03
Printed in U.S.A.
Copyright
4002-123
CONNECTOR 117 - AIR FILTER RESTRICTION
CONNECTOR 125 - LH REAR COMBINATION

225351C1
291718A1
CAV
WIRE IDENT
CIRCUIT
31F Y-1.0
Air Fltr Restriction Switch Signal
0_BD Bk-1.0
Air Fltr Restriction Switch Grnd

CAV
WIRE IDENT
CIRCUIT
44_A T-1.0
Brake Light Signal
45L_A N-1.0
Left Turn Signal
18F_A Or-1.0
Left Tail
35A_A K-1.0
Left Reverse
0_A Bk-1.0
Ground
None
CONNECTOR 127 - RH REAR COMBINATION

382391A1
CAV
WIRE IDENT
CIRCUIT
35R_C Y-0.8
35R_D Y-0.8
Backup Alarm Switch
35A_E Y-0.8
35A_F Y-0.8
225351C1
CAV
WIRE IDENT
CIRCUIT
44_B T-1.0
Brake Light Signal
None
45R_A N-1.0
Right Turn Signal
None
18G_A Or-1.0
Right Tail
None
35A_B K-1.0
Right Reverse
None
0_C Bk-1.0
Ground
0_DW Bk-0.8
0_DAW Bk-1.0
Ground
49_L S-0.8
49_T S-1.0
Pilot Light
None
10
None
Bur 6-48930
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-124
TO HOOD HARNESS
CONNECTOR 131F - SECONDARY STEERING

PRESSURE SWITCH TO FRONT CHASSIS
HARNESS
245485C1
CAV
WIRE IDENT
18G_C Or-1.0
License Plate Light
35R_B Y-1.0
Backup Alarm Switch
0_J Bk-1.0
245485C1
CIRCUIT
CAV
Hood Grounds
WIRE IDENT
CIRCUIT
51P_B W-1.0
Secondary Steer High Pressure
0_AN Bk-1.0
Secondary Steer Signal Ground
35X_A Y-1.0
CONNECTOR 128M - HOOD HARNESS TO REAR

CHASSIS HARNESS

FUEL SOLENOID
245484C1
CAV
WIRE IDENT
CIRCUIT
245480C1
18G_E Or-1.0
License Plate Light
CAV
35R_A Y-1.0
Backup Alarm Switch
0_JA Bk-1.0
Hood Ground
WIRE IDENT
13M Or-1.0
CIRCUIT
CONNECTOR 136 - HYDRAULIC OIL

TEMPERATURE SENDER TO REAR CHASSIS
HARNESS
194788A1
CAV
Bur 6-48930
WIRE IDENT
CIRCUIT
36H P-1.0
Hot Signal
0_W Bk-1.0
Front Rear Wash Hot Ground
Issued 2-03
Printed in U.S.A.
Copyright
4002-125
CONNECTOR 138 - ENGINE COOLANT
TEMPERATURE SENDER TO ENGINE HARNESS
CONNECTOR 140M - DIODE MODULE TO CAB

MAIN HARNESS
194788A1
CAV
WIRE IDENT
CIRCUIT
36C P-1.0
ECT Signal
0_BE Bk-1.0
ECT Ground
245488C1
CAV

DISCONNECT HARNESS
WIRE IDENT
CIRCUIT
63L_B Or-0.8
63H_B Or-0.8
0_DAX Bk-0.8
13C_C Or-0.8
Fuel Solenoid Power
21C_F W-0.8
68L_B Or-0.8
CONNECTOR 142 - TORQUE CONVERTER

OUTPUT TO TRANSMISSION HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
13C Or-1.0
Fuel Solenoid
13M Or-1.0
CONNECTOR 139M - DISCONNECT HARNESS

TO ENGINE HARNESS
291718A1
CAV
WIRE IDENT
CIRCUIT
36G P-1.0
TCO Temperature Signal
36R_D P-1.0
Valve Body Temperature Ret
245482C1
CAV
WIRE IDENT
CIRCUIT
13C_E Or-1.0
Fuel Solenoid Power
13M_A Or-1.0
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-126
CONNECTOR 154 - ALTERNATOR TO ENGINE
HARNESS
CAV
WIRE IDENT
CONNECTOR 159 - BRAKE LAMP PRESSURE

CIRCUIT
None
30 R-1.0
14 LG-1.0
Battery Sensing
Ignition Power
None
None
CONNECTOR 157 - REDUNDANT BRAKE

PRESSURE SWITCH TO REAR CHASSIS
HARNESS
222136A1
CAV
WIRE IDENT
CIRCUIT
1B_A R-1.0
Brake Lamp Switch Power
44 T-1.0
Brake Lamp Input Signal
CONNECTOR 168 - LICENSE PLATE LAMP TO

HOOD HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
33R_A Y-1.0
Red Brake Switch Signal
0_L Bk-1.0
Ground
CONNECTOR 158 - FAN REVERSING SOLENOID

245482C1
CAV
WIRE IDENT
CIRCUIT
18G_E Or-1.0
License Plate Lamp
0_JC Bk-1.0
License Plate Lamp Ground
CONNECTOR 178M - FLOAT PRESSURE SWITCH

TO FRONT CHASSIS HARNESS
225316C1
CAV
WIRE IDENT
CIRCUIT
52 W-1.0
0_X Bk-1.0
Fan Reversing Solenoid Ground
245482C1
CAV
Bur 6-48930
WIRE IDENT
CIRCUIT
53P_D W-1.0
53S_A W-1.0
Issued 2-03
Printed in U.S.A.
Copyright
4002-127
CONNECTOR 179F - FLOAT SOLENOID TO

MODULE HARNESS TO FRONT CHASSIS
HARNESS
225351C1
291718A1
CAV
WIRE IDENT
CAV
CIRCUIT
53S_B W-1.0
0_AP Bk-1.0
Float Solenoid Ground
CONNECTOR 180F - FRONT CHASSIS HARNESS

TO SECONDARY STEERING MODULE HARNESS
WIRE IDENT
CIRCUIT
19M_C Or-1.0
19R_C Or-1.0
35X_D Y-1.0
51P_A W-1.0
0_CC Bk-1.0
None

PEDESTAL HARNESS
225350C1
CAV
WIRE IDENT
CIRCUIT
19M_B Or-1.0
19R_B Or-1.0
35X_C Y-1.0
CAV
51P_B W-1.0
0_AN Bk-1.0
Bur 6-48930
739070C1
WIRE IDENT
28C W-0.8
CIRCUIT
Ether Start Control
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-128
PEDESTAL HARNESS
CONNECTOR 197M - FNR HARNESS TO CAB

MAIN HARNESS
225351C1
245487C1
CAV
WIRE IDENT
CAV
CIRCUIT
WIRE IDENT
CIRCUIT
None
19A_B Or-0.8
FNR Switched Power
26F_A LU-0.8
FNR Forward Signal
25W LU-0.8
25Z LU-0.8
26N_A LU-0.8
FNR Neutral Signal
25Y LU-0.8
Transmission Kick Down Signal
26R_A LU-0.8
FNR Reverse Signal
32J_A Y-0.8
FNR LT Signal
None

FNR HARNESS
CONNECTOR 198 - FNR SWITCH TO FNR
HARNESS
225350C1
CAV
WIRE IDENT
CIRCUIT
19A_C Or-0.8
Transmission Enable Sw Power
26F_B LU-0.8
FNR Forward Signal
26N_B LU-0.8
FNR Neutral Signal
26R_B LU-0.8
FNR Reverse Signal
32J_B Y-0.8
Bur 6-48930
382391A1
CAV
WIRE IDENT
CIRCUIT
26R_A LU-0.8
FNR Reverse Signal
26J LU-0.8
FNR Switch Jumper
26N_A LU-0.8
FNR Neutral Signal
26J LU-0.8
FNR Switch Jumper
19A_B Or-0.8
19A_F Or-0.8
FNR Switched Power
26F-A LU-0.8
FNR Forward Signal
32J_A Y-0.8
FNR LT Signal
19A_F Or-0.8
FNR Switched Power
None
None
10
None
Issued 2-03
Printed in U.S.A.
Copyright
4002-129
CONNECTOR 199F - TRANSMISSION ENABLE
CONNECTOR 201 - GRID HEATER CONTROLLER

TO MAIN CAB HARNESS
CAV
1
WIRE IDENT
18L_C Or-0.8
382391A1
CAV
WIRE IDENT
1
2
19A_D Or-0.8
19A_E Or-0.8
Trans Enable Switched Power
26E LU-0.8
Trans Enable Signal
None
None
None
28GP W-1.0
Feedback of Grid Heater
14_C LG-0.8
Alternator D+
21C_G W-0.8
Cranking Power
28GC W-0.8
Grid Heater Signal
19E Or-1.0
Switched Power
0_DBB Bk-0.8
Ground
10
None
0_DAE Bk-1.0
0_DAP Bk-1.0
Ground
49_G S-0.8
49_R S-1.0
Pilot Light
32J_B Y-0.8
32J_C Y-0.8
10
19A_C Or-0.8
19A_E Or-0.8
None
Indicator Light
None
CIRCUIT
CIRCUIT
None
31T Y-0.8
CONNECTOR 202F - DIODE MODULE TO FRONT

CHASSIS HARNESS
245485C1
CAV
A
CONNECTOR 200 - RETURN-TO-DIG PROXIMITY

SWITCH TO RETURN-TO-DIG HARNESS FOR XT
CHASSIS
WIRE IDENT
58_D W-1.0
B
C
CIRCUIT
None
53S_C W-1.0
Float Switch Signal
245484C1
CAV
WIRE IDENT
CIRCUIT
53B_A W-1.0
RTD Signal
0_AM Bk-1.0
RTD Ground
56_D W-1.0
RTD Power
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-130
CONNECTOR 203F - COMPRESSOR CLUTCH
LOCKOUT RELAY TO CAB MAIN HARNESS

CAB MAIN HARNESS
CAV
A
WIRE IDENT
61T Or-1.0
CIRCUIT

CAB MAIN HARNESS
CAV
A
245731C1
CAV
WIRE IDENT
CIRCUIT
30
61A_B Or-0.8
61A_C Or-0.8
Relay Power
85
0_DA Bk-0.8
86
61R_C Or-0.8
AC Relay Signal
87
61R_B Or-0.8
61R_C Or-0.8
61R_D Or-0.8
AC Relay Signal
87A
61C_B Or-0.8
AC Comp Clutch
CONNECTOR 204F - BRAKE LAMPS RELAY TO

CAB MAIN HARNESS
WIRE IDENT
61A_D Or-0.8
CIRCUIT
AC Thermostat

JUMPER
739070C1
CAV
A
WIRE IDENT
35R_D Y-0.8
CIRCUIT
Backup Alarm Switch
CONNECTOR 209M - BACKUP ALARM DISABLE

JUMPER
245731C1
CAV
WIRE IDENT
CIRCUIT
30
1B_E R-0.8
Brake Lamp Relay Power
85
0_DC Bk-0.8
0_DG Bk-0.8
86
44A_B T-0.8
Brake LT Input Signal
87
44_E T-0.8
Brake LT Relay Signal
CAV
None
87A
Bur 6-48930
631801C1
WIRE IDENT
35A_F Y-0.8
CIRCUIT
Issued 2-03
Printed in U.S.A.
Copyright
4002-131
CONNECTOR 210F - FAN REVERSER SWITCH
TO CAB MAIN HARNESS

TO CAB MAIN HARNESS
199436A1
382391A1
CAV
WIRE IDENT
CIRCUIT
CAV
1
WIRE IDENT
19R_E Or-0.8
CIRCUIT
Cab Switched Power
None
19P_B Or-1.0
Fan Rev Pin Engage Fused Pwr
52_A W-0.8
None
None
None
0_DAF Bk-1.0
0_DAY Bk-1.0
Switch Ground
49_H S-0.8
49_U S-0.8
Pilot Light
None
10
None
CONNECTOR 217F - ENGINE SHUTDOWN

JUMPER
739070C1

TO CAB MAIN HARNESS
CAV
A
WIRE IDENT
13K_D Or-0.8
CIRCUIT
CONNECTOR 217M - ENGINE SHUTDOWN

JUMPER
199436A1
CAV
1
WIRE IDENT
14_B LG-0.8
14_C LG-0.8
CIRCUIT
Alternator D+
631801C1
CAV
A
Bur 6-48930
WIRE IDENT
13C_B Or-0.8
CIRCUIT
Fuel Solenoid Power
Issued 2-03
Printed in U.S.A.
Copyright
4002-132
CONNECTOR 229M - DIODE MODULE TO FRONT
CHASSIS HARNESS
CONNECTOR 259F - CIGAR LIGHTER TO CIGAR

LIGHTER HARNESS
245488C1
CAV
WIRE IDENT
CIRCUIT
3227856R1
CAV
WIRE IDENT
CIRCUIT
58_E W-1.0
19W_A Or-3.0
Cigar Lighter Power
53S_D W-1.0
0_S Bk-3.0
Cigar Lighter Ground
0_AQ Bk-1.0
Ground
None
None
None

TO CIGAR LIGHTER HARNESS

TO RADIO HARNESS
CAV
A
WIRE IDENT
19L_A Or-1.0
CIRCUIT
Radio Power

TO CONVERTER HARNESS
CAV
A
WIRE IDENT
19L_B Or-1.0
CIRCUIT
276720A1
CAV
Converter Power Ignition
CONNECTOR 253F - POWER OUTLET TO

CONVERTER HARNESS
WIRE IDENT
19W_A Or-3.0
CIRCUIT
Cigar Lighter Power
CONNECTOR 262F - DIODE MODULE TO CAB

MAIN CHASSIS HARNESS
245485C1
314908A1
CAV
WIRE IDENT
CIRCUIT
12V_A R-3.0
12 V Power to Outlet
0_RB Bk-3.0
Outlet Ground
Bur 6-48930
CAV
A
WIRE IDENT
19R_F Or-0.8
B
C
CIRCUIT
None
19R_D Or-0.8

Issued 2-03
Printed in U.S.A.
Copyright
4002-133
SOLENOID TO SECONDARY STEERING
HARNESS
CONNECTOR 267F - ENGINE HARNESS TO AIR

CONDITIONING DIODE HARNESS
245481C1
225316C1
CAV
WIRE IDENT
CIRCUIT
CAV
1
51_C W-1.0
Sec Steer Solenoid Power
0_CF Bk-1.0
Secondary Steering Ground
WIRE IDENT
61C_D Or-1.0
CIRCUIT
CONNECTOR 269 - RADIO FUSE HOLDER

CONNECTOR 265F - AIR CONDITIONING DIODE
MODULE TO AIR CONDITIONING DIODE
HARNESS
CAV
WIRE IDENT
CIRCUIT
1_X R-1.0
Radio Memory Power
18_H Or-0.8
Radio Memory Fused Power
CONNECTOR 270F - RADIO MEMORY POWER

CAV
1
WIRE IDENT
Ground
61C_C Or-1.0
B
C
CIRCUIT
0_BJ Bk-1.0
1_X R-1.0
CIRCUIT
Radio Memory Power
CONNECTOR 271M - FRONT CHASSIS

ROLLBACK JUMPER HARNESS
245485C1
CAV
WIRE IDENT
None
CONNECTOR 266M - AIR CONDITIONING DIODE

HARNESS TO AIR COMPRESSOR CLUTCH
245484C1
CAV
A
WIRE IDENT
58_F W-1.0
B
C
CIRCUIT
Float Switch Signal
None
53S_E W-1.0
245480C1
CAV
1
WIRE IDENT
61C_E Or-1.0
Bur 6-48930
CIRCUIT
Issued 2-03
Printed in U.S.A.
Copyright
4002-134
CONNECTOR 275M - COOLANT JUMPER
COOLANT SENDER (COOLANT SENSOR
JUMPER HARNESS)
CONNECTOR 272F - ROLLBACK JUMPER

PRESSURE SWITCH (ROLLBACK SWITCH
JUMPER HARNESS)
194788A1
245483C1
CAV
WIRE IDENT
CAV
CIRCUIT
58A_A W-1.0
Float Switch Signal
58_F W-1.0
CONNECTOR 273F - ROLLBACK JUMPER DIODE

MODULE (ROLLBACK SWITCH JUMPER
HARNESS)
WIRE IDENT
CIRCUIT
31D_C Y-0.8
0_VA Y-0.8

TO RELAY HARNESS
245483C1
245485C1
CAV
A
WIRE IDENT
58A_A W-1.0
B
C
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
28GC_B W-1.0
Grid Heater Signal
0_UA Bk-2.0
None
53S_E W-1.0
Float Switch Signal
CONNECTOR 276M - RELAY HARNESS TO REAR

CHASSIS HARNESS
CONNECTOR 274F - REAR CHASSIS COOLANT

JUMPER (COOLANT SENSOR JUMPER
HARNESS)
CAV
WIRE IDENT
CIRCUIT
31D_C Y-0.8
0_VA Y-0.8
245482C1
CAV
Bur 6-48930
WIRE IDENT
CIRCUIT
28GC_C W-1.0
Grid Heater Signal
0_UC Bk-2.0
Issued 2-03
Printed in U.S.A.
Copyright
4002-135
RELAY HARNESS
CAV
WIRE IDENT
CONNECTOR 280 - FUEL FILTER HEATER

RELAY TO RELAY HARNESS
CIRCUIT
1Y_C R-2.0
1Y_B R-2.0
31U W-1.0
13C_G Or-1.0
CONNECTOR 277M - RELAY HARNESS TO

ENGINE HARNESS
245731C1
CAV
WIRE IDENT
CIRCUIT
30
1Y_E R-2.0
1Y_D R-2.0
85
31U_X W-1.0
86
13C_H Or-1.0
87
1Y_A R-8.0
Fuel Filter Relay Power
87A
None
239451A1
CAV
WIRE IDENT
CONNECTOR 287 - SECOND FUEL FILTER

HEATER TO ENGINE HARNESS
CIRCUIT
1Y_E R-2.0
1Y_D R-2.0
31U_X W-1.0
13C_H Or-1.0
CONNECTOR 279M - GRID HEATER RELAY TO

RELAY HARNESS
182069A1
CAV
WIRE IDENT
CIRCUIT
1Y_B R-2.0
0_BK Bk-2.0
Fuel Filter Heater Ground
3227856R1
CAV
WIRE IDENT
CIRCUIT
0_UC Bk-2.0
Grid Heater Ground
28GC_C W-1.0
Grid Heater Ground
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-136
CONNECTOR 288 - FIRST FUEL FILTER HEATER
TO ENGINE HARNESS
CONNECTOR 291 - FUEL FILTER

TEMPERATURE SWITCH TO ENGINE HARNESS
(621D ONLY)
182069A1
CAV
WIRE IDENT
CIRCUIT
371614A1
1Y_C R-2.0
CAV
0_BC Bk-2.0
Fuel Solenoid Ground
31U W-1.0
0_BM Bk-1.0
Signal Ground
WIRE IDENT
CIRCUIT
CONNECTOR 289 - FUEL FILTER

TEMPERATURE SWITCH TO ENGINE HARNESS
(521D ONLY)
256340A1
CAV
WIRE IDENT
CIRCUIT
31U W-1.0
0_BM Bk-1.0
Fuel Solenoid Ground
CONNECTOR 290 - GRID HEATER

TEMPERATURE SENSOR TO REAR CHASSIS
HARNESS
CAV
WIRE IDENT
CIRCUIT
31T_A Y-1.0
Grid Heater Temp Snsr Signal
0_BC Bk-1.0
Grid Heater Temp Snsr Ground
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-137
INDEX
Symbols
12 Volt Radio ..........................................................76
24 Volt Radio ..........................................................76
A
A/C High Pressure Switch (In Rear Chassis) .........73
A/C Low Pressure Switch (In Cab) .........................73
Accessory Relay No. 3 ...........................................43
Air Filter Restriction Switch.....................................50
Alarm
Back-up ..............................................................46
Back-up, Disable Switch ....................................46
Back-up, Relay No. 7 .........................................45
Alternator ................................................................37
B
Back-up Alarm ........................................................46
Back-up Alarm Disable Switch ...............................46
Back-up Alarm Relay No. 7 ....................................45
Batteries .................................................................36
Beacon Switch ........................................................78
Beacon, Rotating ....................................................79
Blower Motor ..........................................................73
Blower Motor Speed Resistors with Thermal Fuse 73
Blower Switch .........................................................72
Brake Lamp Pressure Switch .................................79
Brake Lamps Relay No. 6.......................................79
Brake Warning Pressure Switch .............................48
Bucket Control Valve Electromagnet Detents ........59
Bulb
See Lamp ...........................................................79
C
Cigar Lighter ...........................................................75
Cluster, Instrument .....................................51, 52, 53
Compressor Clutch .................................................74
Compressor Clutch Lockout Relay No. 14 .............74
Compressor, Seat...................................................72
Connector 1 ............................................................90
Connector 10 ..........................................................92
Connector 100 ......................................................120
Connector 101 ......................................................120
Connector 102 ......................................................120
Connector 104 ......................................................121
Connector 107M ...................................................121
Connector 108F....................................................121
Connector 109M ...................................................121
Connector 110F....................................................121
Connector 111M ...................................................122
Connector 112M ...................................................122
Connector 113 ......................................................122
Connector 114F....................................................122
Connector 114M ...................................................122
Connector 117 ......................................................123
Bur 6-48930
Connector 118F.................................................... 123

Connector 125 ...................................................... 123
Connector 127 ...................................................... 123
Connector 128F.................................................... 124
Connector 128M ...................................................124
Connector 12F........................................................ 92
Connector 12M....................................................... 92
Connector 131F.................................................... 124
Connector 133M ...................................................124
Connector 136 ...................................................... 124
Connector 138 ...................................................... 125
Connector 139F.................................................... 125
Connector 139M ...................................................125
Connector 13F........................................................ 93
Connector 13M....................................................... 94
Connector 140M ...................................................125
Connector 142 ...................................................... 125
Connector 154 ...................................................... 126
Connector 157 ...................................................... 126
Connector 158 ...................................................... 126
Connector 159 ...................................................... 126
Connector 168 ...................................................... 126
Connector 178M ...................................................126
Connector 179F.................................................... 127
Connector 17M....................................................... 95
Connector 180F.................................................... 127
Connector 180M ...................................................127
Connector 182 ...................................................... 127
Connector 183 ...................................................... 128
Connector 197F.................................................... 128
Connector 197M ...................................................128
Connector 198 ...................................................... 128
Connector 199F.................................................... 129
Connector 19F........................................................ 98
Connector 1F..........................................................90
Connector 2 ............................................................91
Connector 200 ...................................................... 129
Connector 201 ...................................................... 129
Connector 202F.................................................... 129
Connector 203F.................................................... 130
Connector 204F.................................................... 130
Connector 207F.................................................... 130
Connector 208F.................................................... 130
Connector 209F.................................................... 130
Connector 209M ...................................................130
Connector 20M....................................................... 98
Connector 210F.................................................... 131
Connector 215F.................................................... 131
Connector 216F.................................................... 131
Connector 217F.................................................... 131
Connector 217M ...................................................131
Connector 21F........................................................ 99
Connector 21M....................................................... 99
Connector 229M ...................................................132
Connector 22F...................................................... 100
Issued 2-03
Printed in U.S.A.
Copyright
4002-138
Connector 22M .....................................................100
Connector 23F......................................................101
Connector 23M .....................................................101
Connector 246M ...................................................132
Connector 24F......................................................101
Connector 24M .....................................................101
Connector 253F....................................................132
Connector 259F....................................................132
Connector 25F......................................................102
Connector 260M ...................................................132
Connector 262F....................................................132
Connector 264M ...................................................133
Connector 265F....................................................133
Connector 266M ...................................................133
Connector 267F....................................................133
Connector 269 ......................................................133
Connector 270F....................................................133
Connector 271M ...................................................133
Connector 272F....................................................134
Connector 273F....................................................134
Connector 274F....................................................134
Connector 275M ...................................................134
Connector 276F....................................................134
Connector 276M ...................................................134
Connector 277F....................................................135
Connector 277M ...................................................135
Connector 279M ...................................................135
Connector 27M .....................................................102
Connector 280 ......................................................135
Connector 287 ......................................................136
Connector 288 ......................................................136
Connector 289 ......................................................136
Connector 28M .....................................................102
Connector 290 ......................................................136
Connector 291 ......................................................136
Connector 29M .....................................................102
Connector 3 ............................................................91
Connector 30F......................................................102
Connector 31 ........................................................103
Connector 32F......................................................103
Connector 33F......................................................103
Connector 34F......................................................103
Connector 35F......................................................104
Connector 36F......................................................104
Connector 37 ........................................................104
Connector 38F......................................................105
Connector 39F......................................................105
Connector 4 ............................................................91
Connector 40F......................................................105
Connector 41F......................................................106
Connector 42F......................................................106
Connector 44F......................................................106
Connector 45F......................................................107
Connector 47F......................................................107
Connector 48F......................................................107
Connector 49F......................................................107
Connector 50F......................................................108
Bur 6-48930
Connector 51F...................................................... 108

Connector 53F...................................................... 108
Connector 54F...................................................... 108
Connector 55F...................................................... 109
Connector 56F...................................................... 109
Connector 57F...................................................... 109
Connector 58F...................................................... 109
Connector 59F...................................................... 110
Connector 5F.......................................................... 91
Connector 6 ............................................................ 91
Connector 60........................................................ 110
Connector 61........................................................ 110
Connector 62M..................................................... 110
Connector 63M..................................................... 111
Connector 64F...................................................... 111
Connector 64M..................................................... 111
Connector 66........................................................ 111
Connector 67........................................................ 111
Connector 68........................................................ 112
Connector 69........................................................ 112
Connector 70........................................................ 112
Connector 71........................................................ 112
Connector 72........................................................ 113
Connector 74........................................................ 113
Connector 75........................................................ 114
Connector 76........................................................ 114
Connector 77F...................................................... 115
Connector 78F...................................................... 115
Connector 79F...................................................... 115
Connector 8 ............................................................ 92
Connector 80F...................................................... 115
Connector 81M..................................................... 115
Connector 82M..................................................... 115
Connector 83F...................................................... 116
Connector 84F...................................................... 116
Connector 85F...................................................... 116
Connector 86........................................................ 116
Connector 87........................................................ 116
Connector 88........................................................ 117
Connector 89M..................................................... 117
Connector 90M..................................................... 117
Connector 92........................................................ 117
Connector 94F...................................................... 118
Connector 94M..................................................... 118
Connector 95........................................................ 119
Connector 96........................................................ 119
Connector 97........................................................ 119
Connector 98........................................................ 119
Connector 99........................................................ 120
Connector, Diagnostic ............................................ 45
Controller
Grid Heater ........................................................ 40
Converter, Radio Power (24 volts to 12 volts)........ 77
Coolant Level Sender .............................................48
Courtesy Lamp ....................................................... 89
Issued 2-03
Printed in U.S.A.
Copyright
4002-139
D
Declutch Brake Switch............................................45
Declutch Switch ......................................................45
Detent Switch .........................................................59
Diagnostic Connector .............................................45
Dome Lamp ............................................................89
E
Engine Coolant Temperature Sender .....................49
Engine Fuel Solenoid .............................................37
Engine Oil Pressure Switch ....................................55
Engine Speed Sensor.............................................45
Ether Start Solenoid ...............................................39
F
Fan Reversing Solenoid .........................................57
Fan Reversing Switch.............................................56
Filter Maintenance Switch ......................................45
First Fuel Filter Heater ............................................39
Five Position Rotary Lamp Switch ..........................88
Flasher Module.......................................................81
Float Pressure Switch.............................................61
Float Solenoid.........................................................61
FNR Switch.............................................................45
Front
LH Work Lamp ...................................................87
RH Work Lamp...................................................87
Front LH Combination Lamp ..................................85
Front RH Combination Lamp ..................................86
Front Washer Pump Motor .....................................69
Front Wiper and Washer Switch .............................69
Front Wiper Motor...................................................68
Fuel Filter
Heater, First .......................................................39
Heater, Second (621D Only) ..............................39
Fuel Filter Heater Relay No. 16 ..............................38
Fuel Filter Heater Switch ........................................39
Fuel Level Sender ..................................................48
Fuel Solenoid, Engine ............................................37
Fuse Block 18F.......................................................96
Horn Relay No. 5 .................................................... 71

Horn Switch ............................................................80
Hydraulic Filter Restriction Switch .......................... 49
Hydraulic Oil Temperature Sender ......................... 49
I
Ignition Relay No. 1 ................................................ 41
Ignition Relay No. 2 ................................................ 42
Ignition Switch ........................................................ 41
Instrument Cluster ...................................... 51, 52, 53
Intermediate Speed Sensor.................................... 45
L
Lamp
Courtesy............................................................. 89
Dome .................................................................89
High Beam ...................................................85, 86
LH Front Combination ........................................ 85
LH Rear Combination......................................... 83
LH Rear Work .................................................... 86
License Plate .....................................................89
Low Beam ....................................................85, 86
Position ........................................................85, 86
Reverse........................................................83, 84
RH Front Combination .......................................86
RH Front Work ................................................... 87
RH Rear Combination ........................................ 84
RH Rear Work.................................................... 87
Stop..............................................................83, 84
Switch, Five Position Rotary .............................. 88
Tail ...............................................................83, 84
Turn..................................................83, 84, 85, 86
Left Speaker ........................................................... 77
LH Front Combination Lamp ..................................85
LH Front Work Lamp ..............................................87
LH Rear Combination Lamp ................................... 83
LH Rear Work Lamp............................................... 86
License Plate Lamp ................................................ 89
Locating Components on the Schematic Posters .. 31
M
G
Grid Heater .............................................................40
Grid Heater Controller ............................................40
Grid Heater Relay No. 15 .......................................39
Grid Heater Temperature Sensor ...........................40
H
Hazard Switch ........................................................80
Heater
First Fuel Filter ...................................................39
Grid ....................................................................40
Second Fuel Filter (621D Only)..........................39
Height Control/Return-To-Travel Proximity Switch .61
Hi/Low Beam Switch...............................................80
High/Low Beam Relay No. 13 ................................88
Horn ........................................................................72
Bur 6-48930
Master Disconnect Switch ...................................... 37

Module
Flasher ............................................................... 81
Secondary Steering............................................ 63
Time Delay ......................................................... 43
Transmission Electronic Control ........................ 45
Motor, Starter ......................................................... 38
N
Neutral Start Relay No. 8 .......................................41
O
Outlet, Power..........................................................76
Output Speed Sensor ............................................. 45
Issued 2-03
Printed in U.S.A.
Copyright
4002-140
P
Parking Brake Relay No. 9 .....................................55
Parking Brake Solenoid ..........................................56
Parking Brake Switch .............................................50
Pilot Control Relay No. 10 ......................................55
Pilot Control Switch ................................................53
Pilot Pressure Solenoid ..........................................56
Pin Engage Solenoid ..............................................65
Pin Engage Switch .................................................65
Power Converter (24 volts to 12 volts) ...................76
Power Outlet...........................................................76
Program Reset Switch............................................50
Proximity Switch
Height Control/Return-To-Travel ........................61
Return-To-Dig ....................................................60
R
Radio
12 Volt ................................................................76
24 volt.................................................................76
Power Converter (24 volts to 12 volts) ...............77
Remote...............................................................76
Rear
LH Combination Lamp .......................................83
LH Work Lamp ...................................................86
RH Combination Lamp .......................................84
RH Work Lamp...................................................87
Rear Washer Pump Motor......................................70
Rear Wiper and Washer Switch .............................70
Rear Wiper Motor ...................................................70
Redundant Brake Pressure Switches .....................57
Relay
Accessory, No. 3 ................................................43
Backup Alarm, No. 7 ..........................................45
Brake Lamps No. 6 ............................................79
Compressor Clutch Lockout No. 14 ...................74
Grid Heater No. 15 .............................................39
High/Low Beam No. 13 ......................................88
Horn No. 5 ..........................................................71
Ignition, No. 1 .....................................................41
Ignition, No. 2 .....................................................42
Neutral Start No. 8 .............................................41
Parking Brake No. 9 ...........................................55
Pilot Control No. 10 ............................................55
Ride Control No. 4..............................................66
Starting ...............................................................38
Voltmeter, No. 12 ...............................................43
Relay No. 16
Fuel Filter Heater ...............................................38
Relay Socket No. 11 ...............................................57
Remote Radio.........................................................76
Return-To-Dig Proximity Switch .............................60
Return-To-Travel/Float Switch................................60
RH Front Combination Lamp..................................86
RH Front Work Lamp..............................................87
RH Rear Combination Lamp ..................................84
RH Rear Work Lamp ..............................................87
Bur 6-48930
Ride Control Relay No. 4........................................66

Ride Control Solenoid ............................................ 66
Ride Control Switch ................................................ 66
Right Speaker......................................................... 77
Rotating Beacon..................................................... 79
S
Seat Compressor and Switch .................................72
Second Fuel Filter Heater (621D Only) .................. 39
Secondary Steering Module ................................... 63
Secondary Steering Motor...................................... 64
Secondary Steering Pressure Switch .....................63
Secondary Steering Solenoid .................................64
Sender
Coolant Level ..................................................... 48
Engine Coolant Temperature ............................. 49
Fuel Level .......................................................... 48
Hydraulic Oil Temperature .................................49
Torque Converter Output Temperature ............. 45
Sensor
Engine Speed ....................................................45
Grid Heater, Temperature .................................. 40
Intermediate Speed............................................ 45
Output Speed ..................................................... 45
Transmission Solenoid Valve and Temperature 45
Turbine Speed ................................................... 45
Shifter, Transmission.............................................. 45
Solenoid
Engine, Fuel ....................................................... 37
Ether ..................................................................39
Fan Reversing....................................................57
Float ................................................................... 61
Parking Brake ....................................................56
Pilot Pressure..................................................... 56
Pin Engage ........................................................ 65
Ride Control ....................................................... 66
Secondary Steering ........................................... 64
Speaker
Left ..................................................................... 77
Right................................................................... 77
Specifications ........................................................... 7
Speed Resistors
Blower Motor ...................................................... 73
Starter Motor .......................................................... 38
Starting Relay......................................................... 38
Steering
Secondary, Module ............................................ 63
Secondary, Motor...............................................64
Secondary, Pressure Switch .............................. 63
Secondary, Solenoid .......................................... 64
Switch ..................................................................... 74
A/C High Pressure (In Rear Chassis) ................ 73
A/C Low Pressure (In Cab) ................................ 73
Air Filter Restriction............................................ 50
Back-up Alarm Disable ...................................... 46
Beacon ............................................................... 78
Blower ................................................................ 72
Issued 2-03
Printed in U.S.A.
Copyright
4002-141
Brake Lamp Pressure ........................................79
Brake Warning Pressure ....................................48
Declutch .............................................................45
Declutch Brake ...................................................45
Detent.................................................................59
Engine Oil Pressure ...........................................55
Fan Reversing ....................................................56
Filter Maintenance..............................................45
Five Position Rotary Lamp .................................88
Float Pressure ....................................................61
FNR ....................................................................45
Front Wiper and Washer ....................................69
Fuel Filter Heater ...............................................39
Hazard................................................................80
Hi/Low Beam ......................................................80
Horn ...................................................................80
Hydraulic Filter Restriction .................................49
Ignition................................................................41
Master Disconnect .............................................37
Parking Brake.....................................................50
Pilot Control Switch ............................................53
Pin Engage.........................................................65
Program Reset ...................................................50
Proximity, Height Control/Return-To-Travel .......61
Proximity, Return-To-Dig....................................60
Rear Wiper and Washer.....................................70
Redundant Brake Pressure ................................57
Return-To-Travel/Float .......................................60
Ride Control .......................................................66
Seat Compressor ...............................................72
Secondary Steering Pressure ............................63
Transmission Auto .............................................45
Transmission Enable..........................................45
Transmission Kick-down ....................................45
Turn Signal .........................................................80
Up/down Count ..................................................53
U
Understanding the Troubleshooting Tables ........... 31
Up/down Count Switch ........................................... 53
V
Voltmeter Relay No. 12 .......................................... 43
W
Wiper
Front Motor......................................................... 68
Front Switch ....................................................... 69
Front Washer Pump Motor................................. 69
Front Washer Switch.......................................... 69
Rear Motor ......................................................... 70
Rear Switch........................................................ 70
Rear Washer Pump Motor ................................. 70
Rear Washer Switch .......................................... 70
T
Temperature Sensor
Grid Heater.........................................................40
Thermal Fuse
Blower Motor ......................................................73
Thermostat .............................................................74
Thermostat Switch ..................................................74
Time Delay Module.................................................43
Torque Converter Output Temperature Sender .....45
Transmission Auto Switch ......................................45
Transmission Electronic Control Module ................45
Transmission Enable Switch ..................................45
Transmission Kick-down Switch .............................45
Transmission Shifter ...............................................45
Transmission Solenoid Valve and Temperature
Sensors .....................................................45
Turbine Speed Sensor............................................45
Turn Signal Switch..................................................80
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4002-142
NOTES
Bur 6-48930
Issued 2-03
Printed in U.S.A.
Copyright
4003
Section
4003
BATTERIES
CASE CORPORATION
700 State Street
Bur 6-42330

Printed in U.S.A.
August, 2001
Copyright
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42330
Issued 8-01
3
3
4
4
4
5
5
5
6
7
7
8
8
Printed in U.S.A.
Copyright
4003-3
SAFETY RULES
Never try to charge the battery if the electrolyte in the

battery is frozen.
47-83A
Never cause sparks to occur or smoke near batteries

that are charging or have been recently charged.
13-8A
Disconnect the ground cable first when the battery

cables are disconnected from the battery.
Battery acid causes severe burns. Batteries contain

sulfuric acid. Avoid contact with skin, eyes, or clothing.
Antidote: EXTERNAL-Flush with water. INTERNALDrink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention.
Connect the ground cable last when the battery cables

are connected to the battery.
47-55A
Batteries produce explosive gases. Keep sparks,

flame, and cigarettes away. Ventilate when charging or
using in enclosed area. Always shield eyes when working near batteries.
Keep out of reach of children.
D-47-53A
SPECIAL TOOLS
B795328M
The CAS-10147 tester is used to do the Capacity

(Load) Test. This tool is first used on page 4003-7.
Bur 6-42330
Issued 8-01
Printed in U.S.A.
Copyright
4003-4
MAINTENANCE
Electrolyte Level
NOTE: Add water only. DO NOT add electrolyte.
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 hours of operation.
Inspecting and Cleaning a Battery
NOTE: Before checking the electrolyte level in the

battery, the battery must have been idle for at least
16 hours. During charging the level of the liquid may
raise.
Check the level of the electrolyte more often
during hot weather. The use of a large amount of
water by the battery can be caused by high battery
temperature or a voltage regulator setting that is too
high. Keep the electrolyte level above the top of the
plates in the battery at all times to prevent damage to
the battery.
If the level of the electrolyte is low, add distilled
water or other clean water until the electrolyte is just
below the cell well bottom, approximztely 5 mm (3/16
inch).Do not add more water than is needed. Too
much water can cause bad performance, a short
service life, and corrosion around the battery.
Bur 6-42330
If damage causes an electrolyte leak, replace the

battery.
Inspect the battery at regular intervals for dirt,
corrosion, and damage. Electrolyte and dirt on the
top of the battery can cause the battery to discharge
by making a passage for the current to flow.
If the battery must be cleaned, remove the battery
from the battery carrier and clean the battery, cable
terminals, and the battery carrier. When available,
use Case Battery Saver and Cleaner according to
the instructions on the container. Case Battery Saver
and Cleaner also helps prevent corrosion. If Case
Battery Saver and Cleaner is not available, use
baking soda and water as a cleaner. DO NOT permit
any type of cleaner to enter the cells of the battery.
Install the battery in the machine and make sure
the fasteners are tight. Apply Case Battery Saver and
Cleaner or Urethane Seal Coat to the cable terminals
to prevent corrosion. See the Parts Counter Catalog.
DO NOT apply grease.
Issued 8-01
Printed in U.S.A.
Copyright
4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the
battery.
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 4003-4.
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

A hydrometer is used to check the specific gravity
(weight) of the electrolyte. The specific gravity is an
indication of the level of charge for each cell.
Hydrometers are made to show the co rrect
sp e c ific g r a vi ty w h e n t he te m p e ra t ur e of t h e
electrolyte is 26.7C (80F).
When you check the specific gravity, you must
know the temperature of the electrolyte. If your
hydrometer does not have a thermometer, get a
the rmo me ter to c he ck the tem pe ra tur e o f th e
electrolyte. The thermometer must indicate a high
temperature of at least 52C (120F).
1. Remove enough electrolyte from a cell so that
the float is free in the tube.
NOTE:
If the specific gravity cannot be checked
without first adding water to the cell, the battery must
be tilted to the left and right to about a 30 angle to
mix the water and acid. Next the battery must be
charged for 15 minutes at 15 to 25 amperes to
further mix the water with the electrolyte. Then check
the specific gravity.
2. Read the float.
3. Read the thermometer. If the reading is above
26.7C (80F) add specific gravity points to the
reading for specific gravity. If the reading is below
26.7C (80F) subtract specific gravity points from
the reading for specific gravity. See the following
illustration and add or subtract specific gravity
points as needed.
Bur 6-42330
B790863J
1. TEMPERATURE IN F
2. TEMPERATURE IN C
4. Make a record of the corrected specific gravity

reading for each cell.
5. If the difference between the high reading and
the low reading is 0.050 or more, charge the
battery and check the specific gravity again. If
after charging, the difference is still 0.050 or
more, install a new battery.
6. The corrected specific gravity reading shows the
level of charge for the cell. The level of charge
must be at least 75% in each of the cells. In
maintenance free batteries the level of charge is
at least 75% if the corrected specific gravity
reading is 1.240 or higher. In all other batteries
the level of charge is at least 75% if the corrected
specific gravity reading is 1.230 or higher.
the low reading is less than 0.050, and the level
of charge is at least 75% in all of the cells, do the
Capacity (Load) Test.
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.
Issued 8-01
Printed in U.S.A.
Copyright
4003-6
Capacity (Load) Test

This test can be done using a variable load tester
s u c h a s th e S u n E le c tr ic VAT- 3 3 . O th e r te s t
equipment can be used. Connect the test equipment
according to the instructions of the manufacturer of
the equipment.
1. The level of charge of the battery must be at
least 75%. Do the Specific Gravity Check in this
section.
2. Prepare the tester (Sun Electric VAT-33 shown)
for the test.
4. Apply a 15 ampere load to the battery for 15

seconds. Wait at least three minutes before
applying the load again.
5. Check and make a record of the temperature of
the electrolyte.
6. Find the correct load for this test in Specifications
in Section 4002.
NOTE: The correct load is half of the cold cranking amperes at
-17C (0F).
A. Select the voltmeter range that will measure 1

to 18 volts.
7. Turn the load control knob until the ammeter

indicates the specified load. Keep the load for 15
seconds and read the voltmeter. Turn the load
control knob to OFF.
B. Make sure the load control knob is in the OFF

position.
8. Compare the test reading and the temperature of

the electrolyte to the chart below.
C. Select the ammeter range that will measure 0

to 1000 amperes.
D. Move the volt lead switch to the INT. position.
3. Connect the tester to the battery as shown.
TEMPERATURE OF
ELECTROLYTE
MINIMUM
VOLTAGE
21C (70F) and above . . . . . . . . . . . . . . . . . . . . . 9.6

16C (60F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10C (50F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
4C (40F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1C (30F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
-7C (20F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12C (10F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
-18C (0F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
voltage shown, the battery is in good
condition.
B. If the test result is less than the voltage

shown, discard the battery.
B790499J
1. LOAD CONTROL KNOB

2. AMMETER CLAMP (TIP OF ARROW
AWAY FROM BATTERY)
NOTE: Never apply a load for longer than 15

seconds. After each 15 seconds, turn the load control
knob to OFF for at least one minute.
Bur 6-42330
Issued 8-01
Printed in U.S.A.
Copyright
4003-7
CHARGING A BATTERY
Before you charge the battery, check the level of
the electrolyte.
1. Too much gas causes the electrolyte to flow from

the cells.
It is difficult to give an e xa ct cha rgin g rate

because of the following variable conditions: (1)
temperature of the electrolyte, (2) level of charge,
and (3) condition of the battery. Use the charging
guide for the correct charging rate and time.
2. The temperature of the electrolyte rises above

52C (125 F).
Se e Sp ecifica tio ns in Se ctio n 4 002 for th e

reserve capacity of the battery in this machine.
The charging rate must be decreased if:
NOTE: For the best charge, use the slow charging

rates.
The battery is fully charged when, over a three
hour period at a low charging rate, no cell is giving
too much gas, and the specific gravity does not
change.
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See Reserve
Capacity under Specifications
Slow Charge
Fast Charge
10 Hours at 5 Amperes
2.5 Hours at 20 Amperes

Above 80 to 125 Minutes


80 Minutes or Less
*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.
Bur 6-42330
Issued 8-01
Printed in U.S.A.
Copyright
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 Specifications
Slow Charge
Fast Charge



Above 250 Minutes
80 Minutes or Less
*Initial rate for standard taper charger
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery.
4. Connect a battery charger to the battery.
2. Fill each cell to the top of the separators with

ele ctro ly te . Th is will p er mit the vo lu me of
electrolyte to increase when heated by charging
the battery.
5. Charge the battery at 30 amperes until the

s p e cif ic g ra v it y is 1 .2 5 0 o r m o r e a n d t h e
temperature of the electrolyte is at least 15.5C
(60 F).
3. Install the caps on the battery. If the battery in

your machine must have nonspill caps, install the
nonspill caps. See Specifications in Section 4002
to find if the battery in your machine must have
nonspill caps.
6. If necessary, fill each cell with electrolyte until the

electrolyte is just below split ring at the bottom of
the cell opening.
Bur 6-42330
Issued 8-01
Printed in U.S.A.
Copyright
Section
4005
4005
INFORMATION AND DIAGNOSTIC CENTER
CASE CORPORATION
700 State Street
Bur 6-42351

Printed in U.S.A.
August, 2001 (Revised November, 2001)
Copyright
4005-2
TABLE OF CONTENTS
INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicators and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop Master Indicator (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Master Indicator (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Beacon Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Work Light Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Coolant Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering Indicator (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Indicator Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
6
6
6
6
6
6
6
6
6
7
7
7
7
7
7
7
7
8
8
8
8
9
WARNING DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Non-Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INFORMATION AND DIAGNOSTIC CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requested Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actual Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Mode (Automatic or Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
SETTINGS, DIAGNOSTICS, AND FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming the Information Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Scrolling Gauge Displays (01, 02, or 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatically Scrolling Gauge Displays (03 or 04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Display Center Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltmeter at Key ON Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
15
15
15
15
16
17
17
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-3
Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Park Brake Information Center Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Lockout Information Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Work Lights Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Filter Restriction Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requested Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actual Gear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Line Shift Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hourmeter Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Movement Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Beacon Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Turn Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution and Warning Master Indicator Lights Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Park Brake Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Brake Pressure Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Brake Foot Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Lockout Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Location 047 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Location Numbers (048 and 049) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Range Read Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset Diagnostic Stack for Locations 071 through 090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Location Numbers (056 - 060) Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Interval Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF Transmission ECM Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF Transmission ECM Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Information Center Software Revision Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LCD Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Information Center Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Location Number 097 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entry Code for Accessing Test Mode Locations 100 to 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Identification Numbers (VINS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Location Numbers 104 - 113 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument Cluster (Information Center) Part Number (1st part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument Cluster (Information Center) Part Number (2nd part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument Cluster (Information Center) Date Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Location Numbers 117 - 120 Reserved for Supplier Information . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Location Numbers 121 -129 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Location Numbers 131 - 139 Reserved for Speedometer Calibration . . . . . . . . . . . . . . . . . . . . . .
Display Location Numbers 141 - 170 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary Fault Code Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42351
Revised 11-01
17
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17
18
18
18
18
18
18
19
19
19
20
20
20
20
20
21
21
21
21
21
21
21
22
22
22
22
22
22
23
23
23
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23
24
24
24
25
25
25
25
25
25
25
25
26
26
26
27
27
27
27
27
28
28
28
Printed in U.S.A.
Copyright
4005-4
Display
Display
Display
Display
Location Numbers 191 - 196 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location Number 197 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location Number 198 Reserved for Future Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location Number 199 Reserved for Manufacturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
28
28
DISPLAY LOCATION NUMBERS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

FAULT CODES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-5

The information and diagnostic center monitors a number of functions and can be tailored to fit the operators
preferences, refer to Figure 1. The information center 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 information and diagnostic center will perform the following
self-test:
10
11
12
20
13
14
19
15
18
16
17
RD98K316
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
BEACON INDICATOR
WORK LIGHT INDICATOR
PILOT CONTROL INDICATOR
LOW COOLANT INDICATOR
BRAKE PRESSURE INDICATOR
STOP MASTER INDICATOR
CAUTION MASTER INDICATOR
SECONDARY STEERING INDICATOR
PARKING BRAKE INDICATOR
AIR-CONDITIONING INDICATOR
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
HYDRAULIC OIL FILTER INDICATOR

AIR FILTER INDICATOR
TRANSMISSION OIL FILTER INDICATOR
TRANSMISSION OIL TEMPERATURE GAUGE
HYDRAULIC OIL TEMPERATURE GAUGE
VOLTMETER GAUGE
FUEL LEVEL GAUGE
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE GAUGE
SERVICE INDICATOR ICON
FIGURE 1. INFORMATION CENTER
Self-Test
IMPORTANT: During operation, if the stop master
indicator (on the front console) flashes, and the
warning alarm is continuous, stop the machine, stop
the engine, and find the problem.
1. Turn the ignition (key) switch to the ON position.
2. The information center will automatically check
each monitored system.
Bur 6-42351
3. All LEDs (Light Emitting Diodes) will illuminate

for 2 - 3 seconds.
4. Six bar graphs will energize for 2 - 3 seconds.
5. The warning alarm will sound for 2 - 3 seconds.
6. If there is an open circuit between a sensor and
the information center, the LED will flash and the
warning alarm will sound for 5 seconds.
Revised 11-01
Printed in U.S.A.
Copyright
4005-6
7. If there were no faults detected during the check,
all monitored systems will return to normal
operation.
8. If only some of the LEDs illuminate, replace the
information center.
9. If the LEDs illuminate, but the warning alarm
does not sound, replace the information center.
10. If the warning alarm sounds but the LEDs do not
illuminate, replace the information center.
Caution Master Indicator (Yellow)

When the caution master indicator illuminates:
1. The warning alarm sounds for three seconds.
2. The indicator turns yellow and one or more of the
following conditions exist:
A. Parking brake engaged when shifting into
forward or reverse.
B. High engine coolant temperature.
11. If the warning alarm does not sound and the

LEDs do not illuminate on the information center,
do the following steps to test the power circuit:
C. High hydraulic oil temperature.
Power Circuit Test
F. Air filter restriction.
A. Check the 7.5 amp fuse V. If the fuse is bad,

replace the fuse and repeat Self-Test steps 1
through 7. If the fuse is good, do the next step.
B. Check wire 19V for continuity. Repair/replace
the wire as required. If continuity is found do
the next step.
C. Check wire 13V for continuity. Repair/replace
the wire as required. If continuity is found, do
the next step.
D. Check the voltmeter relay #12 for proper
operation, see Section 4002. If voltmeter
operates properly, do the next step.
E. If no faults are found in Power Circuit Test
steps A through D, then remove and replace
the information center.
D. High transmission oil temperature.

E. High or low air conditioning pressure.
G. Transmission filter restriction.
H. Hydraulic filter restriction.
I. Alternator malfunction.
J. Low fuel.
Beacon Indicator
The beacon indicator illuminates when the Beacon (if
equipped) is in the ON position.
Work Light Indicator

The work light indicator illuminates when the work
lights are ON.
Pilot Control
The Pilot Control indicator illuminates when the pilot
lockout is actuated.
Indicators and Gauges
Low Coolant Indicator
Stop Master Indicator (Red)
The low coolant indicator illuminates when the

engine coolant is low.
IMPORTANT: Failure to follow these procedures may

result in injury and/or damage to the machine.
1. The warning alarm sounds continuously.
When the stop master indicator illuminates:
2. The stop master indicator will be red.
1. Stop the machine immediately.
3. Stop the engine and add coolant to the radiator.
2. Turn OFF the engine.
Brake Pressure Indicator
3. The warning alarm sounds continuously and one

or more of the following conditions exist:
The brake pressure indicator illuminates when the

brake system pressure is too low.
A. Low engine oil pressure.
B. Low brake pressure.
C. Low steering pressure.
3. Stop the engine and correct the problem.
D. Low engine coolant level.

E. High engine coolant temperature.
F. High hydraulic oil temperature.
G. High transmission oil temperature.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-7
Secondary Steering Indicator (If

equipped)
Transmission Oil Temperature Gauge
The secondary steering indicator illuminates when

the primary steering system pressure is too low.
The transmission oil temperature gauge is shown as

an indicator bar with a green, yellow or red zone.
3. Replace the transmission oil filter(s) as required.
Green Zone:
Indicates normal operating temperature, 20 to 120

C (68 to 248 F).
3. Stop the engine and correct the problem.
Parking Brake Indicator

The parking brake indicator illuminates when the
parking brake is applied. If the transmission is shifted
into FORWARD or REVERSE when the parking
brake is applied:
Yellow Zone:
1. Transmission oil temperature is too low, 20 C or
below (68 F or below), or it has increased, 120
to 125 C (248 to 257 F).
2. The indicator bars flash.
1. The warning alarm sounds for 3 seconds.
2. The caution master indicator turns yellow.
4. The yellow caution master indicator turns on.
3. Disengage the parking brake before shifting the

machine.
Air Conditioning Indicator

The air conditioning indicator illuminates when the air
conditioner has stopped due to refrigerant pressures
that are too high or too low.
Red Zone:
NOTE: The machine must not be operated when the
temperature is in the red zone.
1. Transmission oil temperature continues to
increase, 125 C and above (257 F and above).
2. The indicator bar flashes.
4. The red stop master indicator turns on.
3. Service the air conditioning system, or the

outside air temperature is too cool for the system
to work.
5. Stop the machine.
Air Filter Indicator

The air filter indicator illuminates when the air filter is
restricted.
3. Replace or clean the air filter as required.
6. Shift the transmission into NEUTRAL.

7. Run the engine at half throttle until the
transmission cools.
8. If the transmission oil temperature does not
return to normal operating temperature, run the
engine at idle speed and check the transmission
oil level.
9. Correct the problem before continuing to operate
the machine.
Hydraulic Oil Filter Indicator
Hydraulic Oil Temperature Gauge
The hydraulic oil filter indicator illuminates when the

hydraulic filters are restricted.
The hydraulic oil temperature gauge is shown as an

indicator bar with a green, yellow, or red zone.
Green Zone:

C (68 to 221 F).
3. Replace the hydraulic oil filters as required.
Transmission Oil Filter Indicator

The transmission oil filter indicator illuminates when
the transmission filter(s) are restricted.
Yellow Zone:
1. Hydraulic oil temperature has decreased, 20 C
or below (68 F or below), or it has increased
105 to 110 C (221 to 230 F).

Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-8
Red Zone:
Engine Oil Pressure Gauge

The engine oil pressure gauge is shown as an

indicator bar with a green or red zone.
1. Hydraulic oil temperature continues to increase

110 C and above (230 F and above).
Green Zone:
Indicates normal operating pressure, 110 kPa (16

psi) and over.
Red Zone:

oil pressure is in the red zone.
5. Stop the machine and correct the problem.
Voltmeter Gauge
1. Engine oil pressure decreased to less than 70

kPa (less than 10 psi).
The voltmeter gauge is shown as an indicator bar

with a green or yellow zone.
Green Zone:
Indicates normal operating range:

A. 26 to 32 volts above low idle = normal

operating range.
Engine Coolant Temperature
B. 18 to 24 volts stopped or at low idle = low to

normal battery charge.
The engine coolant temperature gauge is shown as

an indicator bar with a green, yellow, or red zone.
C. 18 to 24 volts at above low idle = problem in

charging system.
Green Zone:
Yellow Zone:

C (68 to 221 F).
Voltage has increased or decreased:
Yellow Zone:
A. 0 to 18 volts stopped or at low idle = very low

battery charge.
B. 32 volts and above = problem in charging
system (overcharging).
1. Engine coolant temperature has decreased 20

C or below (68 or below), or increased 105 to
110 C (221 to 230 F).
Red Zone:

Fuel Level Gauge

The fuel level gauge is shown as an indicator bar
with a green or yellow zone.
1. Engine coolant temperature continues to

increase, 110 C or above (230 F or above).
Green Zone:
Indicates normal operating range, 5 percent and
above.
Yellow Zone:
The tank is almost empty, 5 percent and below.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-9
Service Indicator Icon
When a fault code is written, the service indicator

icon (a manual with a wrench) will be displayed on

Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-10
WARNING DISPLAYS
Critical Warning Displays
IMPORTANT: Failure to follow these procedures may result in injury and/or damage to the machine.
The following table is a listing of critical warning displays that may appear on the information center and the
corrective action required. When a fault occurs, a continuous warning alarm will sound, the STOP indicator will be
RED, and the Display indicator will be illuminated. When this occurs bring the machine safely to a stop and
shutdown the engine to help avoid expensive repairs
.
DISPLAY
DESCRIPTION
ENGINE OIL
PRESSURE
Low engine oil

pressure.
BRAKE PRESSURE
Low brake pressure.
1. Bring the machine to a safe stop and shut the engine

OFF immediately.
2. Check brake system for proper charging and leaks.
Low steering pressure.

OFF immediately.
2. Check the hydraulic fluid level.
3. Check hydraulic system and steering system for leaks.
Low coolant level.

OFF immediately.
2. Check the coolant level.
3. Check the engine cooling system for leaks.
COOLANT
TEMPERATURE
High engine coolant

temperature.

OFF immediately.
2. Check the coolant levels after allowing the engine and
coolant to cool down.
3. Clean the radiator.
HYDRAULIC OIL
TEMPERATURE
High hydraulic oil

temperature.

OFF immediately.
2. Check the hydraulic fluid level.
3. Clean the cooler.
High transmission oil

temperature.

OFF immediately.
2. Check the transmission fluid level.
4. Check transmission for leaks.
5. Select lower gear.
STEERING
PRESSURE
COOLANT LEVEL
TRANSMISSION OIL
TEMPERATURE
Bur 6-42351
CORRECTIVE ACTION
1. Check low idle specifications.
2. Change engine oil and filter.
3. Change operating procedures.
Revised 11-01
Printed in U.S.A.
Copyright
4005-11
Non-Critical Warning Displays

The following table is a listing of warning displays that may appear on the information center and the corrective
action required. When a fault occurs, a warning alarm will sound for three seconds, the CAUTION indicator will be
YELLOW, and the display indicator will be illuminated. When this occurs, do the corrective action and return the
machine to service. If the noncritical warning display continues, shutdown the machine and perform repairs.
DISPLAY
DESCRIPTION
CORRECTIVE ACTION
PARKING BRAKE
Parking brake engaged and

shifts from Forward to Reverse.
COOLANT
TEMPERATURE
High engine coolant

temperature.
1. Idle machine and monitor temperature.

2. Clean radiator.
HYDRAULIC
TEMPERATURE
High hydraulic temperature.

TRANSMISSION
TEMPERATURE
High transmission temperature.

3. Use a lower gear.
AIR CONDITIONING
High or low air conditioning

pressure.
AIR FILTER
High air filter restriction.
TRANSMISSION
FILTER
Transmission filter restriction.
HYDRAULIC FILTER
Hydraulic filter restriction.
Release the parking brake and depress the

service brake.
1. Turn air conditioning OFF.

2. Low outside temperature.
3. Servicing required.
1. Clean air filter.
2. Replace primary and secondary filters.
Replace transmission filter.
Replace hydraulic filter.
ALTERNATOR
Alternator malfunction.
1. Check electrical system.

2. Voltages are out of range.
3. Change operating procedure.
FUEL
Low fuel.
Fill fuel tank within the next hour.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-12

Many of the machine functions can be displayed on the Programmable Information Center. It can be programmed
to display all functions, or only the functions important to the operator. The following functions can be displayed on
the Information Center, refer to Figure 2:
2
4
6
RD98K316
1. DIRECTION (F-N-R)
2. TRANSMISSION DISPLAY
3. DISPLAY CENTER
4. REQUESTED GEAR (1, 2, 3, 4)

5. ACTUAL GEAR BARS
6. TRANSMISSION MODE (A OR BLANK)
FIGURE 2. INFORMATION CENTER AND TRANSMISSION DISPLAY
Hourmeter
Engine Coolant Temperature
The hourmeter displays the accumulated running

time of the engine in hours and tenths of an hour with
an hour glass symbol.
Displays the engine coolant temperature in Celsius

with the engine coolant temperature bar graph
flashing. See page 8 for a detailed description of the
bar graph function.
Tachometer
The ta ch omete r d isp la ys the en gine sp ee d in
revolutions per minute along with a r/min symbol.
Speedometer
The speedometer displays the ground speed in
either kilometers per hour (km/h) or miles per hour
(mph) along with either a km/h or mph symbol.
Engine Oil Pressure

Displays the engine oil pressure in kilopascals (kPa)
with the engine oil pressure bar graph flashing. See
page 8 for a detailed description of the bar graph
function.
Fuel Level
Displays the fuel level in percent remaining in the
tank with the fuel level bar graph flashing. See page
8 for a detailed description of the bar graph function.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-13
Transmission Oil Temperature
Transmission Display
Displays the transmission oil temperature in Celsius

with the transmission oil temperature bar graph
flashing. See page 7 for a detailed description of the
bar graph function.
The Transmission Display shows the status of the

transmission control. The display center contains the
following information, refer to Figure 2:
Hydraulic Oil Temperature
Shown at the top of the display center:
Direction Selected
F
Forward
Neutral
Reverse
Voltmeter
Flashing forward not engaged.
Displays the electrical system voltage level in volts

with the voltmeter bar graph flashing. See page 8 for
a detailed description of the bar graph function.
Flashing set control lever to neutral

position.
Flashing reverse not engaged.
Displays the hydraulic oil temperature in Celsius with

the hydraulic oil temperature bar graph flashing. See
page 7 for a detailed description of the bar graph
function.
Requested Gear
Th e gea r positio n on sh ift lever, sh own in the
center of the gear symbol:
1
1st gear
2nd gear
3rd gear
4th gear
Actual Gear
Shown with bars to the right of the gear symbol. The
number of bars indicates the gear the transmission is
actually in.
Transmission Mode (Automatic or

Manual)
Shown in the lower left of the display center:
A
Automatic Mode
No symbol will be displayed when
transmission is in Manual Mode.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-14
SETTINGS, DIAGNOSTICS, AND FAULT CODES
2
1
RD98K316
1. INFORMATION CENTER
2. DISPLAY CENTER
3. UP COUNT
4. DOWN COUNT
5. PROGRAM
6. RESET
FIGURE 3. INFORMATION CENTER
Programming the Information

Center
NOTE: The machine must be OFF
programming the information center.
prior
1. Turn the machine OFF.

2. Turn the key to the RUN position.
to
Two switches are used during the programming of

the information center: the up/down count switch and
th e program/reset switch. The se sw itch es are
located on the right hand side of the information
center, refer to Figure 3.
For an up count press the left side of the up/down
count switch. For a down count press the right side of
the up/down count switch. The center position is OFF
or NEUTRAL.
3. Press the program/reset switch to program.

4. Press the up/down count switch to up count
program location 010.
5. Center the program/reset switch to OFF.
6. Note the gauge display setting that is displayed,
01, 02, 03, 04, or 05. If the desired setting has
already been selected go to step 7.
7. Press the up/down count switch to up count to
choose one of the following gauge disp lay
settings:
For programming pres s the left s ide of t he

program/reset switch. For resetting press the right
side of the program/reset switch. The center position
is OFF or NEUTRAL.
To program the information center do the following
steps:
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-15
Individual Function Display
01
Manually scrolls through Hourmeter,

Tachometer, and Speedometer (km/h).
02

Tachometer, and Speedometer (mph).
03
Automatically scrolls through Hourmeter

(at start-up), Tachometer (in 1st, 2nd and
3rd gears), and Speedometer (km/h in 4th
gear).
04
Automatically scrolls through Hourmeter

(at start-up), Tachometer (in 1st, 2nd and
3rd gears), and Speedometer (mph in 4th
gear).
05
Do the following steps to display any individual

function, at anytime, regardless of the gauge display
that was programmed:

Tachometer, and Speedometer (mph),
Speedometer (km/h), Engine Oil
Temperature (Celsius), Engine Oil
Pressure, Fuel Level, Transmission Oil
Temperature (Celsius), Hydraulic Oil
Temperature (Celsius), and Voltmeter.
NOTE: 05 is the factory installed setting.
8. Press the program/reset

momentarily.
switch
to
2. Press the up/down count switch to up count and

select one of the following individual functions:
000
Hourmeter
001
Tachometer
002
Speedometer (mph)
003
Speedometer (km/h)
004
Engine Oil Temperature
005
Engine Oil Pressure
006
Fuel Level
007
Transmission Oil Temperature
008
Hydraulic Oil Temperature
009
Voltmeter
reset
9. If the Information Center does not function

properly, do the programming steps again.
10. If the Information Center continues
malfunction replace the instrument panel.
to
Manual Scrolling Gauge Displays (01, 02,

or 05
If the Information Center has been programmed to
display one of the manual scrolling displays (01, 02,
or 05) press the up/down count switch to up count
and scroll through the gauge displays.
1. Press the up count switch one time to display the
Tachometer.
3. Put the program/reset switch in the OFF (center)

position.
4. If one of the individual functions (004 through
009) is selected, the corresponding bar graph will
flash indicating that this individual function is
being displayed.
5. The individual function selected will be shown on
Testing the Park Brake

Do the following steps to test the parking brake:
NOTE: The Transmission Control Module will
disconnect the transmission if any gear other than
3rd is used.
2. Press the up count switch again to display the

Speedometer (km/h).
1. Turn the machine ON.
3. Press the up count switch again to display the

Hourmeter.
2. Make sure the transmission is in the manual shift

mode, the gear selector is in 3rd neutral gear,
and the park brake switch is ON.
Automatically Scrolling Gauge Displays

(03 or 04)
If the Information Center has been programmed with
one of the automatic scrolling displays the gauge
display will automatically scroll through after starting
the machine. The up/down count switch has no effect
on the display.
Bur 6-42351
3. Set the park brake calibration as follows:

A. Press the program/reset switch to program.
B. Press the up/down count switch to up count
until the display reads 011.
C. Put the program/reset switch in the OFF
(center) position.
Revised 11-01
Printed in U.S.A.
Copyright
4005-16
D. Press the up/down count switch to up count
once, so the display reads 01.
E. Shift the transmission selector into 3rd forward
and slowly increase the engine rpm.
F. The park brake should hold the machine at full
throttle.
G. To exit the test mode, press the program/reset
switch to reset.
Transmission Clutch Calibration

Clutch Calibration ensures the most optimum shifting
of the transmission. Before doing the following
transmission clutch calibration procedures make
sure of the following:
1. The machine is running and the transmission oil
is warm.
2. Engine low idle speed is correct.
If this occurs, the code in the 3rd and 4th

spaces will be a Clutch Calibration Main Code
09 through 14 and indicate what process the
calibration was in when it was aborted
The 1st and 2nd spaces will produce the
Clutch Calibration Sub Code, which is the
code that informs the operator of the reason
the process was aborted.
K. After completing the Clutch Calibration
procedure, turn the machine OFF for 15
seconds. This sets the calibration in the
controller.
CLUTCH CALIBRATION MAIN CODES
Main Code
00
Clutch Calibration Mode was not

initiated because one of the
requirements was not met.
01
Adjusting 1st gear.
02
Adjusting 2nd gear.
03
Adjusting 3rd gear.
04
Adjusting 4th gear.
05
Adjusting Forward gear.
06
Adjusting Reverse gear.
07
Clutch Calibration Completed.
08
Operator aborted calibration

procedure.
09
Aborted while adjusting 1st gear.
10
Aborted while adjusting 2nd gear.
11
Aborted while adjusting 3rd gear.
12
Aborted while adjusting 4th gear.
13
Aborted while adjusting Forward

gear.
14
Aborted while adjusting Reverse

gear.
3. The transmission is in neutral.

4. The park brake is applied.
5. If steps 1 through 4 have been accomplished,
calibrate the transmission clutches as follows:
A. Put the transmission in the manual shift mode
and the gear selector in 3rd gear neutral.
B. Press the program/reset switch to program.
C. Press the up/down count switch to up count
D. Put the program/reset switch in the OFF
(center) position.
E. Press the up/down count switch to up count
twice, so the display reads 02.
F. 2 00 00 will begin to flash in the display center.
G. After one second, the Clutch Calibration Main
Code status will be displayed in the 3rd and
4th spaces (2 XX 00, the XX represents the
3rd and 4th spaces).
H. The Modulation Cycle Number will be
displayed in the 1st and 2nd spaces (2 00 XX,
the XX represents the 1st and 2nd spaces).
I. During Clutch Calibration, the Clutch
Calibration Main Code will change from 01 to
07 as the process is completed. Code 07
in dic ates tha t th e calib ratio n p rocess is
complete and the information center will return
to normal working status.
J. If any of the Clutch Calibration parameters are
incorrect, the display center will stop flashing
and display a code in the 1st, 2nd, 3rd, and
4th spaces.
Bur 6-42351
Meaning
CLUTCH CALIBRATION SUB CODES

Sub Code
Meaning
00
Calibration in process.
01
Fault present.
02
Shift lever not in neutral.
Revised 11-01
Printed in U.S.A.
Copyright
4005-17
03
Park brake not applied.
04
Output speed not 0 kph/mph.
05
Low transmission oil temperature.
06
High transmission oil temperature.
07
Low engine RPM.
08
High engine RPM.
Setting Display Center Lighting

Do the following procedures to set the brightness
of the display lighting:
2. Press the up/down count switch to up count until
the display reads 012 (for working lights OFF) or
013 (for working lights ON).

the display reads 015.
3. The alarm will begin to sound intermittently.
4. Place the program/reset switch in the OFF
(center) position.
5. The Information Center will display 00 and sound
the alarm, when the machine is being checked,
while all systems are normal. If there is a fault in
the system that would cause the alarm to sound,
the Information Center will display 01 while the
alarm is being checked. The alarm will sound
intermittently.
Coolant Level Check

Do the following procedures to check the coolant
level indicator light and the coolant level switch.

(center) position.

4. Increase the brightness by pressing the up/down

count switch to the up count position.
3. The coolant light will flash intermittently.
5. Decrease the brightness by pressing the

up/down count switch to the down count position.
NOTE: The brightness can be varied between 001
and 100, with 100 being the brightest. The factory set
brightness is 070 for working lights OFF and 020 for
working lights ON.
6. Press the program/reset switch to reset
(m o m e n ta r ily, 0 . 2 5 s e c o n d s) to e n te r t h e
selected brightness setting.
Voltmeter at Key ON Position

Do the following procedures to read the system
voltage at the key ON position.
(center) position.
4. The system voltage is displayed at the key ON
position.
5. Press the program/reset switch to reset to exit
the monitoring mode.
Alarm Check

(center) position.
5. The Information Center will display 00, when the
machine is being checked, if the coolant level is
normal. If the coolant level is low, the Information
Center will display 01 while the coolant level
switch is being checked. The coolant light will
flash intermittently on the Information Center.
Brake Pressure
Do the following procedures to check the brake
pressure indicator light and the brake pressure
switch.
the display reads 017. The brake pressure light
will flash intermittently.
(center) position.
machine is being checked, if the brake pressure
is normal. If the brake pressure is low, the
Information Center will display 00 while the brake
pressure switch is being checked. The brake
pressure light will flash intermittently on the
Information Center.
Do the following procedures to check the audible

alarm system.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-18
Secondary Steering Pressure Switch

Do the following procedures to check the secondary
steering pressure indicator light and the secondary
steering switch.
the display reads 018. The secondary steering
pressure light will flash intermittently.
(center) position.
machine is being checked, if the secondary
steering switch is not activated. If the secondary
steering switch is activated, the Information
Cente r will displa y 00 while th e secondary
steering switch is being checked. The secondary
steering light will flash intermittently on the
Information Center.
Park Brake Information Center Output

Check
Do the following procedures to check the park brake
indicator light and the status of the signal that the
Information Center is sending to the park brake relay
(to engage or disengage).
the display reads 019. The park brake light will
flash intermittently.
(center) position.
Information Center is not activating the park
brake relay. The Information Center will display
01 when it is activating the park brake relay. The
park brake light will flash intermittently on the
Information Center.
Pilot Lockout Information Output Check

Do the following procedures to check the pilot lockout
Information Center is sending to the pilot lockout
relay (to engage or disengage).
the display reads 020. The pilot lockout light will
(center) position.

Information Center is not activating the pilot
lockout relay. The Information Center will display
01 when it is activating the pilot lockout relay.
The pilot lockout light will flash intermittently on
the Information Center.
Hydraulic Filter Restriction Switch Check

Do the following procedures to check the hydraulic
filter restriction indicator light and the hydraulic filter
restriction switch.
the display reads 021. The h y d ra u lic filte r
restriction indicator light will flash intermittently.
(center) position.
machine is being checked, if the hydraulic filter
r e s t r i c t i o n s w i t c h is n o t a c t iva te d . I f t h e
hydraulic filter restriction switch is activated, the
Information Center will display 00 while the
h y d r a u lic fil te r re st r ic tio n s w it ch is bein g
c h e c k e d . Th e h y d r a u l i c f i l t e r r e s t r i c t i o n
indicator light will flash intermittently on the
Information Center.
Air Filter Restriction Switch Check

Do the following procedures to check the air filter
restriction indicator light and the air filter restriction
switch.
the display reads 022. The air filter restriction
indicator light will flash intermittently.
(center) position.
ma ch in e is b e ing ch ec ke d , if th e a ir filte r
restriction switch is not activated. If the air filter
restriction switch is activated, the Information
C e n te r w il l d i s p la y 0 0 w h ile th e a ir f i lt e r
restriction switch is being checked. The air filter
restriction indicator light will flash intermittently
on the Information Center.
Work Lights Check

Do the following procedures to check the work lights
indicator light and the work light electrical signal
coming into the Information Center.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-19
the display reads 023. The work lights indicator
light will flash intermittently.

machine is being checked, if the transmission
filter restriction switch is not activated. If the
transmission filter restriction switch is activated,
the Information Center will display 01 while the
transmission filter restriction switch is being
checked. The transmission filter restriction
Information Center.

(center) position.
4. The Information Center will display 00 when the
work lights are OFF and 01 when the work lights
are ON. The work lights ind icator lig ht will
continue to flash intermittently and the numbers
on the display will change in accordance with the
status of the work lights.
Air Conditioning Switch Check
High Beam Check

Do the following procedures to check the high beam
indicator light and the high beam switch.
Do th e fo llow in g p ro c ed u r es to ch e ck th e a ir
conditioning indicator light and the air conditioning
high/low pressure switch.

the display reads 027. The high beam indicator
light will flash intermittently.

(center) position.

the display reads 025. The a ir con ditioning
indicator light will flash intermittently.
4. The Information Center will display 00 when the

high beam lights are OFF and 01 when the high
beam lights are ON. The high beam indicator
light will continue to flash intermittently and the
numbers on the display w ill change in
accordance with the status of the high beam
lights.

(center) position.
machine is being checked, if the air conditioning
high/low pressure switch is not activated. If the
air conditioning high/low pressure switch is
activated, the Information Center will display 01
while the air conditioning high/low pressure
switch is being checked. The air conditioning
Information Center.
Requested Gear Check

Do the following procedures to check that the gear
being requested by the shifter is the same gear that
the Information Center is reading.
Transmission Filter Restriction Switch

Check

the display reads 028. The F, N or R indicator in
the transmission display will flash intermittently.
Do the follow ing procedures to check the

transmission filter restriction indicator light and the
transmission filter restriction switch.

(center) position.
4. Place the gear shifter in all positions and verify
that the code in each position corresponds to the
codes in the table below

the display reads 026. The transmission filter
restriction indicator light will flash intermittently.
(center) position.
Bur 6-42351
Forward 1Code 101
Neutral 1Code 201
Reverse 1Code 301
Forward 2Code 102
Neutral 2Code 202
Reverse 2Code 302
Forward 3Code 103
Neutral 3Code 203
Reverse 3Code 303
Forward 4Code 104
Neutral 4Code 204
Revised 11-01
Printed in U.S.A.
Copyright
4005-20
Operational Indicator Status

Do the following procedures to check the status of
the operational indicator.

the display reads 031. The drive line shift status
bars flash intermittently.
(center) position.

the display reads 029. The operational indicator
flashes intermittently.
5. The Information Center will read 000.

(center) position.
7. The Information Center will read 001 while the

shift is being made.
8. The Information Center will read 000 if the

transmission does not engage the drive line or
010 if the transmission does engage the drive
line; 010 also indicates the transmission is in
Normal Mode.
Actual Gear Check

Do the following procedures to check that the gear
engaged in the transmission is the same gear that
the Information Center is reading.
1. With the engine running put the transmission in
manual mode and release the parking brake.
the display reads 030. The bars that outline the
large gear in the transmission display will flash
intermittently.
(center) position.
5. Place the gear selector in all positions and verify
that the code in each position corresponds to the
codes in the table below.
6. Shift the shift lever.

transmission is in Substitute Clutch Control
Mode.
transmission is in Limp Home Mode.
transmission is in Shutdown Mode.
transmission is in TECM Shutdown Mode.
Hourmeter Indicator Status

the hourmeter indicator.
Forward 1Code 101
Neutral 1Code 201
Reverse 1Code 301
Forward 2Code 102
Neutral 2Code 202
Reverse 2Code 302
Forward 3Code 103
Neutral 3Code 203
Reverse 3Code 303
Forward 4Code 104
Neutral 4Code 204
Limp Home
Mode - 115
Limp Home
Mode - 215

the display reads 032. The hourmeter indicator
(center) position.
Tachometer Indicator Status

Limp Home
Mode - 315

the tachometer indicator.
Drive Line Shift Status

Do the following procedures to check the drive line
shift status.

the display reads 033. The tachometer indicator
1. With the engine running, release the parking

brake.

(center) position.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-21
Service Indicator Status

the service indicator.
4. The Information Center will read 00 if the left turn

indicator is OFF or 01 if the left turn indicator is
ON.
Right Turn Indicator Status

the display reads 034. The service indicator

the right turn indicator.

(center) position.
4. The Information Center will read 00 if the service
indicator is OFF or 01 if the service indicator is
ON.
Movement Indicator Status

the movement indicator.
th e d isp l a y re a d s 0 3 5 . Th e K p h a n d M p h
indicators flash intermittently.
(center) position.
Beacon Status
the beacon.
the display reads 036. The beacon indicator
(center) position.
4. The Information Center will read 00 if the beacon
is OFF or 01 if the beacon is ON.
Left Turn Indicator Status

the left turn indicator.
the display reads 037. The left turn indicator
(center) position.

the display reads 038. The right turn indicator
(center) position.
4. The Information Center will read 00 if the right
turn in dicator is OFF or 01 if the righ t tu rn
indicator is ON.
Caution and Warning Master Indicator

Lights Status
Do the following procedures to ensure that the
caution and warning lights are working correctly.
the display reads 039 (Critical Master Light Red).
(center) position.
indicator is OFF under normal operation, or 01 if
the indicator is ON under normal operation
the display reads 041 (Caution Master Light
Yellow).
(center) position.
indicator is OFF under normal operation, or 01 if
the indicator is ON under normal operation
Diagnostic Indicator Status

the diagnostic indicator.
the display reads 040. The diagnostic indicator
(center) position.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-22
Master Reset
Do the following procedure to reset the Information
Center to the values set at the factory for the Gauge
Display, Information Center lighting for work lights off
and on, minimum gear selection in automatic mode,
maximum gear selection, and declutch modulation
selection.
(center) position.
4. Press the up/down count switch to up count
twice to change the readings from 00 to 01.
5. Press the program/reset switch momentarily
(0.25 second) to reset.
Park Brake Switch Check

Do the following procedures to check the park brake
switch and the s tatus of the signal that the
Information Center is receiving from the park brake
switch (to engage or disengage).
(center) position.
Information Center is not receiving a signal from
the park brake switch to engage the park brake.
The Information Center will display 01 when it is
receiving a signal from the park brake switch to
engage the park brake.
5. Cycle the park brake switch to ensure it is
working in both directions.
Redundant Brake Pressure Switch Check

Do the following procedures to check the redundant
brake pressure switch.
the display reads 044. The brake light will flash
intermittently.
(center) position.
Bur 6-42351

machine is being checked, if the brake pressure
is normal and there is nothing wrong with the
c i r c u i t . I f t h e b r a k e p r e s s u r e i s l o w, t h e
Information Center will display 01 while the
re du n da nt br ak e p re ss ure s witch is b ein g
checked. The brake light will flash intermittently
on the Information Center.
Service Brake Foot Switch Check

Do the following procedures to check the service
brake foot switch.
the display reads 045. The park brake light
(center) position.
4. The Information Center will read 00 when the
switch is open (service brakes are not applied)
and 01 when the switch is closed (service brakes
are applied).
Pilot Lockout Switch Check

Do the following procedures to check the pilot lockout
Information Center is receiving from the pilot lockout
switch (to engage or disengage).
(center) position.
Information Center is not receiving a signal from
the switch to engage the pilot lockout. The
Information Center will display 01 when it is
receiving a signal from the switch to disable the
loader hydraulic controls.
5. Cycle the switch to ensure it is working in both
directions.
Display Location 047

Do the following procedures to check display location
047.
the display reads 047. The pilot lockout light
Revised 11-01
Printed in U.S.A.
Copyright
4005-23
(center) position.
4. The Information Center will read 00 if the circuit
is closed or 01 if there is a circuit malfunction.
Display Location Numbers (048 and 049)

Reserved for Future Use
Minimum Gear Selection
D o t h e f o l lo w in g p r o c e d u r e s t o p r o g r a m th e
transmission for the lowest gear possible in the
automatic mode.
NOTE: The 1st or 2nd gear can be selected. The
gear that is selected will be the gear that the
transmission is in when the machine begins to move.
The factory minimum gear setting is 1.
5. If you want a different maximum gear selection,

press the up/down count switch to up count until
the desired number is displayed.
(0.25 seconds) to reset.
Gear Range Read Only

Do the following procedures to read the gear range.
(center) position.
4. The Information Center will read 1 or 2 (gears).



(center) position.
4. Read the number (1 or 2) shown on the
Information Center. If this is the desired gear
selection, press the program/reset switch to
either program or reset.

(center) position.
8. The Information Center will read 2, 3, or 4
(gears).
5. If you want the other minimum gear selection,

press the up/down count switch to up count.
Reset Diagnostic Stack for Locations 071

through 090

(0.25 seconds) to reset.
Do the following procedure to remove all diagnostic

codes from field number locations 071 through 090.
Maximum Gear Selection

D o t h e f o l lo w in g p r o c e d u r e s t o p r o g r a m th e
transmission for the highest gear possible in the
manual or automatic mode.
NOTE: The 2nd, 3rd, or 4th gear can be selected.
The gear that is selected will be the highest
attainable gear that the transmission will be able to
reach. The factory maximum gear setting is 4.

the display reads 055. The service indicator will
(center) position.
5. Press the program/reset switch to reset. If there
are diagnostic codes in field number locations
071 through 090 they will be removed, unless the
condition still exists.

(center) position.
4. Read the number (2, 3, or 4) shown on the
Information Center. If this is the desired gear
selection, press the program/reset switch to
either program or reset.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-24
Display Location Numbers (056 - 060)

1. To view the fault codes and the hours they

occurred do the following:
Service Interval Hours

Field number locations 61 through 70 are service
interval hour settings. The service interval hours
accumulate until they are reset. Once they are reset,
they begin accumulating hours independent from the
machine hours until they are reset again. Do the
following procedures to view or reset the service
interval hours.
NOTE: If the operator wanted location 061 to
indicate when the engine oil should be changed,
location 061 would be reset to begin accumulating
hours for the next oil change. The operator could
then go into location 061 and monitor accumulating
hours. When location 061 reaches the engine oil
change interval, the operator would change the oil
and reset location 061 again.
1. To view the service hour interval locations do the
following:
until the display reads the desired location
(061 - 070).

(071 - 090).
C. Place the program/reset switch in the OFF
(center) position.
D. Read any fault codes in the chosen location.
NOTE: A complete list of fault codes can be
found in the Fault Code Table in this section.
E. Press the program/reset switch to program.
F. Press the up/down count switch to up count
one time to advance to the next location.
G. Place the program/reset switch in the OFF
(center) position.
H. Read the hours that the previous fault code
occurred at.
NOTE: The hour location will always follow the fault
code location.

(center) position.
NOTE: Example: Location 072 will display the hours

on the machine when the fault code in location 071
was written. Location 074 will display the hours on
the machine when the fault code in location 073 was
written.
D. Read the accumulated hours in the chosen

location.
2. To monitor a particular location without going into

the programming mode do the following:
2. To reset the service interval hours do the

following:
(061 - 070).
(center) position.
D. Press the up/down count switch to down count
and hold it for 3 seconds. The service interval
hours in the chosen location will reset to 0.
Fault Code Status

Field number locations 071 through 090 display fault
cod es a nd th e h our s the fa ults occu rred . Th e
Infor matio n C en ter co ntinu ous ly mo nitors th e
machines condition and records any fault codes;
however, it will only record a duplicate code once
every hour. When a fault code is written, the service
indicator icon (a manual with a wrench) will be
displayed on the Information Center.
Bur 6-42351

until the location to be monitored is displayed.
(center) position.
D. Press the program/reset switch to program
and wait 5 seconds. The numbers on the
display will change.
E. Place the program/reset switch in the OFF
(center) position.
F. Within 3 seconds, press the program/reset
switch to reset once.
G. With the machine in normal operating mode
press the program/reset switch to reset to
display the hours accumulated in the selected
lo c a t io n . L o c a t i o n 0 0 0 ( h o u r m e t e r ) is
programmed into the Information Center from
the factory.
Revised 11-01
Printed in U.S.A.
Copyright
4005-25
H. To reset a programmed location back to 000
(h o u r m e te r - fa c to r y se t tin g ), h o ld t h e
program/reset switch to reset for 5 seconds.
When it is reset, the operator can view the
hour meter at any time during normal
operating conditions by pressing the reset
switch.
ZF Transmission ECM Part Number (1st

part)
Do the following to display the first part of the
transmission ECM ZF part number.
(center) position.
4. The Information Center will display the first part
of the ZF Tra ns mis sion EC M p a rt n u mbe r
(6009#, # is a digit from 0 to 9).
ZF Transmission ECM Part Number (2nd

part)
Do the following to display the second part of the
transmission ECM ZF part number.

(center) position.
4. The Information Center will display the LED duty
cycle in units of 0.01 percent.
LCD Duty Cycle

Do the following to display the LCD duty cycle.
(center) position.
4. The Information Center will display the LCD duty
cycle in units of 0.01 percent.
Internal Information Center Temperature

Do the following to display the internal temperature of



(center) position.

(center) position.
4. The Information Centers internal temperature

will be displayed in degrees Celsius.
4. The Information Center will display the second

part of the ZF Transmission ECM part number
(#####, # is a digit from 0 to 9).
Information Center Software Revision

Number
Do the following to display the Information Center
software revision number.
(center) position.
4. The Information Center will display the software
revision number.
Display Location Number 097 Reserved

for Future Use
Entry Code for Accessing Test Mode
Locations 100 to 199
Do the following to access test mode locations 100 to
199.
2. Press the up/down count switch to down count
(center) position.
LED Duty Cycle

Do the following to display the LED duty cycle.
Bur 6-42351
6. Press the up/down count switch one time so that

Revised 11-01
Printed in U.S.A.
Copyright
4005-26
(center) position.

(center) position.


the display reads 010. This sends the VINS data
to the TECM.

10. Press the up/down count switch to up count past
location 099.
NOTE: When locations 098 and 099 are reset at 21,
the Information Center will scroll past location 099.
Once location 100 or higher is reached, locations 098
and 099 are automatically reset to 000. If only one of
the locations is set at 21, and the user leaves the
range of 098-099, locations 098 and 099 are
automatically reset to 000.
Vehicle Identification Numbers (VINS)

Do the following to view and change the vehicle
identification numbers.
1. Access test mode locations 100 to 199.
(center) position.
5. Use the up/down count switch to change the
display to read 001. This allows changes to
locations 100 and 101.
(center) position.
vehicle identification number: if a 521D machine
enter 52101; if a 621D machine enter 62101.
(center) position.
(center) position.
vehicle identification number: if a 521D machine
enter 52101; if a 621D machine enter 62101.
Bur 6-42351
18. Press the up/down switch until the display reads

000. This locks locations 100 and 101.
NOTE: In location 102, 000 means locations 100
and 101 are the same and locked; 001 means
reprogram locations 100 and 101 only; 101 means
reprogram TECM; and 1-- in the third position means
VIN data stored in locations 100 and 101 are
different.
NOTE: In location 103, 0-- in the third position
means no data received from TECM once location
102 is set at 010; 1-- in the third position means data
received from TECM once location 102 is set at 010;
100 means VINS data are identical; 101 means VINS
data different; 110 means VINS data reprogrammed;
and 111 means VINS data not present as received.
(center) position. When the TECM has been
reprogrammed, 110 will be displayed. If 110 is
not displayed, press program/reset switch to
reset and turn ignition switch OFF. Wait 15
seconds and repeat procedure (from Step 1) until
110 is displayed. If 110 is displayed continue with
Step 22.
22. Press the reset button momentarily.
23. Turn off and restart the machine.
Display Location Numbers 104 - 113

Instrument Cluster (Information Center)
Part Number (1st part)
D o th e fo llo win g t o e nt er t he firs t p a r t o f th e
instrument cluster (Information Center) part number.
until the display reads 114. The service indicator
(center) position.
4. Use the up/down count switch to enter the first
part of the instrument cluster part number from
the parts catalog.
Revised 11-01
Printed in U.S.A.
Copyright
4005-27

Part Number (2nd part)
Do the following to enter the second part of the
instrument cluster (Information Center) part number.
(center) position.
A. Obtain the tire revolution/km (obtainable from

most manufacturers).
B. If the tire revolution/km is not available,
measure the distance the tire travels (in
meters) in 10 revolutions. Divide that number
into 1000. Multiply the answer by 10. This is
how many revolutions your tire makes in a km.
2. Multiply the tire revolution/km by the axle ratio.
Th e a n sw e r will b e t he n ew sp e ed o me te r
calibration number.
MACHINE/TIRE
AXLE RATIO
TIRE REV/KM
CALIBRATION NUMBER
4. Use the up/down count switch to enter the

sec ond pa rt o f th e ins trume nt cluste r p art
number from the parts catalog.
1. If your tire and calibration number are listed in

the table below go to step 3. Do the following to
calculate a calibration number:
521D w/15.5 x 25 L2, L3,

XTLA, XHA
19.20
260
4992

521D w/17.5 x 25 L2, L3,

XTLA, XHA
19.20
246
4723

(center) position.
621D w/17.5 x 25 L2, L3,

XTLA, XHA or 20.5 x 25
XLD 70
20.36
246
5009
4. The Information center will display the date code.

Read the date code as follows: the first two
numbers = year, next three numbers = day.
621D w/20.5 x 25 L2, L3,

XTLA, XHA
20.36
222
4520
NOTE: The part number may contain the letter A

followed by a number, to show revision level. Using
the up/down count switch, enter the A as 0 (zero)
followed by the number, (A1 = 01, A2 = 02).

Date Code
Do the following to display the instrument cluster
date code.

Reserved for Supplier Information

Display Location Numbers 121 -129


(center) position.
Speedometer Calibration
6. Use the up/down count switch to enter the

calibration number from the table.
Do the following to reset the speed ometer

calibration.
NOTE: If a dealer or customer changes tire sizes,
the speedometer calibration will have to be changed
to match the Information Center and transmission
ECM to the new tire size.
NOTE: A calibration number is required to perform
this function.
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-28

Reserved for Speedometer Calibration
Temporary Fault Code Status
Field number locations 171 through 190 display
temporary fault codes and the hours the faults
oc curred. These tem porary fault codes will
automatically be erased when the Information Center
is turned off. The Information Center monitors the
machines condition and records any fault codes into
the short-term resettable memory once every 3
minutes. This will enable a technician to quickly
check conditions to verify if a problem was resolved
or still exists after maintenance. When a fault code is
written, the service indicator icon (a manual with a
wrench) will be displayed on the Information Center.
1. To view the temporary fault codes and the hours
they occurred do the following:
(171 - 190).
(center) position.
D. Read any fault codes in the chosen location.
NOTE: A complete list of fault codes can be
found in the Fault Code Table in this section.
E. Press the program/reset switch to program.
F. Press the up/down count switch to up count
one time to advance to the next location.
2. To monitor a particular location without going into

the programming mode do the following:
until the location to be monitored is displayed.
(center) position.
D. Press the program/reset switch to program
and wait 5 seconds. The numbers on the
display will change.
E. Place the program/reset switch in the OFF
(center) position.
F. Within 3 seconds, press the program/reset
switch to reset once.
G. With the machine in normal operating mode
press the program/reset switch to reset to
display the hours accumulated in the selected
lo ca t ion . ( L o ca t ion 0 0 0 ( h o u r me te r ) is
programmed into the Information Center from
the factory.
H. To reset a programmed location back to 000
(h o u r m e te r - fa c to r y se t tin g ), h o ld t h e
program/reset switch to reset for 5 seconds.
When it is reset, the operator can view the
hour meter at any time during normal
operating conditions by pressing the reset
switch.

for Manufacturing Data
G. Place the program/reset switch in the OFF

(center) position.

for Future Use
H. Read the hours that the previous fault code

occurred at.

for Manufacturing Data
NOTE: The hour location will always follow the fault

code location.
NOTE: Example: Location 172 will display the hours
on the machine when the fault code in location 171
was written. Location 174 will display the hours on
the machine when the fault code in location 173 was
written.
Bur 6-42351
NOTE: To exit the upper range of display location

numbers (100-199) press the program/reset switch to
reset.
Revised 11-01
Printed in U.S.A.
Copyright
4005-29
DISPLAY LOCATION NUMBERS AND DESCRIPTIONS

DISPLAY
LOCATION
NUMBER
DEFINITION
STATUS
000
Engine Hours
001
Engine Tachometer
002
Speedometer in Miles Per Hour
003
Speedometer in Kilometers Per Hour
004
Engine Coolant Temperature in Degrees Celsius
005
Engine Oil Pressure in Kilopascals
006
Fuel Level in Percent of Fuel in Tank
007
Transmission Oil Temperature in Degrees Celsius
008
Hydraulic Oil Temperature in Degrees Celsius
009
Voltmeter Reading (Continuous)
010
Gauge Display Selection
011
Parking Brake Test / Clutch Calibration
012
Information Center Light Setting - Work Lights Off
013
Information Center Light Setting - Work Lights On
014
Voltmeter Reading at Key-on
015
Alarm Status
00 = Off, 01 = On
016
Coolant Level Status
00 = Normal Level
01 = Low Level
017
Brake Pressure Switch Status
00 = Switch Closed
01 = Switch Opened
(Open = Normal Pressure)
018
Steering Pressure Switch Status
00 = Switch Closed
01 = Switch Opened
019
Parking Brake Status
00 = Off, 01 = On
020
Pilot Lockout Status
00 = Off, 01 = On
021
Hydraulic Filter Restriction Switch Status
00 = Switch Closed
01 = Switch Opened
(Open = Filter is OK)
022
Air Filter Restriction Switch Status
00 = Switch Closed
01 = Switch Opened
(Open = Filter is OK)
023
Present Work Lights Status
00 = Off, 01 = On
024
Present Fog Lights Status
00 = Off, 01 = On
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-30
DISPLAY
LOCATION
NUMBER
DEFINITION
STATUS
Air Conditioning High/Low Pressure Switch Status
00 = Switch Open
01 = Switch Closed
026
Transmission Filter Restriction Indicator Status
00 = Filter Acceptable
01 = Filter Restricted
02 = Filter Fault
03 = Not Available
(Open - Filter is OK)
027
High Beam Lights Status
00 = Off, 01 = On
028
Requested Gear and FNR Status
101 =
104 =
203 =
302 =
401 =
to N
029
Status of Transmission Operation Indicator - In

Transmission Display
00 = Always
Actual Gear Status
101
104
200
201
204
301
315
025
030
=
=
=
=
=
=
=
F1, 102 = F2, 103 = F3,

F4, 201 = N1, 202 = N2,
N3, 204 = N4, 301 = R1,
R2, 303 = R3, 304 = R4
Request to move shifter
F1, 102 = F2, 103 = F3,

F4, 115 = Limp Home,
Neutral or Declutch
N1, 202 = N2, 203 = N3,
N4, 215 = Limp Home,
R1, 302 = R2, 303 = R3,
Limp Home
First Digit =
000 = Shift Not In Process
001 = Shift In Process
031
Shift Status
Driveline Status
Operational Mode
Second Digit =
001 = Driveline Not Engaged
010 = Driveline Engaged
Third Digit = Mode Control
010 = Normal
110 = Substitute Clutch control
210 = Limp Home Mode
300 = Transmission Shutdown
400 = T.E.C.M. Shutdown
032
Hourmeter Status
00 - Always
033
Tachometer Status
00 - Always
034
Current Status of Service Indicator for Normal Operating

Mode (Book with the wrench)
00 = Off, 01 = On
035
Movement indicator Status
00 - Always
036
Beacon Status
00 = Off, 01 = On
037
Left Turn Indicator Status
00 = Off, 01 = On
038
Right Turn Indicator Status
00 = Off, 01 = On
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-31
DISPLAY
LOCATION
NUMBER
DEFINITION
STATUS
039
Current Status Master Indicator (Red)
00 = Off, 01 = On
040
Current Status of Diagnostic Indicator (Book without the

wrench - Operators Manual)
00 - Always
041
Current Status Master Indicator (Yellow)
00 = Off, 01 = On
042
Master Reset - Reset Information Center to Factory Setting
043
Park Brake Switch Status
00 = Switch Open
01 = Switch Closed
(Closed = engaged Parking
Brake)
044
Redundant Brake Pressure Switch Status
00 = Switch Closed
01 = Switch Open
(Closed = Normal Operation)
045
Service Brake Foot Switch Status
00 = Switch Open
01 = Switch Closed
(Closed = Actuated)
046
Pilot Lockout Switch Status
00 = Switch Open
01 = Switch Closed
(Closed = Loader Controls
Locked)
047
Seat Switch Status
00 = Switch Closed
01 = Switch Open
(open = unoccupied)
050
Minimum Gear Selection
Range - 1st and 2nd gear
051
Maximum Gear Selection
Range - 2nd, 3rd and 4th gear
052
Minimum Gear Read Only
053
Maximum Gear Read Only
055
Reset Diagnostic Stack, 071 to 090 to zero
061 - 070
Service Hour interval Selection #1 - 10
071,073,
075,077,
079,081,
083,085,
087, 089
Fault Code #1 Through Fault Code #10
072, 074,
076, 078,
080, 082,
084, 086,
088, 090
Bur 6-42351
Range = 0 to 99
Default = 0
Set to 21 and then exit this
location 055 to reset diagnostic
stack 071 -099 to zero
Hour Code #1 Through Hour Code #10. Hour Codes Follow

Fault Codes Respectively.
I.e.: Hour Code #1 (072) Corresponds with Fault Code #1
(071)
Revised 11-01
Printed in U.S.A.
Copyright
4005-32
DISPLAY
LOCATION
NUMBER
DEFINITION
STATUS
091
1st Portion Of Transmission Electronic Control Module

(ECM) Part Number (5 digits from 0-9)
ZF part number
092
2nd Portion Of Transmission ECM Part Number (5 digits

from 0-9)
ZF part number
093
Cluster Software Revision Number
1 - 21
094
Light Emitting Diode (LED) Duty Cycle
In units of 0.01%
095
Liquid Crystal Display (LCD) Duty Cycle
In units of 0.01%
096
Internal Cluster Temperature
In units of deg C
098
Entry Code for Accessing Test Mode Locations 100 to 199
Set to 21 to enter Test Mode

locations (Range = 0 to 99)
099
Entry Code for Accessing Test Mode Locations 100 to 199
Set to 21 to enter Test Mode

locations (Range = 0 to 99)
Vehicle Identification Number (VINS)
521D = 52101
621D = 62101
Allows Changing Locations 100 and 101
000 = Locations 100 and 101

are the same and locked
001 = Reprogram Locations
100 and 101 only
010 = Reprogram TECM
1-- = Locations 100 and 101 are
different
103
Reprogramming Status
0-- = No data received from

TECM once location 102 is sent
as 010
1-- = Data received from TECM
once location 102 is sent as 010
100 = VINS identical
101 = VINS different
110 = VINS reprogrammed
114
Cluster Part Number
115
Cluster Part Number
116
Cluster Date Code
130
Speedometer Calibration
100-101
102
171 - 190
Bur 6-42351
Temporary Fault Code Status
Revised 11-01
Printed in U.S.A.
Copyright
4005-33
FAULT CODES
CODE
DEFINITION
12110
Engine coolant temperature is 110 C (230 F)

or greater
12900
Engine coolant temperature sensor short

circuit measuring less than 50 ohms.
12901
Engine coolant temperature sensor open

circuit measuring greater than 10,000 ohms
with hydraulic oil temperature at 40 C (104
F) or more.
13000
Low engine coolant level - This code will not

be generated if the engine coolant
temperature is below 20 C (68 F).
21070
Engine oil pressure is measured below 70 kPa

(10 psi)
21900
Engine oil pressure sensor short circuit

measuring less than 16 ohms.
21901
Engine oil pressure sensor open circuit

measuring more than 270 ohms.
33900
Fuel level sender short circuit measuring less

than 16 ohms.
33901
Fuel level sender open circuit measuring more

than 270 ohms.
34000
Short circuit in fuel solenoid circuit.
35000
42125
45000
46017
46018
46020
Bur 6-42351
POSSIBLE STEPS FOR REPAIR
Troubleshoot electrical circuits.
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
the critical area.
NOTE: Fault code 21900 is possible during cold
engine start-up. After machine warm up, verify
proper operation.
High air filter restriction.
1. A caution level warning has occurred.

2. Yellow caution indicator comes on and buzzer
sounds for 3 seconds.
3. Perform required service on the cautioned area.
Transmission temperature measured above

125 C (257 F)

buzzer sounds.
the critical area.
High transmission filter restriction when the

transmission oil is above 20 C (68 F).

Gear range fault error
1. Check the cables from TCU to shift lever.

2. Check signal combinations of shift lever
positions for gear range.
Logical error at direction select signal
1. Check the cables from TCU to shift lever.

2. Check signal combinations of shift lever
positions F-N-R.
Logical fault at park brake status
1. Check the cables from the electronic boxes to

the status switches.
2. Check signals of the status switches.
Revised 11-01
Printed in U.S.A.
Copyright
4005-34
CODE
DEFINITION

1. Check the cables from the TCU to the FNR
switch.
2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch.
46021
Logical error at FNR switch
46023
Short circuit to ground at ride control
46024
Short circuit to battery voltage at ride control
46025
Open circuit at ride control
1. Check the cables from the TCU to the ride

control relay.
2. Check the connectors from the TCU to the ride
control relay.
3. Check the ride control relay.
46037
Short circuit to battery voltage or open circuit

at temperature sensor
1. Check the connectors.

2. Check the temperature sensor.
46038
Short circuit to ground at temperature sensor
46039

at converter output temperature sensor
46040
Short circuit to ground at converter output

temperature sensor
46049

at engine speed sensor
46050
Short circuit to ground at engine speed sensor
1. Check the cables from TCU to the sensor.

3. Check the temperature sensor.

3. Check the speed sensor.
46051
Logical error at engine speed sensor input
46052

at turbine speed sensor input
46053
Short circuit to ground at turbine speed sensor

input
46054
Logical error at turbine speed sensor input
NOTE: This fault code is reset after power up of the

TCU. It is also reset if the signal is above zero
speed threshold.
TCU.
46055

at intermediate speed sensor input
46056
Short circuit to ground at intermediate speed

input
46057
Bur 6-42351
Logical error at intermediate speed sensor

input

TCU.
Revised 11-01
Printed in U.S.A.
Copyright
4005-35
CODE
DEFINITION
46058

at output speed sensor
46059
Short circuit to ground at output speed sensor
46060
Logical error at output speed sensor

TCU.
46062
Output speed zero, does not match other

speeds.
1. Check the sensor signal of the output speed

sensor.
2. Check the connector connected to the output
speed.
3. Check the cable from the TCU to the sensor.
TCU.
46064
Invalid gear range restriction (CAN)
46065
Invalid declutch modulation selection (CAN)
46089
Invalid test mode signal (CAN)
46090
Invalid park brake status (CAN)
46091
Invalid shift quality selection (CAN)
Bur 6-42351
1. Check the cluster controller.

2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.

2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
Revised 11-01
Printed in U.S.A.
Copyright
4005-36
CODE
DEFINITION
46113
Short circuit to battery voltage at clutch K1
46114
Short circuit to ground at clutch K1
46115
Open circuit at clutch K1
46116
46117
46118
46119
46120
46121
46129
46130
46131
46132
Short circuit to battery voltage at clutch KV
46133
Short circuit to ground at clutch KV
46134
Open circuit at clutch KV
46135
Short circuit to battery voltage at clutch KR
46136
Short circuit to ground at clutch KR
46137
Open circuit at clutch KR
46145
Short circuit to ground at backup alarm relay
46146
Short circuit to battery voltage at backup alarm

relay
46147
Open circuit at backup alarm relay
46177
46178
46179
Bur 6-42351
1. Check the cable from the TCU to the

transmission control valve.
2. Check the connectors from the TCU to the
3. Check the regulator resistance.
4. Check internal wire harness of the transmission
control valve.
1. Check the cable from the TCU to the backup.

alarm relay.
2. Check the connectors from the backup alarm
relay to TCU.
3. Check the resistance of backup alarm relay
circuit.
Slippage at clutch K1
1.
2.
3.
4.
5.
Check pressure at clutch K1.

Check main pressure in the system.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.
1.
2.
3.
4.
5.

Replace clutch.
1.
2.
3.
4.
5.

Replace clutch.
Revised 11-01
Printed in U.S.A.
Copyright
4005-37
CODE
DEFINITION
1.
2.
3.
4.
5.

Replace clutch.
Slippage at clutch KV
1.
2.
3.
4.
5.
Check pressure at clutch KV.

Replace clutch.
Slippage at clutch KR
1.
2.
3.
4.
5.
Check pressure at clutch KR.

Replace clutch.
46183
Oil temperature at valve body is above limit

buzzer sounds.
the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
46185
Engine speed is measured above 5,000 rpm

for 0.2 seconds
46180
46181
46182
1. Check engine speed sensor
TCU sensed a voltage at oil filter maintenance

switch out of the allowed range (dirty filter)
1. Check oil filter.

2. Check wiring from TCU to filter maintenance
switch.
3. Check filter maintenance switch (measure
resistance).
46195
Oil temperature at converter output is above

limit

buzzer sounds.
the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
46196
Short circuit to ground at transmission enable

switch indicator circuit
46197
Short circuit to battery voltage at transmission

enable switch indicator circuit
46198
Open circuit at transmission enable switch

indicator circuit
46209
Short circuit to battery voltage at power supply

for sensors
46210
Short circuit to ground at power supply for

sensors
46186
Bur 6-42351
1. Check the cable from the TCU to the

transmission enable switch.
2. Check the connectors from the transmission
enable switch to the TCU.
3. Check the transmission enable switch.
1. Check cables from the TCU to the sensors.

2. Check the connectors from the TCU to the
sensors.
Revised 11-01
Printed in U.S.A.
Copyright
4005-38
CODE
DEFINITION

1. Check batteries.
2. Check B+ wires from batteries to TCU.
3. Check voltage at TCU connector pin 45.
46211
Low voltage at battery
46212
High voltage at battery
46213
Error at switch 1 for solenoid power supply
46214
Error at switch 2 for solenoid power supply
46227
Short circuit to battery voltage at display

output
46228
Short circuit to ground at display output
46229
Error at communication on CAN
46230
Undefined VIN request via CAN.
46241
General EEPROM fault
Replace the TCU.
46242
Current ID not set or corrupt
Reprogram the correct configuration for the

vehicle.
46243
Application error (ZF internal)
Replace the TCU.
46245
Clutch calibration fault
Check the clutch.
46246
Clutch adjustment data lost
Do the transmission clutch calibration procedure.
47000
CAN interface failure where no signals are

received over one second of time
1. Clear the codes.

2. Restart the machine.
3. Monitor machine operation and diagnostics.
47001
Engine speed is missing
1. Verify corresponding function is displayed on

the information center and is working properly:
47002
Output shaft speed is missing
1.
2.
3.
4.
Check fuse A2.

Check cable from control valve to TCU.
Check connectors from control valve to TCU.
Replace TCU.
1. Check the cable from TCU to the display.

2. Check the connectors at the display.
3. Change display.
2. Check the wire of the CAN-Bus.
3. Check cable to cluster controller.
A. Engine rpm - run engine LO to HI and verify

display shows rpm.
B. Output shaft speed - drive unit with mph/kph
d is pl ay e d an d ve r if y th a t it is w o rk in g
properly.
47011
Bur 6-42351
Transmission oil temperature is missing
C. Transmission oil temperature - display

temperature values on information center
an d ru n ma chine to ve rify tha t the
temperature changes with machine
operation.
4. If operation is satisfactory, clear fault codes and
continue to monitor.
5. If there are problems during operation,
troubleshoot the appropriate electrical circuits.
Revised 11-01
Printed in U.S.A.
Copyright
4005-39
CODE
DEFINITION
47012
Transmission filter restriction information is

missing
47013
Current VINS is outside of the range
47014
Result code (11)
51000
Low steering pressure has been detected after

a normal operating pressure has been
reached since start up.
61000
Low brake pressure (1700 PSI / 11721 kPa)

has been detected after a normal operating
pressure has been reached since start up.
61900
1700 PSI (11,721 kPa) Brake pressure switch

has not cycled within 50 hours of operation
time.
61901
900 PSI (6250 kPa) Redundant brake

pressure switch has not cycled within 100
hours of operation time.
64000
Park brake solenoid output short circuit.
66900
Park brake switch has not cycled within 50

hours of operation time.

1. Check
the
function/operation
of
the
tra nsm iss io n filter r estr ictio n b y g oing to
program count location 026.
2. Read filter restriction status: 00 = filter
acceptable, 01 = filter restricted, 02 = filter fault.
3. If filter restricted, 01, replace filter.
4. If 00 or 02, clear fault codes and monitor
machine performance and diagnostic codes.
1. Reprogram VINS.
2. Verify program count location reads 110 or 100.
3. Clear codes and monitor machine performance
and continue to operate.
buzzer sounds.
the critical area.
1. Turn machine off.

2. Pump service brake 30 full strokes.
3. Start machine and verify proper operation and
no diagnostic codes.
4. Operate machine and monitor performance.
1.
2.
3.
4.
Check park brake for proper operation.

Do park brake test, see section 7008.
Adjust/repair park brake as required.
Clear diagnostic codes and monitor machine
performance.
Service brake foot switch has not cycled within

50 hours of operation.
1. Verify full pedal actuation and return, make sure

debris does not obstruct pedal travel.
2. Clear codes.
3. Verify proper machine operation.
4. If code reappears, check brake light switch and
troubleshoot electrical circuits.
72110
Hydraulic oil temperature is 110 C (230 F) or

greater.

buzzer sounds.
the critical area.
72900
Hydraulic oil temperature sensor short circuit

measuring less than 50 ohms.
72901
Hydraulic oil temperature sensor open circuit

measuring greater than 10,000 ohms with the
engine coolant temperature at 90 C (194 F)
or more.
74000
Pilot pressure solenoid output short circuit.
66901
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-40
CODE
DEFINITION
75000
High hydraulic filter restriction when the

hydraulic oil is above 20 C (68 F).
84018
System voltage is below 18 volts.
84032
System voltage is above 32 volts.
86010
86020
Bur 6-42351

Corrupt engine hours, data lost
1. Operate the machine to verify all functions and

monitoring systems are working properly (no
yellow or red warnings, normal operation).
2. Monitor cluster performance during machine
operational check (no new diagnostic codes, no
erratic behavior, flashing icons, etc.).
3. If all systems and operations are normal, clear
d ia g n o s t ic co d e s a n d c o n t in u e ma c h in e
operation.
4. Monitor machine for recurrence of fault codes.
5. Repeated codes may be an indication of a
pending cluster failure.
Corrupt tire calibration numbers, data lost

The calibration number will default back to the
number used at cluster shipment
1. Reprogram correct tire calibration number for

the machine.
2. Verify proper machine operation and machine
travel speed to displayed speed.
3. Continue machine operation and monitor for
recurring fault codes.
Revised 11-01
Printed in U.S.A.
Copyright
4005-41
CODE
DEFINITION
86040
Information Center program memory error
86050
Information Center RAM failure
86060
Information Center Reset This code is

generated if the Information Center Program
goes astray. The Information Center is reset.
This code will also be generated if there is a
brief intermittent open between the time the
engine is shut off and the Information Center
shuts off.
86070
Open range setting
86071
Brightness setting
86072
Machine ID
86073
Machine info
86075
Cluster date code
86076
Cluster reserved
86077
Calibration number
86078
Shift quality
86079
Requested Gmin
86080
Requested Gmax
86081
Declutch modulation
86082
Creep setting
86083
Service hours
86084
Diagnostics stack pointer (internal to software)
86085
Diagnostics stack contents
86086
Digital input states (internal to software)
86087
Engine hour time stamps for digital input

states (internal to software)
91000
Bur 6-42351
Air Conditioning high or low pressure

indication
1. Operate the machine to verify all functions and

monitoring systems are working properly (no
yellow or red warnings, normal operation).
2. Monitor cluster performance during machine
operational check (no new diagnostic codes, no
erratic behavior, flashing icons, etc.).
3. If all systems and operations are normal, clear
d ia g n o s t ic co d e s a n d c o n t in u e ma c h in e
operation.
4. Monitor machine for recurrence of fault codes.
5. Repeated codes may be an indication of a
pending cluster failure.

Revised 11-01
Printed in U.S.A.
Copyright
4005-42
NOTES
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-43
INDEX
A
Actual Gear Check ................................................20
Air Conditioning Indicator ........................................7
Air Conditioning Switch Check ..............................19
Air Filter Indicator ....................................................7
Air Filter Restriction Switch Check ........................18
Alarm Check ..........................................................17
Automatic Scrolling Gauge Displays .....................15
B
Beacon Indicator ......................................................6
Beacon Status .......................................................21
Brake
Park, Information Center Output Check ............18
Park, Testing .....................................................15
Parking Brake Indicator .......................................7
Brake Pressure ......................................................17
Brake Pressure Indicator .........................................6
C
Calibration
Transmission Clutch ..........................................16
Caution and Warning Master Indicator Lights .......21
Caution Master Indicator (Yellow) ...........................6
Check
Actual Gear .......................................................20
Air Conditioning Switch .....................................19
Alarm .................................................................17
Coolant Level ....................................................17
High Beam ........................................................19
Park Brake Switch .............................................22
Requested Gear ................................................19
Switch, Pilot Lockout .........................................22
Switch, Redundant Brake Pressure ..................22
Switch, Service Brake Foot ...............................22
Work Lights .......................................................18
Clutch
Calibration, Transmission ..................................16
Control
Pilot .....................................................................6
Coolant
Engine Temperature ............................................8
Indicator, Low ......................................................6
Coolant Level Check .............................................17
Critical Warning Displays .......................................10
D
Diagnostic Center ....................................................5
Diagnostic Indicator Status ....................................21
Display Center
Lighting, Setting ................................................17
Display Location
047 ....................................................................22
048 and 049 ......................................................23
Bur 6-42351
056 through 060 ................................................ 24

071 through 090 ................................................ 23
097 .................................................................... 25
100 through 199 ................................................ 25
104 through 113 ................................................ 26
117 through 120 ................................................ 27
121 through 129 ................................................ 27
131 through 139 ................................................ 28
140 through 170 ................................................ 28
191 through 196 ................................................ 28
197 .................................................................... 28
198 .................................................................... 28
199 .................................................................... 28
Display Location Numbers and Descriptions ......... 29
Displays
Gauge, Automatic Scrolling ............................... 15
Gauge, Manual Scrolling ................................... 15
Individual Function ............................................ 15
Drive Line Shift Status ........................................... 20
Duty Cycle, LCD .................................................... 25
Duty Cycle, LED .................................................... 25
E
Engine
Coolant Temperature ...........................................8
Oil Pressure Gauge .............................................8
Engine Coolant Temperature ............................8, 12
Engine Oil Pressure ..............................................12
Engine Oil Pressure Gauge .....................................8
Entry Code
Test Mode Locations 100 to 199 ....................... 25
F
Fault Code Status .................................................. 24
Fault Codes ........................................................... 33
Filter
Indicator, Air Filter ...............................................7
Indicator, Hydraulic Oil ........................................7
Indicator, Transmission Oil ..................................7
Restriction Switch, Air
Restriction Switch, Air Filter .......................... 18
Restriction Switch, Hydraulic ............................. 18
Restriction Switch, Transmission ...................... 19
Fuel
Gauge, Level .......................................................8
Fuel Level Gauge ....................................................8
Fuel Lever ............................................................. 12
G
Gauge
Engine Oil Pressure ............................................8
Fuel Level ...........................................................8
Hydraulic Oil Temperature ...................................7
Transmission Oil Temperature ............................7
Voltmeter .............................................................8
Revised 11-01
Printed in U.S.A.
Copyright
4005-44
Gauges and Indicators ............................................6
Gear
Check, Actual ....................................................20
Check, Requested .............................................19
Gear Range Read Only .........................................23
Gear Selection
Maximum ...........................................................23
Minimum ............................................................23
H
High Beam Check ..................................................19
Hourmeter ..............................................................12
Hourmeter Indicator Status ....................................20
Hours
Service Interval .................................................24
Hydraulic Filter Restriction Switch Check ..............18
Hydraulic Oil Filter Indicator ....................................7
Hydraulic Oil Temperature .....................................13
Hydraulic Oil Temperature Gauge ...........................7
L
LCD Duty Cycle ..................................................... 25
LED Duty Cycle ..................................................... 25
Left Turn Indicator Status ...................................... 21
Level
Coolant, Check ................................................. 17
Lighting, Setting Display Center ............................ 17
Lights
Work ..................................................................18
Low Coolant Indicator .............................................. 6
M
Manual Scrolling Gauge Displays ......................... 15
Master Reset ......................................................... 22
Maximum Gear Selection ...................................... 23
Minimum Gear Selection ....................................... 23
Movement Indicator Status .................................... 21
N
Non-Critical Warning Displays ............................... 11
I
Indicator
Air Conditioning ...................................................7
Air Filter ...............................................................7
Beacon ................................................................6
Brake Pressure ...................................................6
Caution and Warning Master, Status Lights ......21
Caution Master (Yellow) ......................................6
Diagnostic, Status .............................................21
Hourmeter, Status .............................................20
Hydraulic Oil Filter ...............................................7
Icon, Service .......................................................9
Left Turn, Status ................................................21
Low Coolant ........................................................6
Movement, Status .............................................21
Operational, Status ...........................................20
Parking Brake ......................................................7
Right Turn, Status .............................................21
Secondary Steering .............................................7
Service, Status ..................................................21
Stop Master (Red) ...............................................6
Tachometer, Status ...........................................20
Transmission Oil Filter .........................................7
Work Light ...........................................................6
Indicators and Gauges ............................................6
Individual Function Display ....................................15
Information and Diagnostic Center ....................5, 12
Information Center ...................................................5
Internal Temperature .........................................25
Software Revision Number ...............................25
Instrument Cluster
Date Code .........................................................27
Part Number (1st part) ......................................26
Part Number 2nd part) ......................................27
Internal Information Center Temperature ..............25
Bur 6-42351
O
Oil
Pressure Gauge, Engine ..................................... 8
Operational Indicator Status .................................. 20
P
Park Brake
Information Center Output Check .....................18
Testing ............................................................... 15
Park Brake Switch Check ...................................... 22
Parking Brake Indicator ........................................... 7
Pilot Control .............................................................6
Pilot Lockout
Information Output Check .................................18
Pilot Lockout Switch Check ................................... 22
Power Circuit Test ................................................... 6
Pressure
Brake Indicator .................................................... 6
Pressure, Brake ..................................................... 17
Programming Information Center ..........................14
Programming, Information Center ......................... 14
R
Redundant Brake Pressure Switch Check ............ 22
Requested Gear Check ......................................... 19
Reset Diagnostic Stack for Display Locations .......23
Reset, Master ........................................................ 22
Right Turn Indicator Status .................................... 21
S
Secondary Steering Indicator .................................. 7
Secondary Steering Pressure Switch .................... 18
Self-Test .................................................................. 5
Service Brake Foot Switch Check ......................... 22
Service Indicator Icon .............................................. 9
Service Indicator Status ........................................21
Revised 11-01
Printed in U.S.A.
Copyright
4005-45
Service Interval Hours ...........................................24
Setting Display Center Lighting .............................17
Settings, Diagnostics, and Fault Codes .................14
Software
Revision Number, Information Center ...............25
Speedometer .........................................................12
Speedometer Calibration .......................................27
Status
Beacon ..............................................................21
Caution and Warning Master Indicator Lights ...21
Diagnostic Indicator ...........................................21
Drive Line Shift ..................................................20
Fault Code .........................................................24
Fault Code, Temporary ......................................28
Hourmeter Indicator ..........................................20
Left Turn Indicator .............................................21
Movement Indicator ...........................................21
Right Turn Indicator ...........................................21
Service Indicator ...............................................21
Tachometer Indicator .........................................20
Steering
Secondary Indicator ............................................7
Secondary Pressure Switch ..............................18
Stop Master Indicator (Red) ....................................6
Switch
Park Brake, Check ............................................22
Pilot Lockout ......................................................22
Pressure, Secondary Steering ..........................18
Redundant Brake Pressure ...............................22
Restriction, Hydraulic Filter ...............................18
Restriction,Transmission Filter ..........................19
Service Brake Foot ............................................22
V
Vehicle Idenification Numbers (VINS) ................... 26
VINS ...................................................................... 26
Voltmeter ............................................................... 13
Voltmeter Gauge .....................................................8
Voltmeter, Key ON ................................................ 17
W
Work Light Indicator ................................................6
Work Lights Check ................................................ 18
Z
ZF Transmission
See Transmission ............................................. 25
T
Tachometer ...........................................................12
Tachometer Indicator Status .................................20
Temperature
Engine Coolant ....................................................8
Internal Information Center ...............................25
Temporary Fault Code Status ...............................28
Test
Power Circuit .......................................................6
Self-Test ..............................................................5
Test Mode Locations 100 to 199 ...........................25
Testing Park Brake ................................................15
Transmission
ZF Transmission
ECM Part Number (1st part) .........................25
ECM Part Number (2nd part) ........................25
Transmission Clutch Calibration ............................16
Transmission Display ............................................13
Transmission Filter Restriction Switch Check .......19
Transmission Oil Filter Indicator ..............................7
Transmission Oil Temperature ..............................13
Transmission Oil Temperature Gauge ....................7
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
4005-46
NOTES
Bur 6-42351
Revised 11-01
Printed in U.S.A.
Copyright
Section
4007
4007
ALTERNATOR
CASE CORPORATION
700 State Street
450 Sherman Avenue
Bur 7-12260

Printed in U.S.A.
January, 1999
Copyright
4007-2
TABLE OF CONTENTS
SPECIFICATIONS ....................................................................................................................................................... 2
SPECIAL TORQUES .................................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................ 3
GENERAL INSPECTION AND TESTING ......................................................................................................................... 4
ALTERNATOR DISASSEMBLY, TESTING, AND ASSEMBLY ............................................................................................. 5
Disassembly and Testing .......................................................................................................................................... 5
Assembly ................................................................................................................................................................ 8
SPECIFICATIONS
Case part number .............................................................................................................................................................1964860C1
Manufacturer ................................................................................................................................................................ Robert Bosch
Robert Bosch part number .......................................................................................................................................... 0 120 468 054
Output ....................................................................................................................................... 28 volts at 65 amperes at full throttle
Resistance of rotor winding .............................................................................................................................................. 8 to 9 ohms
Resistance of stator winding ...................................................................................................................................0.18 to 0.21 ohms
Minimum brush length, outside housing ................................................................................................................... 7 mm (0.27 inch)
SPECIAL TORQUES
Alternator mounting nuts and bolts ................................................................................................................ 100 Nm (74 pound-feet)
Pulley retaining nut ........................................................................................................................ 60 to 70 Nm (44 to 52 pound-feet)
Alternator housing screw........................................................................................................................4 to 5 Nm (3 to 4 pound-feet)
Bur 7-12260
Issued 1-99
Printed in U.S.A
Copyright
4007-3
SPECIAL TOOLS
CAS-1375 PULLEY NUT TOOL
AMMETER
CARBON PILE (100 WATT, 1 OHM)

VARIABLE RESISTOR
CAS-1559 DIGITAL MULTIMETER

CAS-10344 CHARGING SYSTEM ANALYZER
51L7
Bur 7-12260
Issued 1-99
Printed in U.S.A.
Copyright
4007-4
GENERAL INSPECTION AND TESTING

D. Connect the positive voltmeter lead of the
tester (9) to the positive battery post (10)
of the other battery.
1. Park the machine on a level surface and lower

the attachments to the floor.
2. Apply the parking brake and stop the engine.
E. Fasten the ammeter clamp of the tester

(11) around the negative battery cable (4).
The po int of the a rrow on the ammeter
clamp must be toward the battery.
3. Make sure all of the controls are in the

NEUTRAL position.
4. Make sure that the batteries are fully charged
and that all wiring harness leads are connected.
4
5. Turn all accessories OFF.
11
12
6. Make sure there is no oil or grease on the

alternator drive belt and the alternator drive belt
is tight.
7. If the alternator still does not operate correctly,
troubleshoot the alternator, refer to Section 4002.
10
1
8. Make sure the parking brake is applied.
B871240J
9. Make sure the master disconnect switch is in the

ON position.
10. Adjust the controls for the tester as follows:
A. Move the load control to the OFF position.
B. Select the volt range that will measure 24
volts.
C. Select the ampere range that will measure
100 amperes.
D. Put the volt lead selector in the EXT.
position.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
12 VOLT BATTERY
NEGATIVE LOAD LEAD OF TESTER
NEGATIVE BATTERY POST
NEGATIVE BATTERY CABLE
TO MASTER DISCONNECT SWITCH
NEGATIVE VOLTMETER LEAD OF TESTER
POSITIVE LOAD LEAD OF TESTER
POSITIVE BATTERY POST
POSITIVE VOLTMETER LEAD OF TESTER
POSITIVE BATTERY POST
AMMETER CLAMP
JUMPER CABLE
Figure 1. TESTER CONNECTIONS
11. Connect the tester to the batteries (1), refer to

Figure 1, as follows:
12. Start the engine and run the engine at full

throttle.
A. Connect the negative load lead of the

tester (2) to the negative battery post (3) of
the 12 volt battery (1) that is connected to
the master disconnect switch (5).
NOTE: Do not apply a load to the battery for more than

15 seconds at one time. After 15 seconds, turn the load
control to the OFF position for 60 seconds before
applying the load again.
B. Connect the negative voltmeter lead of the

tester (6) to the same negative battery post
(3).
13. Adjust the load control of the tester to get the

maximum amm eter indication. Read the
ammeter and voltmeter. Make a record of the
ammeter and the voltmeter indications.
C. Connect the positive load lead of the tester

(7) to the positive battery post (8) of the
same battery.
14. Turn the load control to the OFF position.

15. Decrease the engine speed and stop the engine.
Bur 7-12260
Issued 1-99
Printed in U.S.A.
Copyright
4007-5
16. The ammeter indication in step 13 must not be
l e s s th a n 6 5 a m p e r e s a n d t h e v o l t m e t e r
indication must be 25 to 29 volts.
A. If the ammeter and voltmeter indications
were correct, the alternator and voltage
regulator are good.
B. If the ammeter and voltmeter indications

were n ot co rrect, the p roblem is in th e
alternator or voltage regulator. If a new
voltage regulator and brush assembly are
available, replace the voltage regulator
and brush assembly and repeat the test.
C. If the alternator still does not operate
correctly, disassemble the alternator and
repair as necessary.
ALTERNATOR DISASSEMBLY, TESTING, AND ASSEMBLY

Disassembly and Testing
3. Remove the pulley (3), refer to Figure 3.
1. Place the alternator on a clean bench.
4. Remove the fan (4).
2. Use the pulley nut tool (1), wrench (2), and

socket (3), and remove the retaining nut (4) and
washer (5) from the alternator drive pulley (6),
refer to Figure 2.
5. Remove the nuts (5), washers (6), nuts (7),

washers (8), and plastic washers (9) that hold
the housings together.
3
2
6. Remove the two screws (10) and washers (11)

that hold the brush holder and voltage regulator
(12) to the alternator. Remove the brush holder
and voltage regulator (12).
7. Disconnect the capacitor (18) from the alternator.
1
8. Remove the screw (16) and washer (17) that
hold the capacitor (18) to the rear housing (21).
Remove the capacitor (18).
9. Put marks on the front housing (20) and rear
housing (21) so they can be correctly assembled.
10. Remove the four housing screws (19) that hold

the front and rear housings (20 and 21) together.
6
44L7
1.
2.
3.
4.
5.
6.
PULLEY NUT TOOL

WRENCH
SOCKET
RETAINING NUT
WASHER
ALTERNATOR PULLEY
11. Separate the front housing (20) from the rear

housing (21). Put a mark on the stator coil (44)
so it can be correctly assembled.
12. Remove the four screws (22) that hold the rotor
(24) in the front housing (20).
13. Remove the rotor (24) from the front housing
(20).
Figure 2. RETAINING NUT REMOVAL
Bur 7-12260
Issued 1-99
Printed in U.S.A.
Copyright
4007-6
20
1
22
23
2
3
28
27
19
24
25
37
44
36
39
26
38
32
31
30
42
34
43
33
41
40
29
16
35
14
13
9
18
15
17
10
11
7
5
21
12
45L7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
RETAINING NUT
WASHER
PULLEY
FAN
NUT
WASHER
NUT
WASHER
PLASTIC WASHER
SCREW
WASHER
BRUSH HOLDER AND
VOLTAGE REGULATOR
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
SPRING
BRUSH
DUST SEAL
SCREW
WASHER
CAPACITOR
HOUSING SCREW
FRONT HOUSING
REAR HOUSING
SCREW
SPACER
ROTOR
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
REAR BEARING
SNAP RING
FRONT BEARING
BEARING RETAINING PLATE
NUT
WASHER
NUT
WASHER
FIBER WASHER
FIBER SPACER
INSULATOR
RECTIFIER SCREW
37.
38.
39.
40.
41.
42.
43.
44.
RECTIFIER BRIDGE
INSULATOR
D+ TERMINAL
B+ TERMINAL
DUST SEAL
TERMINAL
BUSHING
STATOR COIL
Figure 3. ALTERNATOR ASSEMBLY

Bur 7-12260
Issued 1-99
Printed in U.S.A.
Copyright
4007-7
14. Check the rotor shaft for damage. Make sure that
the coils are not loose on the shaft. Check the
slip rings for too much wear or deep grooves.
The slip rings can be cleaned by using fine 400
grit sand paper.
15. Connect one of the test leads from an ohmmeter
to the rotor shaft (ground). Connect the other test
lead to one of the slip rings. There must not be
any electrical connection between the slip ring
and the rotor shaft. The ohmmeter reading must
not be low or zero ohms. If the ohmmeter reading
is low or zero ohms, replace the rotor assembly.
Repeat this test on the other slip ring.
16. Connect an ohmmeter between the two slip
rings. The reading on the ohmmeter must be 8 to
9 ohms. If the reading on the ohmmeter is high,
there is a break in the rotor coil and the rotor
assembly will have to be replaced.
17. Remove the rear bearing (25) from the rotor (24)
using a bearing puller.
18. Remove the front bearing (27) and spacer (23)
by using a bearing puller and hydraulic press.
19. Remove the bearing retaining plate (28).
20. Check the capacitor (18) for continuity between
th e mo u ntin g ta b an d th e lea d . If the r e is
continuity, the capacitor (18) is bad. Check the
capacitor (18) by connecting an ohmmeter
b e t w e e n t h e mo u n ti n g ta b a n d l e a d . T h e
ohmmeter will initially show movement and then
return to indicating no continuity as the capacitor
(18) is charged. Discharge the capacitor (18) by
grounding the lead to the tab before installation.
21. Check for continuity between each brush (14)
and the brush terminal. If there is no continuity,
replace the brushes (14).
22. Measure the length of the brush (14) projecting
from the brush holder and voltage regulator (12).
Replace the brushes if the length is 7 mm (0.27
inch) or less.
23. Use a soldering iron to disconnect the brush
lead. Remove the brush (14) and the spring (13)
from the brush holder and voltage regulator (12).
NOTE: When soldering leads to the terminals, the
solder must not flow into copper leads.
Bur 7-12260
24. Install a new brush (14) and spring (13) in the

brush holder and voltage regulator (12). Solder
lead to terminal using rosin-cored solder. Clamp
rubber tube in terminal next to the solder point.
Te st fo r e a s y m o v e m e n t o f b r u s h e s a ft e r
installation. Brushes will project 14 mm (0.55
inch) from holder.
25. Remove the nuts (29), washers (30), nuts (31),
washers (32) and fiber washers (33) from the
rectifier bridge terminals.
26. Remove the insulator (35) from the B+ terminal
(40).
27. Remove the rectifier screws (36) that hold the
rectifier bridge (37) to the rear housing (21).
Remove the rectifier bridge (37) from the rear
housing (21).
28. Remove the insulator (35) from the B+ terminal
(40).
29. Remove the insulator (38) from the D+ terminal
(39).
30. Unsolder the stator coil (44) at the connections to
the rectifier bridge (37). Remove the stator coil
(44).
NOTE: Bend phase lead-out wires as little as possible.
31. Test the positive diodes in the rectifier bridge
(37). Connect the negative lead of the ohmmeter
to the output B+ terminal (40). Connect the
positive lead of the ohmmeter to one of the leads
for the positive diodes. The positive diodes are
the seven diodes closest to the B+ terminal (40).
32. Reverse the ohmmeter leads. Read the
ohmmeter. There must be a high reading and a
low rea ding . If the read ings are the same,
replace the rectifier bridge (37). Repeat this step
for the other six diodes.
NOTE: D+ terminal (39) must be installed on a new
rectifier bridge (37).
33. Check the negative diodes in the rectifier bridge
(37). Connect the negative lead of the ohmmeter
to the surface of the diode plate that is not
p a in te d . C o n n e ct t h e p o sit ive lea d o f t h e
ohmmeter to one of the leads for the negative
diodes. The negative diodes are the seven
diodes on the side of the rectifier bridge (37)
opposite the B+ terminal (40).
Issued 1-99
Printed in U.S.A.
Copyright
4007-8
34. Reverse the ohmmeter leads. Read the
ohmmeter. There must be a high reading and a
low rea ding . If the read ings are the same,
replace the rectifier bridge (37). Repeat this step
for the other six diodes.
NOTE: D+ terminal (39) must be installed on a new
rectifier bridge (37).
35. Measure the resistance of the stator windings by
connecting the ohmmeter across the leads. The
resistance in each coil should be 0.18 to 0.21
ohms.
36. Check the stator coil (44) for short circuit.
Co n ne c t o ne le a d of th e oh mme te r to th e
housing of the stator coil (44). Connect the other
lead to each of the four leads from the stator coil
(44). If the ohmmeter moves there is a short
circuit in the stator coil (44). Install a new stator
coil (44).
Assembly
1. Solder the stator coil (44), at the connections, to
the rectifier bridge (37), refer to Figure 3.
2. Install the insulator (38) on the D+ terminal (39).
3. Install the insulator (35) on the B+ terminal (40).
Check the dust seal (41) and make sure it is in
place.
4. Align the rectifier bridge (37) in the rear housing
(21) and install the rectifier screws (36) that hold
the rectifier bridge (37) to the housing.
5. Install the insulator (35) on the B+ terminal (40).
6. Install the fiber washers (33), washers (32), nuts
(31), washers (30), and nuts (29) on the rectifier
bridge terminals.
7. Install the bearing retaining plate (28).
11. Install and tighten the four screws (22) that hold
the rotor (24) in the front housing (20).
12. Assemble the front housing (20) and rear
housing (21), making sure the reference marks
align.
13. Install the four housing screws (19) that hold the
housing halves together. Do not tighten the
housing screws (19).
14. Put three 0.2 mm (0.008 inch) feeler gauges
between the stator coil (44) and rotor (24). This
will correctly position the rotor (24) in relation to
th e stato r, and align the drive end bearing
hou sing w ith the collector ring en d shie ld.
Alternate tightening the two housing screws (19)
opposite of each other until the four housing
sc r e ws (1 9 ) t h a t h o ld th e h o us in g ha lv e s
together are tightened to a torque of 4 to 5 Nm (3
to 4 p oun d-fe et). Remo ve the th ree fe eler
gauges.
15. Install the capacitor (18). Install and tighten the
sc re w ( 1 6 ) a nd w as h e r (1 7 ) th a t ho ld th e
capacitor (18) to the rear housing (21).
16. Connect the capacitor terminal to the alternator.
17. Check the dust seal (15) on the brush holder and
v o l t a g e r e g u l a t o r ( 1 2 ) t o m a k e s u r e i t is
positioned correctly.
18. Install the brush holder and voltage regulator
(12). Make sure the rectifier bridge contact spring
is in contact with the brush holder and voltage
regulator (12). Make sure the dust seal (15) is in
contact with the housing.
19. Install and tighten the two screws (10) and
washers (11) that hold the brush holder and
voltage regulator (12) to the alternator.
20. Install plastic washers (9), washers (8), nuts (7),
washers (6) and nuts (5).
8. Install a new front bearing (27) on the rotor shaft

if it has been removed. Install the front bearing
(27) and spacer (23) with a hydraulic press.
21. Install the fan (4).
9. Install a new rear bearing (25) on the rotor shaft

if it has been has been removed. Install the rear
bearing (25) using a hydraulic press.
23. Install the retaining nut (1) and washer (2) on the
front of the alternator.
22. Install the pulley (3).
10. Install the rotor (24) in the front housing (20).
Bur 7-12260
Issued 1-99
Printed in U.S.A.
Copyright
4007-9
24. Use the pulley nut tool (1), wrench (2), and
socket (3) to tighten the retaining nut (4) and
washer (5), refer to Figure 2. Tighten retaining
nut (4) to a torque of 60-70 Nm (44 to 52 poundfeet).
Bur 7-12260
Issued 1-99
Printed in U.S.A.
Copyright
Copyright
Section
4008
4008
ALTERNATOR - 45 AMPERE
CASE CORPORATION
700 State Street
Bur 6-42360

Printed in U.S.A.
August, 2001
Copyright
4008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 Ampere Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Testing of the Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Testing of the Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Replacement of the Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42360
Issued 8-01
3
3
4
4
8
9
10
10
11
11
14
Printed in U.S.A.
Copyright
4008-3
SPECIFICATIONS
45 Ampere Alternator
Rated output ........................................................................................................................... 28 volts at 45 amperes
Resistance of rotor ............................................................................................................................. 8.1 to 9.9 ohms
Maximum runout for slip rings ....................................................................................................0.05mm (0.002 inch)
Minimum diameter of slip rings.................................................................................................. 26.8 mm (1.055 inch)
Resistance of stator........................................................................................................................ 0.20 to 0.24 ohms
Minimum length of brushes ...............................................................................................................7mm (0.27 inch)
Torque nut for pulley ..............................................................................................60 to 73 Nm (45 to 54 pound-feet)
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-4
ALTERNATOR
STEP 3
Disassembly
STEP 1
B523411M
Remove the retainer and the pulley from the shaft.

B518007M
Fasten the pulley of the alternator in a vise that has

soft jaws. Loosen and remove the nut and washer.
STEP 4
STEP 2
B523413M
Remove the fan from the shaft.

B523405M
STEP 5
Hit the face of the pulley softly with a hammer to

loosen the retainer in the pulley.
B8971201M
Loosen and remove the screws and flat washers that

fasten the voltage regulator and brush holder to the
housing.
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-5
STEP 6
STEP 9
B8971204M
Remove the voltage regulator and brush holder.
B8971213M
Loosen and remove the nut, flat washer, and fiber

washers from the D+ terminal.
STEP 7
STEP 10
B8971207M
Disconnect the lead for the capacitor.
B8971216M
Loosen and remove the nut, flat washer, and fiber

washers from the B+ terminal.
STEP 8
STEP 11
B8971210M
Loosen and remove the screw and remove the

capacitor.
B8971219M
Make an alignment mark on the cover, the stator, and

the housing.
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-6
STEP 12
STEP 15
B8971222M
Loosen and remove the screws that fasten the cover,

stator, and housing together.
B8971301M
Remove the rotor from the cover.
STEP 16
STEP 13
B8971304M
B8971231M
Remove the cover and rotor from the stator and

housing. The cover can be difficult to remove. Use a
soft hammer as required to remove the cover.
1. SCREWS
Loosen and remove the screws that fasten the

rectifier bridge to the housing.
STEP 17
STEP 14
B8971307M
B8971508M
Loosen and remove the screws that fasten the

bearing retainer to the cover. The rotor now can be
removed.
Bur 6-42360
Remove the housing.
Issued 8-01
Printed in U.S.A.
Copyright
4008-7
STEP 18
STEP 20
B8971310M
Remove the insulator from the B+ terminal.
B8971319M
Remove the shield from the housing.
STEP 19
B8971313M
Remove the insulator from the D+ terminal.
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-8
STEP 23
Inspection of the Brushes

STEP 21
B9064418M
B9064411M
Use an ohmmeter and check the continuity from

each terminal and brush. If the reading is not zero,
replace the brush or voltage regulator and brush
holder.
Measure the length of each brush. If one brush is

less than 7 mm (0.27 inch) long replace both brushes
or the voltage regulator and brush holder.
STEP 24
STEP 22
B9064421M
B9064414M
Remove the shield.
To replace the brushes, use a soldering iron to

remove the original brushes. Install the springs and
new brushes and use rosin core solder to solder the
leads to the terminals. Before soldering the terminal
shown, open the sleeve for the brush lead and then
crimp the sleeve.
STEP 25
B9064414M
Install the shield.

Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-9
Inspection and Testing of the Rotor
STEP 28
STEP 26
B9064433M
B9064405M
Touch the leads of the ohmmeter to the slip rings.

The reading must be as specified, see below. If the
reading is not as specified, a new rotor must be
installed.
45 Ampere Alternator . . . . . . . . . . . . 8.1to 9.9ohms
Use a dial indicator and measure the runout of each

slip ring. If the runout is more than 0.05 mm (0.002
inch) a new rotor must be used or use a lathe to
remove enough material until the runout is less than
specified.
STEP 29
STEP 27
B9064436M
Measure the diameter of the slip ring. The diameter

must not be less than 26.8 mm (1.055 inch).
B9064407M
Touch the leads to each slip ring and the shaft. If a

reading shows continuity, a new rotor must be
installed.
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-10
STEP 33
Inspection and Testing of the

Stator
STEP 30
Look for burned insulation on the coils of the stator.
This is an indication of a short circuit. Install a new
stator.
STEP 31
B9064502M
Use a high watt soldering iron and rosin core solder

to solder the leads of the stator to the rectifier bridge.
Testing the Capacitor

STEP 34
B9064319M
Touch the leads of the ohmmeter to each lead from

the stator and the common connection. The readings
must be as specified, see below. If the readings are
not as specified, a new stator must be installed.
45 Ampere Alternator . . . . . . . . . 0.20 to 0.24 ohms
STEP 32
B9064424M
Touch the leads of the ohmmeter to the capacitor as

shown. The reading will initially approach zero ohms,
then gradually increase to an open circuit as the
capacitor is charged. If there is no indication of
resistance, a new capacitor must be installed. The
capacitor is used to reduce radio noise.
STEP 35
B9064322M
Touch the leads of the ohmmeter to each lead from

th e s ta t o r a n d t he fr a me . If a re a d in g sh o w s
continuity, a new stator must be installed.
Bur 6-42360
Touch the terminal to the bracket to discharge the

condenser.
Issued 8-01
Printed in U.S.A.
Copyright
4008-11
Testing the Rectifier Bridge
Inspection and Replacement of the

Bearings
STEP 36
STEP 38
B9064402M
Touch the leads of the ohmmeter to a positive diode

and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero
reading. Then test the other two positive diodes. If a
positive diode did not have readings as specified, the
positive diode is bad and a new rectifier bridge must
be installed.
B8971402M
Inspect the bearings on the rotor. If the bearings are

damaged, use the following procedure to replace the
bearings.
STEP 37
B8971426M
B9064332M
1. Use a suitable support between the front bearing

and the bearing retainer on the rotor shaft and
press the rotor shaft out of the front bearing and
the spacer.
Touch the leads of the ohmmeter to a negative diode

and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero
reading. Then test the other two negative diodes. If a
negative diode did not have readings as specified,
the negative diode is bad and a new rectifier bridge
must be installed.
NOTE: If the tester you are using has a diode test
function, use the tester according to the instructions
of the manufacturer to check the positive and
negative diodes.
B8971429M
2. Remove the bearing retainer.
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-12
B8971432M
B8971504M
3. Use a suitable support between the rear bearing

and the slip ring on the other end of the rotor
shaft and press the rotor shaft out of the rear
bearing.
6. Press the spacer onto the rotor shaft until the

spacer stops moving.
B8971505M
B8971429M
7. Press the new rear bearing onto the other end of

the rotor shaft.
4. Install the bearing retainer on the rotor shaft.
B8971435M
5. Press the new front bearing onto the rotor shaft

until the front bearing stops moving.
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-13
18
23 22
24
20
21
22
23
16
24
22
23
17
19
10
21
11
23
26
27
7
15
12
13
14
3
5
6
7
8
4
BS01B125
1.
2.
3.
4.
5.
6.
7.
NUT
WASHER
RETAINER
SCREW
PULLEY
FAN
SCREW
8.
9.
10.
11.
12.
13.
14.
COVER
SPACER
FRONT BEARING
BEARING RETAINER
KEY
ROTOR
REAR BEARING
15.
16.
17.
18.
19.
20.
21.
STATOR
SCREW
RECTIFIER BRIDGE
INSULATOR
SHIELD
HOUSING
FIBER WASHER
22.
23.
24.
25.
26.
FLAT WASHER
NUT
LOCK WASHER
BRUSH
VOLTAGE REGULATOR
AND BRUSH HOLDER
27. CAPACITOR
45 AMPERE ALTERNATOR
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-14
STEP 42
Assembly
STEP 39
B8971601M
Install the housing on the rectifier bridge.

B8971316M
STEP 43
Install a new shield in the housing.
STEP 40
1
B8971304M
1. SCREWS
B8971313M
Install the insulator on the D+ terminal.
STEP 41
Install and tighten the screws that fasten the rectifier

bridge to the housing.
STEP 44
B8971310M
Install the insulator on the B+ terminal.
Bur 6-42360
B8971604M
Install the fiber washers, flat washer, and nut on the

B+ terminal.
Issued 8-01
Printed in U.S.A.
Copyright
4008-15
STEP 45
STEP 48
B8971607M
Check for a short circuit between the terminal and

the housing. If there is continuity, the insulator is bad.
B8971301M
Install the rotor in the cover.
STEP 49
STEP 46
B8971508M
B8971610M
Install the fiber washers, flat washer, and nut on the

D+ terminal.
Install and tighten the screws that fasten the bearing

retainer and rotor to the cover.
STEP 50
STEP 47
B8971231M
B8971613M
Check for a short circuit between the terminal and

the housing. If there is continuity, the insulator is bad.
Bur 6-42360
Make sure the marks are in alignment and install the

cover and rotor in the stator and housing.
Issued 8-01
Printed in U.S.A.
Copyright
4008-16
STEP 51
STEP 54
B8971222M
B8971622M
Install and tighten the screws evenly that fasten the

housing, stator, and cover.
Install the voltage regulator and the brush holder. Be

careful not to damage the brushes.
STEP 52
STEP 55
B8971616M
Install the capacitor and tighten the screw.
B8971625M
Install the screws and flat washers and tighten the

screws.
STEP 53
STEP 56
B8971619M
Connect the lead to the terminal.
B523413M
Install the fan.
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-17
STEP 57
STEP 59
B523418M
Install the pulley and the retainer.
B518009M
Fasten the pulley in a vise with soft jaws. Tighten the

nut to a torque of 60 to 73 Nm (45 to 54 pound-feet).
STEP 58
B523407M
Install the washer and start the nut onto the shaft.
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
4008-18
NOTES
Bur 6-42360
Issued 8-01
Printed in U.S.A.
Copyright
SECTION INDEX
STEERING
Section Title
Section Number
Removal and Installation of Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001

Steering Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5003
Steering Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5004
Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005
Center Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006
Auxiliary Steering Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5008
CASE CORPORATION
700 State Street
Bur 6-42370

Printed in U.S.A.
August, 2001
Copyright
5001
Copyright
Section
5001
REMOVAL AND INSTALLATION OF STEERING
COMPONENTS
CASE CORPORATION
700 State Street
Bur 6-42380

Printed in U.S.A.
August, 2001
Copyright
5001-2
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42380
Issued 8-01
4
4
4
6
6
6
8
8
8
10
10
10
Printed in U.S.A.
Copyright
5001-3
NOTES
Bur 6-42380
Issued 8-01
Printed in U.S.A.
Copyright
5001-4
STEERING CONTROL VALVE

Removal
1. Remove the left, right, and front cab skirts,
located under the cab or canopy.
2. Remove all dirt and grease from the steering
co ntr ol v alve ( 5) a nd th e ar ea a ro un d th e
steering control valve (5), refer to the illustration
on page 5.
3. Remove the fill cap for the hydraulic reservoir.
4. Fasten identification tags to the hoses at the
steering control valve (5).
5. Disconnect the hoses from the fittings in the
steering control valve (5).
6. Cap or plug the fittings and hoses.
7. Turn the steering wheel as required for access to
the cap screw (1) that holds the steering column
shaft (6) of the steering control valve (5) in the
coupling (2).
8. Remove the cap screw (1) that holds the steering
column shaft (6) of the steering control valve (5)
in the coupling (2).
9. Hold the steering control valve (5) in position and
remove the bolts (7), washers (3), and steering
isolator mounts (4) that fasten the base plate (11)
and steering control valve (5) to the bottom of the
pedestal (12).
10. Remove the steering control valve (5) and base
plate (11) from the machine.
11. Remove the bolts (9) and lock washers (10) that
fasten the base plate (11) to the steering control
valve (5).
12. Remove the base plate (11) and seals (8) from
the steering control valve (5).
Bur 6-42380
Installation
1. Put the seals (8) and base plate (11) in position
on the steering control valve (5). Install the bolts
(9) and lock washers (10) that fasten the base
plate (11) to the steering control valve (5). Refer
to the illustration on page 5.
2. Put the base plate (11) and steering control valve
(5) assembly in position on the bottom of the
pedestal (12). Make sure that the notch in the
steering column shaft (6) on the steering control
valve (5) is aligned with the hole in the coupling
(2).
3. Install the bolts (7), washers (3), and steering
isolator mounts (4) that fasten the base plate (10)
and steering control valve (5) assembly to the
bottom of the pedestal (12).
4. Turn the steering wheel as required for access to
the hole for the cap screw (1) that holds the
steering column shaft (6) of the steering control
valve (5) in the coupling (2).
5. Install the cap screw (1) that holds the steering
column shaft (6) of the steering control valve (5)
in the coupling (2).
6. Connect the hoses to the fitting in the steering
control valve (5).
7. Install the fill cap on the hydraulic reservoir.
8. Start the engine and turn the machine all the way
to the left and right several times to remove any
air in the circuits.
9. Stop the engine and check for leaks.
10. Check the fluid level in the hydraulic reservoir.
Add oil as re qu ir ed. S ee Section 10 02 for
specifications.
Issued 8-01
Printed in U.S.A.
Copyright
5001-5
12
2
9
10
8
4
4
4
11
3
4
3
7
6
BS01C107
1. CAP SCREW
2. COUPLING
3. WASHER
4. STEERING ISOLATOR MOUNT

5. STEERING CONTROL VALVE
6. STEERING COLUMN SHAFT
7. BOLT
8. SEAL
9. BOLT
10. LOCK WASHER

11. BASE PLATE
12. PEDESTAL
STEERING CONTROL VALVE ILLUSTRATION
Bur 6-42380
Issued 8-01
Printed in U.S.A.
Copyright
5001-6
PRIORITY VALVE
Removal
1. Remove all dirt and grease from the priority valve
(3) and the area around the priority valve (3),
refer to the illustration on page 7.
Installation
1. Start the vacuum pump.
2. Install the bolt (8), washer (6), and lock nut (7), to
fasten the priority valve (3) to the bracket (4).
Refer to the illustration on page 7.
3. Connect a vacuum pump to the hydraulic

reservoir.
3. Connect the hose (1) to the elbow in the side of

the priority valve (3).
4. Connect the hose (10) to the elbow in the side of

the priority valve (3).
5. Tag and disconnect the hose (9) from the priority

valve (3).
6. Plug the hose (9).
valve (3).
5. Connect the hose (5) to the top of the priority

valve (3).
6. Connect the hose (2) to the top of the priority
valve (3).
7. Connect the hose (9) to the bottom of the priority

valve (3).

valve (3).
8. Stop the vacuum pump.
9. Disconnect the vacuum pump from the hydraulic

reservoir.
11. Tag and disconnect the hose (10) from the

priority valve (3).
10. Install the fill plug on the hydraulic reservoir.
11. Start the engine and run at low idle for 30

seconds. Stop the engine and check for leaks.
valve (3).
15. Loosen and remove the locknut (7), washer (6)
and bolt (8) which fasten the priority valve (3) to
the bracket (4).
12. Check to make sure the priority valve works

correctly. See Section 5002.
Add oil as re qu ir ed. S ee Section 10 02 for
specifications.
Bur 6-42380
Issued 8-01
Printed in U.S.A.
Copyright
5001-7
2
1
10
8
7
6
4
8
9
11
13
14
12
17
15
16
18
BS01C105
1.
2.
3.
4.
5.
6.
HOSE
HOSE
PRIORITY VALVE
BRACKET
HOSE
WASHER
7.
8.
9.
10.
11.
12.
LOCKNUT
BOLT
HOSE
HOSE
SOLENOID VALVE
13.
14.
15.
16.
17.
18.
AUXILIARY STEERING PRESSURE FITTING

HOSE TO LOADER CONTROL VALVE
HOSE TO PRIORITY VALVE
HOSE TO LOADER CONTROL VALVE
PRIORITY VALVE ILLUSTRATION
Bur 6-42380
Issued 8-01
Printed in U.S.A.
Copyright
5001-8
AUXILIARY STEERING PUMP AND MOTOR

Removal
reservoir.
4. Tag and disconnect the hose (1) from the fitting
(9) on the auxiliary steering pump and motor (2)
and in sta ll a plu g in the h ose, refer to th e
illustration on page 9.
5. Tag and disconnect the hose (3) from the elbow
(8) on the auxiliary steering pump and motor (2)
and install a plug in the hose (3).
Installation
1. Install the auxiliary steering pump and motor (2).
Install the nuts (4), bolts (5) and flat washers.
Tighten the bolts. Refer to the illustration on page
9.
3. Connect the hose (1) to the fitting (9) on the
auxiliary steering pump and motor (2).
4. Connect the hose (3) to the elbow (8) on the
5. Stop the vacuum pump. Install the fill cap in the
hydraulic reservoir.
6. Connect the ground wire to the rear chassis (7).
7. Turn the master disconnect switch to the OFF

position.
7. Connect the electrical wires to the auxiliary

steering pump and motor (2).
8. Tag and disconnect the electrical wires from the

8. Place the master disconnect switch in the ON

position.
9. Tag and disconnect the ground wire from the rear

chassis (7).
9. Start and run the engine at low idle, loosen the

hose at the pressure switch to bleed out air in the
line.
10. Remove the nuts (4), bolts (5) and washers (6)
that hold the auxiliary steering pump and motor
(2).
11. Remove the auxiliary steering pump and motor
(2).

11. Disconnect the wire from the fuel shutoff
solenoid on the fuel injection pump.
12. Actuate the starter for 3 to 5 seconds to actuate
the auxiliary steering pump and motor.
13. Turn the steering wheel all the way to the left and
to the right to make su re that the auxiliary
steering pump and motor works correctly. Turn
the key switch to OFF.
14. Connect the wire to the fuel shutoff solenoid.
Bur 6-42380
Issued 8-01
Printed in U.S.A.
Copyright
5001-9
5
6
7
4
5
6
1
4
2
8
3
BS01C106
1. HOSE
2. AUXILIARY STEERING PUMP AND MOTOR
3. HOSE
4. NUT
5. BOLT
6. WASHER
7. REAR CHASSIS
8. ELBOW
9. FITTING
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
Bur 6-42380
Issued 8-01
Printed in U.S.A.
Copyright
5001-10
STEERING CYLINDER
Removal
1. Loosen the fill cap for the hydraulic reservoir to
release pressure in the reservoir, then tighten the
fill cap.
2. Disconnect the hoses (13,14,16 and 17) for the
steering cylinder (1), refer to the illustration on
page 11.
3. Install plugs in hoses 16 abd 17.
4. Remove the grease hose (11) from the tube end
of the steering cylinder (1).
5. Loosen and remove the locknut (4) that holds the
pin (2) to the steering cylinder (1).
6. Remove the bolt (3).
7. Remove the pin (2).
8. Remove the washers (6).
9. Remove the bolt (8), washer (9) and spacer (10)
that hold the pivot pin (7) at the rear of the
steering cylinder (1).
10. Use an acceptable driver and drive the pivot pin
(7) out of the steering cylinder (1)
11. Remove the washer(s) (15) from between the
steering cylinder (1) and the rear frame of the
machine.
12. Remove the steering cylinder (1).
Installation
1. Put the steering cylinder (1) into position in the
machine. Make sure that the washer (15) is
installed between the steering cylinder (1) and
the rear frame. Refer to the illustration on page
11.
NOTE: Use a washer (15) on top and bottm of the
steering cylinder (1) if possible. If only one washer
(15) is used, place the washer (15) on the bottom of
the steering cylinder (1).
2. Make sure the washers (6) are in position
between the steering cylinder (1) and the front
frame of the machine.
3. Install the pivot pin (7) to fasten the rear of the
steering cylinder (1) to the machine frame. Install
the spacer (10), washer (9) and bolt (8) to fasten
the pivot pin (7).
4. Tighten the bolt (8).
5. Install the pin (2) in the front of the steering
cylinder (1). Make sure that the washers (6) are
in the correct position.
6. Install the bolt (3) and locknut (4) in the steering
cylinder (1) and pin (2). Tighten the locknut (4).
NOTE: The bolt (3) should turn freely in the hole
after tightening.
7. Connect the hoses (13,14,16 and 17) to the
hydraulic cylinders.
8. Connect the grease hose (11) to the base end of
the steering cylinder (1).
9. Tighten the fill cap for the hydraulic reservoir.
10. Start the engine.
11. Turn the steering wheel all the way to the right
and then to the left several times.
12. Stop the engine. Check the hydraulic oil level.
See Section 1002 for specifications.
Bur 6-42380
Issued 8-01
Printed in U.S.A.
Copyright
5001-11
8
9
16
10
7
13
15
17
14
2
3
15
4
10
12
11
14
12
13
15
6
2
4
15
1
5
3
BS01C108
1.
2.
3.
4.
5.
6.
STEERING CYLINDER
PIN
BOLT
LOCKNUT
GREASE FITTING
WASHER
7.
8.
9.
10.
11.
12.
PIVOT PIN
BOLT
WASHER
SPACER
GREASE HOSE
TEE FITTING
13.
14.
15.
16.
17.
HOSE
HOSE
WASHER
HOSE
HOSE
STEERING CYLINDER ILLUSTRATION
Bur 6-42380
Issued 8-01
Printed in U.S.A.
Copyright
5001-12
NOTES
Bur 6-42380
Issued 8-01
Printed in U.S.A.
5002
Copyright
Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS, AND
TROUBLESHOOTING
CASE CORPORATION
700 State Street
Bur 6-40790

Printed in U.S.A.
March,2001
Copyright
5002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDERSTANDING THE RESULTS OF THE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
3
4
4
4
5
5
5
6
7
7
9
10
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
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)
Steering relief valve
Pressure setting .................................................................................................239 to 243 bar (3465 to 3523 psi)
Location of steering relief valve...................................................................................... in the loader control valve
Bur 6-40790
Issued 3-01
Printed in U.S.A.
Copyright
5002-3
SPECIAL TOOLS
B785789
OEM-1239 (CAS-10280) FLOWMETER
B009638
CAS-1804 PRESSURE TEST FITTING KIT
B797157
CAS-1808 FLOWMETER FITTING KIT
TROUBLESHOOTING THE STEERING SYSTEM

NOTE: The steering hydraulic schematic is included
in the hydraulic schematic. Refer to the rear pocket of
this manual.
3. Do the main hydraulic pump test. See Section

8002. If the main pump is bad, repair or replace
the main hydraulic pump.
1. Make sure the oil level in the hydraulic reservoir

is correct. Visually inspect the steering system
for leakage and damage.
4. Test the steering cylinders for leakage, refer to

instructions on page 10. If a steering cylinder is
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.
Bur 6-40790
Issued 3-01
Printed in U.S.A.
Copyright
5002-4
AUXILIARY STEERING SYSTEM PUMP TEST

Equipment Required
1. CAS- 10280 Flowmeter
2. CAS-1808 Flowmeter fitting kit
Test Procedure
1
BB830300
1. AMMETER CLAMP
6. Connect the ammeter clamp (1) to the cable as

in illustration above.
7. Make sure that the parking brake is applied and

the bucket is on the floor.
BD00M030
1. ARTICULATION LOCK
1. Install articulation lock.

NOTE: When performing this pressure check,
always be sure the articulation lock is in place,
especially when working in the articulation joint
areas.
2. Loosen and remove the outlet hose of the
Auxiliar y Steering Pump from the Steering
Priority Valve.
8. Make sure that

temperature.
the
oil
is
at
operating
9. Make sure that the load valve for the flowmeter is

open (zero pressure).
10. Start and run the engine.
11. Stop the engine and turn the key back to the On
position.
12. Turn the steering wheel, this will activate the
auxiliary steering pump.
3. Install a plug into the hose.
13. Turn the load valve on the flowmeter towards

CLOSED until the pressure is 104 bar (1500 psi).
4. Connect the inlet of the flowmeter to the outlet

fitting on the Steering Priority Valve.
14. Read the flowmeter and ammeter gauges and

record the readings.
5. Install the outlet hose of the flowmeter in the

hydraulic reservoir and hold in place with wire.
15. The flowmeter reading must not be less than

24.6 L/min, (6.5 U.S. gpm). The ammeter reading
must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.
Bur 6-40790
Issued 3-01
Printed in U.S.A.
Copyright
5002-5
AUXILIARY STEERING SYSTEM MOTOR TEST

Test Equipment
1. A 24 volt battery that is fully charged.
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.
1
4
2. A remote starter switch.

3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
System Tester.
Test Procedure
1. Remove the connector that is between the
ter minals on the magnetic switch and the
auxiliary steering motor.
5
B790852
1.
2.
3.
4.
5.
REMOTE STARTER SWITCH

TESTER
AUXILIARY STEERING MOTOR
AMMETER CLAMP
24 VOLT BATTERY SYSTEM
2. Remove the auxiliary steering motor from the

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.
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.
7. Hold the tachometer against the armature shaft.
Look at the tachometer. Make a record of the
indication.
B795328
6. AMMETER
7. VOLTMETER
8. LOAD CONTROL
8. Release the button on the remote starter switch

(1).
Bur 6-40790
Issued 3-01
Printed in U.S.A.
Copyright
5002-6
UNDERSTANDING THE RESULTS OF THE TEST

1. If the ammeter indication in step 6 was 30
amperes or less and the tachometer indication in
step 7 was 6950 r/min (r pm) or more, the
auxiliary steering motor is good.
2. If the armature speed was less than 6950 r/min
(rpm) and the ammeter indication was higher
than 30 amperes, possible causes include the
following:
A. Damaged bearings.
B. Loose pole shoes.
C. A short circuit in the armature coil. The
a r m a t u r e c o i l m u s t b e c h e ck e d o n a n
ar mature tester after the motor is
disassembled.
D. A ground connection in the field coil.
3. If the armature did not turn and the ammeter
indication was higher than 30 amperes, possible
causes include the following:
A. The motor terminal is in contact with the field
frame.
B. A damaged bearing that will not let the
armature turn.
Bur 6-40790
4. If the armature did not turn, and the ammeter

indication was zero amperes, possible causes
include the following:
A. An open field coil.
B. An open armature coil. After the motor is
disassembled, look at the commutator on the
armature. If the commutator is badly burned,
the armature coil is probably open.
C. Broken brush springs or worn brush springs.
5. If the armature speed was less than 6950 r/min
(rpm) and the ammeter indication was less than
30 amperes, possible causes include the
following:
A. Bad connections between the brushes and
the field coil.
B. Dirty commutator.
6. If the armature speed was 6950 r/min (rpm) or
more and the ammeter indication was more than
30 amperes, there is probably a short circuit in
the field coil. A short circuit in the field coil is
difficult to find. It is recommended that a new
field frame assembly be installed.
Issued 3-01
Printed in U.S.A.
Copyright
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
BD00M048
BD00M048
1. SAFETY LINK
1. Install the safety link (1) and lower the loader

arms slowly, until the safety link is supporting the
loader arms.
1. SAFETY LINK
3. Remove the safety link (1) and lower the loader

arms to the ground.
4. Stop the engine.
1
1
BD00M030
BD00M041
1. COVER PLATE
5. Install articulation lock (1).

2. Remove the cover plate (1) to gain access to the
loader control valve.
Bur 6-40790
IMPORTANT: When performing the following

pressure check and adjustment, the articulation lock
must be installed. Use caution when working in or
near the articulation area.
Issued 3-01
Printed in U.S.A.
Copyright
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
2
9. Start and run the engine at full throttle.

10. Hold the bucket control lever in the rollback
position.
BD00N018
1. LOADER CONTROL VALVE

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

of the oil is reached.
16. Connect a 345 bar (5000 psi) pressure gauge to

the test port (2) on the front of the loader control
valve (1).

14. Remove the cap on the hydraulic reservoir to
release any pressure in the hydraulic system.
NOTE: Make sure when you connect the pressure

gauge that you do so in a manner that you can read
the pressure gauge while sitting in the operators
seat.
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.
Bur 6-40790
Issued 3-01
Printed in U.S.A.
Copyright
5002-9
Pressure Setting Adjustment
1
1
BD00M048
BD00M048
1. SAFETY LINK
1. Install the safety link (1) before adjusting the

steering relief valve.
1. SAFETY LINK
3. Remove the safety link (1), and lower the loader

arms to the ground.
4. If the pressure gauge is still connected, repeat
steps 17 through 20 in the Pressure Setting Test
P r o c e d u r e. I f t h e p r e s s u r e g a u g e i s n o t
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.
2
1
BS01A046

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).
Bur 6-40790
Issued 3-01
Printed in U.S.A.
Copyright
5002-10
STEERING CYLINDER LEAK TEST

NOTE: Make sure all persons are clear of the area
of the center pivot. Make sure the center pivot is free
of any obstructions.
1. Park the machine on a level surface.
2. Turn the machine all the way to the right.
3. Stop the engine and apply the parking brake.
4. Find the tube that is connected to the rod end of
the left-hand steering cylinder. Disconnect the
tube from the left-hand cylinder.
5. Install a plug in the tube.
7. Turn the steering wheel to the right. Hold the
steering wheel for a full right turn. Have another
person check for leakage from the opening of the
rod end of the left-hand steering cylinder.
8. If there is constant leakage from the rod end, the
piston packing in the left-hand steering cylinder
is damaged. Repairs must be made. See Section
5005.
Bur 6-40790
9. Connect the tube to the rod end of the left-hand

steering cylinder.
10. Turn the machine all the way to the left.
12. Find the tube that is connected to the rod end of
the right-hand steering cylinder. Disconnect the
tube from the right-hand steering cylinder.
13. Install a plug in the tube.
15. Turn the steering wheel to the left. Hold the
steering wheel for a full left turn. Have another
person check for leakage at the opening of the
rod end of the right-hand steering cylinder.
16. If there is constant leakage from the rod end, the
piston packing in the right-hand steering cylinder
is damaged. Repairs must be made. See Section
5005.
17. Connect the tube to the rod end of the right-hand
steering cylinder.
Issued 3-01
Printed in U.S.A.
Copyright
5003
Section
5003
CASE CORPORATION
700 State Street
Bur 6-42390

Printed in U.S.A.
August, 2001
Copyright
5003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42390
Issued 8-01
............
............
............
............
............
............
3
3
3
3
5
6
Printed in U.S.A.
Copyright
5003-3
SPECIFICATIONS
Manufacturer ..................................................................................................................................................... Eaton
Special Torques
Cap screws for end cap ............................................................................................ 33.9 NM (300 pound-inches)
SPECIAL TOOLS
Retaining ring pliers.......................................................................................................... Eaton part number 600610
Splined shaft end tool, #600604 ........................................................................................... Eaton part number 8063
Order Special Tools from:
Eaton Corporation, Hydraulics Division, 15151 Highway 5, Eden Prairie, MN 55344

Disassembly
1. Clean the port area of the steering control valve
housing before disconnecting the hydraulic lines.
2. Drain the oil, and plug the ports. Clean the
exterior of the steering control valve housing.
Protect the machines surfaces during repair.
3. Put the steering control valve in a vise so that the
end cap (2) is up, refer to Figure 1.
7. Hold the gerotor star and drive shaft (6), with

your hand. Protect both the gerotor star and
hand with a shop towel while turning.
8. Turn the tool clockwise or counter-clockwise to
compress the centering spring (12).
9. Hold the drive shaft (6) stationary.
10. Remove the centering spring (12), spool (9) and
sleeve (8), ball checks (10), pin (11), drive shaft
(6), bearing race (14), retaining ring (18) and
needle thrust bearing (13). Use retaining ring
pliers. (See Special Tools).
11. Remove the back-up washer (15), seal ring (16),
and O-ring (17).
12. Carefully pry the dust seal (19) from the steering
control valve housing (7), using a small blade
screwdriver. Do not damage the dust seal (19).
NOTE: If the steering control valve housing (7) has
anti-cavitation valves, find the anti-cavitation valves
in the steering control valve housing (7).
1
GS98K501
1. VISE
2. END CAP
3. ANTI-CAVITATION
VALVES
FIGURE 1. STEERING CONTROL VALVE-END CAP UP
4. Remove the seven cap screws (1), end cap (2),

O-ring (3), gerotor (4), O-ring (3), spacer plate
(5), and O-ring (3), refer to Figure 2.
13. To disassemble these valves, insert soda straws

(3) in each end of the threaded holes, refer to
Figure 3. Remove the steering control valve
housing from the vise and tilt it until the port face
(4) is upward. Continue turning until the roll pins
(2) and ball checks (1) slide through the straws
(3).
5. Remove the gerotor star from gerotor (4).

6. Using a splined shaft end no. 8063 tool (refer to
Special Tools), start the tool on the splined end
of the spool (9).
Bur 6-42390
Issued 8-01
Printed in U.S.A.
Copyright
5003-4
14
18
13
14
17
16
15
19
6
10
8
11
1
2
10
9
12
21
3
20
5
3
GS98K502
1.
2.
3.
4.
5.
6.
7.
CAP SCREW
END CAP
O-RING
GEROTOR
SPACER PLATE
DRIVE SHAFT
STEERING CONTROL HOUSING
8.
9.
10.
11.
12.
13.
14.
SLEEVE
SPOOL
BALL CHECK
PIN
CENTERING SPRING
NEEDLE THRUST BEARING
BEARING RACE
15.
16.
17.
18.
19.
20.
21.
BACKUP WASHER
SEAL RING
O-RING
RETAINING RING
DUST SEAL
BALL CHECK
ROLL PIN
FIGURE 2. STEERING CONTROL VALVE - EXPLODED VIEW
Bur 6-42390
Issued 8-01
Printed in U.S.A.
Copyright
5003-5
3
4
2
3
GS98K530
1. BALL CHECK
2. ROLL PIN
3. SODA STRAW
4. PORT FACE
5. ANTI-CAVITATION VALVES
FIGURE 3. ANTI-CAVITATION VALVE - DISASSEMBLY
Inspection
1. Clean all parts in cleaning solvent and air dry on
paper towels. Do not use cloths to wipe parts dry,
as it may leave lint on the parts.
2. Check all machined surfaces for wear or
damage. If there are rough places on the ends of
the gerotor star or gerotor (4), steering control
valve housing (7), end cap (2), or spacer plate
(5), use 600 grit emery cloth to smooth the
surfaces, refer to Figure 2. Place the emery cloth
on a flat surface. If the emery cloth is new, rub a
piece of steel across the emery cloth six times to
remove the sharp pieces of grit. Make sure that
the part is held flat on the emery cloth. Rub each
part across the cloth six times. Check to see if
the rough places are removed. Use this method
until all rough places are removed. Clean the
parts in cleaning solvent to remove any grit.
Bur 6-42390
3. If the spool (9) and sleeve (8) or the bore in the

housing of the steering control valve (7) is
damaged or worn, use a new steering control
valve.
4. Inspect the cap screws (1), pin (11), ball check
(10), backup washer (15), seal ring (16), O-ring
(17), needle thrust bearing (13) and bearing race
(14). Use new parts as required.
5. If your steering control valve has anti-cavitation
valves, inspect the ball checks (20) and roll pins
(21) for damage or wear. Use new parts as
required.
Issued 8-01
Printed in U.S.A.
Copyright
5003-6
Assembly
NOTE: Use new seals (3), (16), and (19) when
reassembling the steering control valve.
IMPORTANT: Lubricate the new seals with a
petroleum jelly. Lubricate machined surfaces with
clean hydraulic fluid.
1. Use a soda straw (3) as a guide tool, refer to
Figu re 4. Drop the stra w (3) in to th e
anti-cavitation valve (5) to the bottom of the bore.
Drop the ball check (2) through the straw (3). Pull
the straw (3) out and use the same procedure in
the second ball seat.
2
3
3. Lubricate the spool (3) with clean hydraulic fluid

and slide it into the sleeve (2), along with the ball
check (5), refer to Figure 5.
4. Install the drive shaft (1) and pin (4).
5. Install the centering spring (6). Position one end
of the centering spring (6) in slotted end of spool
(3) and sleeve (2). Compress the centering
spring (6) by turning it counter-clockwise to
engage the free end of the spring.
6. Install the bearing race (8) and retaining ring (7),
onto the spool (3), using retaining ring pliers.
7. Lubricate, using petroleum jelly, the ID of the
dust seal (19) that is mounted in the steering
control valve housing (7), refer to Figure 2.
8. Lubricate, using petroleum jelly, the needle thrust
bearing (13), second bearing race (14), backup
washer (15), seal ring (16) and O-ring (17).
Position each part onto the spool (9). The needle
th ru st b ea rin g (1 3) g oe s b e twe e n t he tw o
bearing races (14), and must be centered around
the retaining ring (18).
9. Lubricate, using clean hydraulic fluid, the spool
(9) and sleeve (8) assembly and slide it into the
steering control valve housing (7), as follows:
IMPORTANT: Do not damage the dust or shaft seals.
A. Protecting the gerotor star and hand with shop
towels, hold the gerotor star and splined end
of drive shaft (6) to keep it from turning.
5
GS98K504
1. ROLL PIN
2. BALL CHECK
3. SODA STRAW
4. PORT FACE
5. ANTI-CAVITATION
VALVES
FIGURE 4. OPTIONAL ANTI-CAVITATION VALVES ASSEMBLY
2. Use a small light and check each bore to make

sure each ball check (2) is in the correct place.
Add the roll pin (1) in each.
Bur 6-42390
B. Insert the splined shaft end No. 8063 (see

Special Tools this section), into the steering
control valve housing (7), and start it onto the
splined end of the spool (9). Turn the tool
clockwise or counter-clockwise to compress
the centering spring (12).
NOTE: If the unit is positioned horizontally, keep the
pin horizontal. If the tension on the pin is released
before the assembly is fully engaged, the pin can
drop and lockup can occur if the pin is not horizontal.
Issued 8-01
Printed in U.S.A.
Copyright
5003-7
5
1
2
4
5
2
1
4
6
8
7
3
GS98K505
1.
2.
3.
4.
DRIVE SHAFT
SLEEVE
SPOOL
PIN
5.
6.
7.
8.
BALL CHECK
CENTERING SPRING
RETAINING RING
BEARING RACE
FIGURE 5. SPOOL AND SLEEVE ASSEMBLY
Bur 6-42390
Issued 8-01
Printed in U.S.A.
Copyright
5003-8
10. Compressing the centering spring (12), carefully
in se r t th e a s se m b le d b e a r in g r a c e s ( 1 4 ),
retaining ring (18), needle thrust bearing (13),
backup washer (15), seal ring (16) and O-ring
(17).
11. Release the centering spring (12) tension.
12. Remove the gerotor star.
13. Remove the splined shaft end No. 8063 tool.
14. Lubricate new O-rings (3) and install in the
groove of the steering control valve housing (7).
Bur 6-42390
15. Install the spacer plate (5), O-ring (3), and align
th e h o le s in th e sp a ce r p la te (5 ) w ith th e
threaded holes in the housing (7).
16. Lubricate a new O-ring (3) and install into the
groove of the spacer plate (5).
17. Install the gerotor (4) and align the screw holes.
18. Lubricate a new O-ring (3) and install into the
groove in the gerotor ring (4).
19. Install the end cap (2) and seven cap screws (1).
Pre-tighten the cap screws in a criss-cross
pattern to 17 Nm (150 pound-inch), and finally, in
a criss-cross pattern, tighten cap screws (1) to
33 .9 N m (3 0 0 po u nd -in ch ). Se e SP ECIA L
TORQUES in this section.
Issued 8-01
Printed in U.S.A.
Copyright
STEERING PRIORITY VALVE
CASE CORPORATION
700 State Street
Bur 6-42400

Printed in U.S.A.
August, 2001
5004
Section
5004
Copyright
5004-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
......
......
......
......
......
.......
......
......
......
......
2
3
3
4
4
SPECIAL TORQUES
Spool Orifice Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 to 9.6 Nm (65 to 85 lb-inch).
Plugs and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9 to 54.2 Nm (25 to 40 lb-ft).
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 to 9.5 Nm (72 to 84 lb-inch).
Bur 6-42400
Issued 8-01
Printed in U.S.A.
Copyright
5004-3
STEERING PRIORITY VALVE

Disassembly
STEP 4
STEP 1
Remove plug (5). Remove and discard O-ring (6)

from plug.
Put the steering priority valve in a soft jawed vise.
STEP 5
STEP 2
Remove spring (7).
Remove adapter (1). Remove and discard O-ring (2)

from adapter.
STEP 6
Remove spool (8).
STEP 3
STEP 7
Remove relief valve (3). Remove and discard O-ring

(4) from relief valve.
3
1
Remove plug (9). Remove and discard O-ring (10)

from plug.
11
10
6
7
8
BS01E129
1.
2.
3.
4.
5.
6.
Bur 6-42400
ADAPTER
O-RING
RELIEF VALVE
O-RING
PLUG
O-RING
7.
8.
9.
10.
11.
SPRING
SPOOL
PLUG
O-RING
HOUSING
Issued 8-01
Printed in U.S.A.
Copyright
5004-4
Cleaning and Inspection
Assembly
STEP 8
STEP 12
Clean all parts in cleaning solvent. Immerse housing

(11) in cleaning solvent and agitate cleaning solvent.
WEAR EYE PROTECTION WHEN USING
COMPRESSED AIR. Use compressed air to remove
foreign matter from interior of valve housing and to
ensure that all orifices and bores are clear.
Install new O-ring (10) on plug (9). Install plug and

O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
(25 to 40 lb-ft).
STEP 9
STEP 14
Insp ect spo ol (8) a nd ho using b ore s for d ee p

scratches, gouges, and other damage. Replace
steering priority valve if any of these conditions are
seen.
Install new O-ring (6) on plug (5). Install plug and

O-ring. Tighten plug to a torque of 33.9 to 54.2 Nm
(25 to 40 lb-ft).
STEP 13
Install spool (8) and spring (7),
STEP 15
STEP 10
Install new O-ring (4) on relief valve (3). Install relief

valve and O-ring. Tighten relief valve to a torque of
33.9 to 54.2 Nm (25 to 40 lb-ft).
Check that orifice screws in each end of spool (8) are

fr e e a n d c le a r o f fo r e ig n m a tt e r. W E AR EY E
PROTECTION WHEN USING COMPRESSED AIR.
If n e c e ss a r y, r e m o ve o ri fic e s c re w s a n d u s e
compressed air to remove foreign matter from interior
of spool (8) and orifice screws. Install orifice screws
in spool (8) ends. Tighten screws to a torque of 7.3 to
9.6 Nm (65 to 85 lb-inch).
STEP 16
Install new O-ring (2) on adapter (1). Install adapter
and O-ring. Tighten adapter to a torque of 8.1 to 9.5
Nm (72 to 84 lb-inch).
STEP 11
Check spring (7) for cracks, breaks, or signs of
permanent set. Replace if any of these conditions are
seen.
3
1
11
10
6
7
8
BS01E129
1. ADAPTER
2. O-RING
3. RELIEF VALVE
Bur 6-42400
4. O-RING
5. PLUG
6. O-RING
7. SPRING
8. SPOOL
9. PLUG
10. O-RING
11. HOUSING
Issued 8-01
Printed in U.S.A.
Copyright
Section
5005
5005
STEERING CYLINDERS
CASE CORPORATION
700 State Street
Bur 6-42410

Printed in U.S.A.
August, 2001
Copyright
5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42410
Issued 8-01
......
......
......
......
......
......
......
......
......
......
3
3
3
3
5
Printed in U.S.A.
Copyright
5005-3
SPECIFICATIONS
Torque for piston cap screw...........................................................................585 to 720 Nm (431 to 531 pound-feet)
Torque for gland.............................................................................................339 to 475 Nm (250 to 350 pound-feet)
Weight ..........................................................................................................................................18kg (39.7 pounds)
STEERING CYLINDER
Disassembly
1. Fasten the tube (1) in a vise. Be careful not to
damage the tube (1). Refer to the illustration on
page 4.
2. Loosen and remove the gland (3) from the tube
(1).
3. Pull the piston (11) straight out of the tube (1).
Inspection
1. Discard the O-ring (6), backup ring (7), seal (4),
seal (5), wiper (9), and guide (8) from the gland
(3). Refer to the illustration on page 4.
2. Discard the seal (12), backup ring (13), and wear
ring (14) that were removed from the piston (11).
4. Fasten the yoke on the piston rod (10) in the vise

and put a support below the piston rod (10) near
the piston (11). Use a shop cloth between the
suppo rt and the pisto n rod (10) to prevent
damage to the piston rod (10).
3. Clean all parts in cleaning solvent.
5. Loosen and remove the bolt (15) and hardened

washer (16) that hold the piston (11).
5. Inspect the inside of the tube (1) for deep

grooves and other damage . If there is any
damage to the tube (1), a new tube (1) must be
used.
6. Remove the piston (11) from the piston rod (10).

7. Remove the seal (12), backup ring (13), and
wear ring (14) from the piston (11).
8. Remove the gland (3) from the piston rod (10).
9. Remove the O-ring (6), backup ring (7), seal (4),
seal (5), wiper (9), and guide (8) from the gland
(3).
Bur 6-42410
4. Check to be sure that the piston rod (10) is

straight. If the piston rod (10) is bent, install a
new piston rod (10).
6. Remove small scratches on the piston rod (10) or

inside the tube (1) with emery cloth of medium
grit. Use the emery cloth with a rotary motion.
7. Inspect the bushings (2) and replace as required.
Issued 8-01
Printed in U.S.A.
Copyright
5005-4
10
9
4
5
3
7
6
14
11
12
13
16
15
17
BS01B202
1.
2.
3.
4.
5.
6.
TUBE
BUSHING
GLAND
SEAL
SEAL
O-RING
7.
8.
9.
10.
11.
12.
BACKUP RING
GUIDE
WIPER
PISTON ROD
PISTON
SEAL
13.
14.
15.
16.
17.
BACKUP RING
WEAR RING
BOLT
HARDENED WASHER
GREASE FITTING
STEERING CYLINDER ILLUSTRATION
Bur 6-42410
Issued 8-01
Printed in U.S.A.
Copyright
5005-5
Assembly
1. Install the seal (4) in the gland (3). The seal (4)
must be installed so that the lips of the seal (4)
are toward the small end of the gland (3). The
seal (4) can be difficult to install. Use tools that
will n o t da ma ge th e s ea l (4 ). R efe r to th e
2. Install the seal (5) in the gland (3).
3. Install the guide (8) in the gland (3).
4. Install the wiper (9) in the gland (3).
5. Install the O-ring (6) on the gland (3). The O-ring
(6) must be toward the small end of the gland (3).
6. Install the backup ring (7) on the gland (3). The
backup ring (7) must be toward the large end of
the gland (3). If the backup ring (7) is not flat on
both sides, the side that is not flat must be
toward the O-ring (6).
7. Fasten the yoke on the piston rod (10) in the vise.
12. Install a new backup ring (13) on the piston (11).

13. Install a new seal (12) over the backup ring (13).
14. Clean the threads on the end of the piston rod
(10) and the threads of the bolt (15) using Loctite
cleaning solvent. Allow to dry. Apply Loctite 242
to the piston rod threads 1/4 inch from the open
end of the piston rod so that there is 1/2 inch of
Loctite 242 on the piston rod threads. DO NOT
apply Loctite to the first 1/4 inch of the piston rod
threads.
15. Install the bolt (15) and hardened washer (16) in
the piston (11).
16. Install the piston (11) on the piston rod (10) and
start the bolt (15) into the piston rod (10).
17. Tighten the bolt (15) according to torque
specifications listed on page 2.
18. Fasten the tube (1) in the vise. Be careful not to
damage the tube (1).
8. Lubricate the piston rod (10) and the bore in the

gland (3) with clean hydraulic oil.
19. Apply petroleum jelly to the O-ring (6) and

backup ring (7) on the gland (3) and to the
sealing surface in the tube (1).
NOTE: If a new gland (3) is being installed, write the

part number of the cylinder on the gland (3).
20. Lubricate the piston (11) and the inside of the

tube (1) with clean hydraulic oil.
9. Push the gland (3) onto the piston rod (10). If

necessary, use a soft hammer to drive the gland
(3) onto the piston rod (10).
21. Push the piston (11) straight into the tube (1). Be
careful not to damage the wear ring (14) and seal
(12) on the piston (11).
10. Put the support below and near the end of the
piston rod (10). Put a cloth between the support
and the piston rod (10) to prevent damage to the
piston rod (10).
22. When the piston (11) is in the smooth part of the

tube (1), start the gland (3) into the tube (1).
23. Tighten the gland (3) to 339 to 475 Nm (250 to
350 pound-feet).
11. Install a new wear ring (14) on the piston (11).
Bur 6-42410
Issued 8-01
Printed in U.S.A.
Copyright
5005-6
NOTES
Bur 6-42410
Issued 8-01
Printed in U.S.A.
Copyright
Section
5006
5006
CENTER PIVOT
CASE CORPORATION
700 State Street
Bur 6-42420

Printed in U.S.A.
August, 2001
Copyright
5006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42420
Issued 8-01
3
3
4
4
6
9
Printed in U.S.A.
Copyright
5006-3
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin.......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for the lower pin plate .......................................................................................124 Nm (91 pound-feet)
M12 bolts screws for the 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 IH molydisulfide grease
Steering cylinder rod eyes........................................................................................ Case IH molydisulfide grease
FLUIDS
Hydraulic system reservoir ..............................................................................................MS-1209, Hy-Tran Ultra
SPECIAL TOOLS
CAS-10219 ...................................................................................................................... Hand pump (hydraulic ram)
CAS-10512 ...................................................................................................................................... 10 ton ram (long)
CAS-10592 .......................................................................................................... Puller set, includes 24827 leg ends
CAS-10600 ............................................................................... Bearing cup and seal puller, includes 24850 adapter
CAS-10193 ............................................................................................................................. Vacuum pump (12 volt)
CAS-1960 .................................................................................. *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from CAS-10592)
Bur 6-42420
Issued 8-01
Printed in U.S.A.
Copyright
5006-4
CENTER PIVOT
Disassembly
19. Disconnect the supply hose.
1. Remove all dirt and grease from the area of the

center pivot. Park the machine on a level surface.
20. Install a cap on the hose and a plug in the fitting.
2. Lower the bucket until the bucket is flat on the

floor.
22. Loosen and remove the self-locking nut and bolt

that hold the pivot pin for the steering cylinder
rod eye.
4. Remove the covers from both sides of the

machine.
23. Remove the pivot pin from the rear frame and the
steering cylinder rod eye.
5. Disconnect the front wiring harness from the cab

floor.
24. Remove the washer from the rear frame. Move

the steering cylinder out of the way.
6. Remove any tie straps that fasten the front wiring

harness to the chassis near the center pivot.
25. Repeat steps 22, 23 and 24 for the other steering

cylinder.
7. Loosen and remove the nut and washer that

fasten the chassis ground wire and cab ground
wire to the studs.
26. Loosen and remove the Ferry head screws and

retainers that fasten the drive shaft to the front
yoke. Move the drive shaft out of the way.
8. Loosen and remove the bolt, lock washer, and

nut that fasten the clamp on the front wiring
harness to the bracket on the rear frame. Move
the front wiring harness out of the way.
27. Place two stands below and in contact with the

front frame.
9. Loosen and remove the fill plug for the hydraulic

reservoir.
reservoir. Start the vacuum pump.
11. Disconnect the brake hose from the backside of
front brake line bracket.
28. Install blocks between the rear axle and the rear
frame on both sides of the machine to prevent
the rear frame from tipping.
29. Put a jack in contact with both sides of the rear
frame near the center pivot area. Use another
jack at the rear of the machine to prevent the rear
frame from tipping.
12. Install a plug in the tube and a cap on the fitting.
30. Loosen and remove the bolt (1), washer (2), and
spacer (3) that fasten the upper pivot pin (4) to
the rear chassis (5), refer to Figure 1.
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 hardened

washers (2) that fasten the lower pin plate (15) to
the lower pivot pin (10).
15. Loosen and remove the bolts, lock washers, and

self-locking nuts that fasten the mounting bracket
for the hoses to the bracket on the front frame.
16. Loosen and remove the bolts, flat washers, and
self-locking nuts that fasten the bracket for the
hoses to the rear frame.
33. Loosen and remove the cap screws (1) and

washers (2) that fasten the lower pin plate (15) to
the bottom of the rear chassis (5).
17. Disconnect the return hose.
34. Use the ram and hand pump to remove the lower
pivot pin (10).
18. Install the cap on the hose and a plug in the

fitting.
35. Install the puller on the bottom spacer (14), see

Special Tools in this section.
Bur 6-42420
Issued 8-01
Printed in U.S.A.
Copyright
5006-5
1
2
3
4
5
1
6
8
9
5
10
6
5
A
5
16
11
12
8
8
13
14
2
1
15
2
BS01B225
1.
2.
3.
4.
BOLT
WASHER
SPACER
UPPER PIVOT PIN
5.
6.
7.
8.
REAR CHASSIS
SEAL
BEARING RETAINER
SHIM
9.
10.
11.
12.
UPPER PIVOT BEARING

LOWER PIVOT PIN
LOWER BEARING SPACER
LOWER PIVOT BEARING
13.
14.
15.
16.
BEARING RETAINER
BOTTOM SPACER
LOWER PIN PLATE
FRONT CHASSIS
FIGURE 1. CENTER PIVOT ASSEMBLY
Bur 6-42420
Issued 8-01
Printed in U.S.A.
Copyright
5006-6
36. Remove the bottom spacer (14).
38. Use prybars to turn the left rear wheel backwards
and the right rear wheel forward to move the front
of the rear frame to the left for access to the
bearings. Install blocks under the wheels to
prevent the rear frame from moving.
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.
Assembly
1. Pack the bearing cones with grease. See
Specifications in this section. Be careful not to
mix the bearing cones.
2. Lubricate the bore in the top pivot with grease.
See Specifications in this section for the correct
grease.
3. Install a bearing cup in the top pivot, refer to
Figure 2.
4. Install the bearing driver and plate.
41. Remove the bearing retainer (13) and shims (8).

42. Remove the lower bearing spacer (11) from the
top of the lower pivot.
43. Loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (7) and shims (8)
to the top of the top pivot.
44. Remove the bearing retainer (7) and shims (8).
45. Use the puller to remove the seal (6) from the top
of the bottom pivot.
46. Use the puller to remove the seal (6) from the
bottom of the top pivot.
47. Use an acceptable driver, the hydraulic ram, and
the h an d pu mp to r emo ve th e u pp e r p iv ot
bearing (9) from the top pivot. See Special Tools
in this section.
NOTE: The spacers are matched to the bearing
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.
48. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the lower pivot bearing
(12) from the bottom pivot. See Special Tools in
this section.
B1423A88J
FIGURE 2.
5. Tighten a nut on the screw until the bearing cup

is seated in the bore of the top pivot. Remove the
bearing driver and plate from the top pivot.
6. Install a bearing cone, spacer, the other bearing
cone, and the remaining bearing cup in the top
pivot, refer to Figure 3.
7. Install the bearing driver and plate.
is sea ted a ga in st the spa ce r. R emo ve th e
bearing driver and plate from the top pivot.
NOTE: The spacers are matched to the bearing

sets. Do not mix the spacers. Do not use the old
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).
B1424A88J
FIGURE 3.
Bur 6-42420
Issued 8-01
Printed in U.S.A.
Copyright
5006-7
9. Put the bearing retainer (7) in place on the upper
pivot bearing (9), refer to Figure 1.
10. Install the bearing driver and plate, refer to
Figure 4.
11. Tighten a nut on the screw until the bearing
retainer (7) is tight against the upper pivot
bearing (9).
17. Fill the other seal (6) for the top pivot with grease.
See Specifications in this section for the correct
grease.
18. Use an acceptable driver to install the seal (6) in
the bottom of the top pivot, refer to Figure 6.
19. The bottom of the seal (6) must be even with the
bottom of the top pivot.
B1425A88J
FIGURE 4.
B1430A88J
FIGURE 6.
12. Measure the gap between the bearing retainer

(7) and the top pivot. Make a record of the
measurement. Subtract 0.0762 to 0.1016 mm
(0.003 to 0.004 inch) from the measurement,
refer to Figure 4. Select shims (8) equal to that
value.
13. Remove the bearing driver, plate, and bearing
retainer (7) from the top pivot.
14. Install the shims (8) and the bearing retainer (7).
15. Install the washers (2) and bolts (1). Tighten the
bolts (1) to 124 Nm (92 pound-feet).
16. Install the seal (6) in the bearing retainer (7). The
top of the seal (6) must be even with the top of
the bearing retainer (7), refer to Figure 5.
20. Apply grease to the upper pivot pin (4).

21. Install the upper pivot pin (4) in the top pivot.
22. Lubricate the top pivot until grease is forced out
of the seal (6). See Specifications in this section.
23. Rotate the upper pivot pin (4) to check the
bearing assembly. The upper pivot pin (4) must
rotate smoothly, but not easily. Leave the upper
pivot pin (4) in place to keep dirt out of the upper
pivot bearing (9).
24. Lubricate the bore for the bottom pivot with
grease. Install a bearing cup in the bottom pivot.
Figure 7.
B1426A88J
FIGURE 5.
Bur 6-42420
B1427A88J
FIGURE 7.
Issued 8-01
Printed in U.S.A.
Copyright
5006-8
is seated in the bore in the bottom pivot.
27. Remove the bearing driver and plate from the
bottom pivot.
28. Install a bearing cone, spacer, the other bearing
cone, and the remaining bearing cup in the
bottom pivot.
Figure 8.
35. Measure the gap between the bearing retainer

(13) and the bottom pivot. Make a record of the
(0.003 to 0.004 inch) from the measurement.
Select shims (8) equal to that value.
36. Remove the bearing driver, plate and bearing
retainer (13) from the bottom pivot.
37. Install the shims (8), the bearing retainer (13),
washers (2) and bolts (1).
38. Tighten the bolts (1) to 124 Nm (92 pound-feet).
39. Fill the seal (6) for the bearing retainer (13) with
grease. See Specifications in this section for the
correct grease.
40. Install the seal (6) in the bearing retainer (13).
The bottom of the seal (6) must be even with the
bottom of the bearing retainer (13). Be careful
not to damage seal (6), refer to Figure 10.
B1428A88J
FIGURE 8.
30. Tighten a nut on the screw until the bottom

bearing cup is seated against the spacer.
31. Remove the bearing driver and plate from the
bottom pivot.
32. Put the bearing retainer (13) in place on the
lower pivot bearing (12).
Figure 9.
B1430A88J
FIGURE 10.
41. Install the other seal (6) in the bottom pivot, refer
to Figure 11. The top of the seal (6) must be even
with the top of the bottom pivot.
B1429A88J
FIGURE 9.
34. Tighten a nut on the screw until the bearing

retainer (13) is tight against the lower pivot
bearing (12).
Bur 6-42420
B1426A88J
FIGURE 11.
42. Install the lower bearing spacer (11) and the

bottom spacer (14).
Issued 8-01
Printed in U.S.A.
Copyright
5006-9
43. Apply grease to the lower pivot pin (10). See
Specifications in this section.
44. Install the lower pivot pin (10) in the bottom pivot.
45. Hold the bottom spacer (14) in place and
lubricate the bottom pivot until grease is forced
out of the seal (6).
46. Rotate the lower pivot pin (10) to check the

bearing assembly. The lower pivot pin (10) must
rotate smoothly, but not easily.
47. Remove the lower pivot pin (10) and the upper
pivot pin (4).
48. Remove the bottom spacer (14).
CONNECTING THE FRONT FRAME TO THE REAR FRAME

20. Remove the blocks from the rear axle.
2. Move the rear frame into alignment with the front

frame.
21. Remove the stands from the front frame.

22. Put the drive shaft in position on the front yoke.
3. Move the steering cylinders as required to move

the rear frame into alignment with the front
frame.
23. Install new Ferry head screws that fasten the

drive shaft to the front yoke.
24. Tighten the Ferry head screws to 61 to 81 Nm

(45 to 60 pound-feet).
5. Apply grease to the upper pivot pin (4), refer to

Figure 1.
6. Install the upper pivot pin (4), spacer (3), washer
(2) and bolt (1). Be careful not to damage the
seal (6).
7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184
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.
26. Align the hole in the pivot pin with the holes in the
steering cylinder rod eye, and install the pivot
pin.
8. Apply grease to the lower pivot pin (10).
27. Install the bolt and self-locking nut that hold the
pivot pin.
9. Install the lower pivot pin (10) in the frames. Be

careful not to damage the seal (6).
28. Repeat steps 25, 26 and 27 for the other steering

cylinder.
10. Use the ram and hand pump to install the bottom
spacer (14). See Special Tools in this section.
11. Install the lower pin plate (15), three inner bolts
(1), and washers (2) that fasten the lower pin
plate (15) to the lower pivot pin (10).
12. Tighten the bolts (1) to 69 Nm (51 pound-feet).
13. Measure the gap between the lower pin plate
(15) and the bottom pivot. Make a record of the
(0.003 to 0.004 inch) from the measurement.
Select shims equal to that value.
14. Loosen the bolts (1) that fasten the lower pin
plate (15) to the lower pivot pin (10).

30. Connect the return hose.
31. Connect the supply hose.
32. Put the bracket for the hoses in position on the
rear frame. Install the bolts, flat washers, and
self-locking nuts that fasten the bracket to the
rear frame.
33. Put the bracket for the hoses in position on the
front frame.
34. Install the bolts, flat washers, and self-locking
nuts that fasten the bracket to the front frame.
35. Connect the hoses for the steering cylinders.
15. Start the six outer bolts (1) into the lower pin
plate (15) and the bottom pivot.
36. Connect the brake hose for the front brakes at

the front bracket.
16. Install the shims (8).
17. Tighten the six outer bolts (1) to 128 to 136 Nm

(94 to 100 pound-feet).
38. Connect the front wiring harness to the rear

wiring harness.
18. Tighten the three inner bolts (1) to 124 Nm (92

pound-feet).
19. Remove the jacks from the rear frame.
Bur 6-42420
Issued 8-01
Printed in U.S.A.
Copyright
5006-10
39. Put the clamp on the wiring harness in position
on the bracket. Install the bolt, lock washer, and
nut that fasten the clamp on the wiring harness to
the bracket.
40. Put the ground wire in position on the stud. Install
the washer and nut that fasten the ground wire to
the stud.
41. Install a tie strap to fasten the wiring harness to
the tube.
42. Disconnect the vacuum pump from the hydraulic
reservoir.
Bur 6-42420

Add oil as required. See Specifications in this
section.
44. Install the fill plug on the hydraulic reservoir.
45. Bleed air from the front axle bleed screws. Refer
to Section 7002 for complete brake bleeding
instructions.
46. Lubricate the pivot pins for the steering cylinder
rod eyes.
47. Install the covers on both sides of the machine.
Issued 8-01
Printed in U.S.A.
Copyright
Section
5008
5008
AUXILIARY STEERING MOTOR AND PUMP
CASE CORPORATION
700 State Street
Bur 6-42430

Printed in U.S.A.
August, 2001
Copyright
5008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42430
Issued 8-01
3
4
4
4
4
Printed in U.S.A.
Copyright
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)
Bur 6-42430
Issued 8-01
Printed in U.S.A.
Copyright
5008-4
AUXILIARY STEERING MOTOR AND PUMP

Disassembly
Assembly
NOTE: Refer to Section 5001 for removal and

installation of the auxiliary steering motor and pump.
1. Lubricate all parts with clean hydraulic oil before

assembly.
NOTE: The pump is the only component that is

disassembled. The switch (8) and motor (1) are
replaced as units and are not serviced. Refer to the
2. Lubricate and install a new seal (4) and retaining

ring (3) on the plate (17). Refer to the illustration
on page 5.
1. Make an alignment mark on the pump assembly

and motor (1).
2. Loosen and remove the two screws (15) and lock
washers (14) that hold the pump assembly to the
motor (1).
3. Remove and discard the mounting gasket (13),
retaining ring (3) and seal (4) from the pump
assembly.
4. Loosen and remove the four bolts (2) that hold
the pump assembly together.
5. Remove the end plate (21) from the body (18).
6. Remove and discard the seal (6) and backup ring
(5) from the end plate (21).
7. Remove the wear plate (23), drive gear (20) and
driven gear (19) from the body (18).
8. Remove the body (18) from the plate (17).
9. Remove and discard the O-rings (7) from the
body (18).
3. Lubricate and install a new backup ring (5) and a

new seal (6) on the plate (17).
4. Lubricate and install new O-rings (7) on the body
(18).
5. Lubricate and install the pins (22), drive gear
(20), driven gear (19) and wear plates (23) on the
body (18).
6. Lubricate and install a new backup ring (5) and a
new seal (6) on the end plate (21).
7. Align the marks, made during disassembly, on
the end plate (21), body (18) and plate (17) and
install the four bolts (2). Tighten the four bolts (2).
8. Install a new gasket (13) on the pump assembly.
9. Align the marks, made during disassembly, on
the pump assembly and the motor (1).
10. Install the lock washer (14) and screw (15).
Torque the screw (15) to 35 to 39 Nm (312 to 348
pound-inches).
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.
Bur 6-42430
Issued 8-01
Printed in U.S.A.
Copyright
5008-5
10
11
16
12
1
13
3
17
14
15
5
6
23
19
7
22
18
22
7
20
23
6
5
21
2
BS01C121
1.
2.
3.
4.
5.
6.
MOTOR
BOLT
RETAINING RING
SEAL
BACKUP RING
SEAL
7.
8.
9.
10.
11.
12.
O-RING
SWITCH
CABLE
SCREW
LOCK WASHER
WASHER
13.
14.
15.
16.
17.
18.
GASKET
LOCK WASHER
SCREW
WIRE
PLATE
BODY
19.
20.
21.
22.
23.
DRIVEN GEAR
DRIVE GEAR
END PLATE
PINS
WEAR PLATE
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
Bur 6-42430
Issued 8-01
Printed in U.S.A.
Copyright
5008-6
NOTES
Bur 6-42430
Issued 8-01
Printed in U.S.A.
Copyright
SECTION INDEX
POWER TRAIN
Section Title
Section Number
Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001

Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Front and Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Front and Rear Axle P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Drive Shafts, Center Bearing, and Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006
Transmission Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6007
((Re
CASE CORPORATION
700 State Street
Bur 6-42442

Printed in U.S.A.
Copyright
6001
Copyright
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN
COMPONENTS
CASE CORPORATION
700 State Street
Bur 6-42451

Printed in U.S.A.
August, 2001 (Revised 2-03)
Copyright
6001-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . .
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Mounting . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Axle Mounting . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Mounting . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
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.................... 2
................... 3
................... 3
. . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . 26
SPECIAL TORQUES
RH and LH Mounting Brackets to Transmission Mounting Bolts . . . . . . . . . . . . . . 481 to 590 Nm (355 to 435 lb-ft)
Top Mounting Bracket to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 251 to 319 Nm (185 to 235 lb-ft)
Transmission Mounting Brackets to Chassis Mounting Bolts . . . . . . . . . . . . . . . . 890 to 1000 Nm (655 to 735 lb-ft)
Engine Drive Shaft to Transmission Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 41 Nm (25 to 30 lb-ft)
Fuel Supply Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Nm (30 lb-inch)
Fuel Return Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Nm (30 lb-inch)
Transmission Fill Tube Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 33 Nm (12 to 24 lb-ft)
Rear Drive Shaft to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft)
Center Drive Shaft to Transmission Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft)
Front Axle Mounting Bolts
P.I.N. JEE0135500 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .845 to 950 Nm (625 to 700 lb-ft)
P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955 to 1075 Nm (705 to 790 lb-ft)
Wheel Bolts
Preliminary Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 Nm (220 lb-ft)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640 to 720 Nm (475 to 530 lb-ft)
Center Bearing Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 to 128 Nm (73 to 94 lb-ft)
Front Drive Shaft Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 to 81 Nm (45 to 60 lb-ft).
Pivot Pin Caps Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 to 280 Nm (185 to 205 lb-ft)
Rear Drive Shaft to Rear Axle Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 to 81 Nm (45 to 60 lb-ft)
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-3
TRANSMISSION
STEP 4
Removal
STEP 1
Note amount of fuel in fuel tank then refer to Section
9007 and remove ROPS cab or ROPS canopy.
9
6
STEP 2
BD01D304
BD01D321
P u t a 3 7 . 8 l it e r ( 1 0 g a l lo n ) c o n t a in e r u n d e r
transmission drain plug (1). Remove drain plug and
drain transmission oil. Install drain plug after oil has
drained.
Loosen clamp (8). Disconnect suction hose (5) from

hydraulic reservoir and remove with tube assembly
(4) attached from machine. Disconnect case drain
hose (6) from fitting (9); remove hose (6). Remove
and discard O-ring face seal from fitting. Plug hoses
and cap fittings to prevent entry of foreign matter into
hydraulic system.
STEP 5
11
STEP 3
13
14
10
2
5
7
12
BD01D308
3
BD01D303
Remove four bolts (2) and washers. Remove two

split flanges (3). Disconnect tube assembly (4) with
suction hose (5) attached from hydraulic pump.
Remove and discard O-ring face seal from flange
head of tube assembly. Tag and disconnect case
drain hose (6) from fitting (7). Remove and discard
O -ring fa ce se al fro m fitting . Plu g h os e, tu b e
assembly, and pump port and cap fitting to prevent
intrusion of foreign matter into hydraulic system.
Bur 6-42451
Identify, tag, and disconnect pump load sensing hose

(10). Remove and discard O-ring face seal from
fitting (11). Remove four bolts (12) and washers.
Remove two split flanges (13). Disconnect pump
pressure hose (14) from hydraulic pump. Remove
and discard O-ring face seal from flange head of
hose (14). Plug hoses and pump port and cap fitting.
Revised 2-03
Printed in U.S.A.
Copyright
6001-4
STEP 6
STEP 9
15
17
22
18
23
16
BD01D306
BD01D310
Identify, tag, and disconnect brake pump pressure

hose (15) and brake to hydraulic reservoir hose (16).
Position hoses away from transmission. Remove and
discard O-ring face seals from fittings (17 and 18).
Remove two socket head bolts securing transmission

wiring harness clamps (22 and 23).
STEP 10
STEP 7
24
25
26
19
20
BD01D312
BD01D315
Disconnect transmission wiring harness connector

(19) from control valve connector. Remove socket
head bolt securing wiring harness clamp (20). Move
wiring harness away from transmission.
Identify, tag, and disconnect transmission wiring

harness connectors from engine speed sensor (24),
intermediate speed sensor (25), and turbine speed
sensor (26). Move transmission wiring harness away
from transmission.
STEP 11
STEP 8
27
21
BD01D316
BD01D317
Just above where clamp (20) was installed, tag and

disconnect transmission wiring harness connector
(21) from torque converter output sender. Move
wiring harness away from transmission.
Bur 6-42451
Remove socket head bolt securing wiring harness

c la m p ( 2 7 ) . M o v e w ir in g h a r n e s s a w a y f r o m
transmission.
Revised 2-03
Printed in U.S.A.
Copyright
6001-5
STEP 12
STEP 15
34
37
28
35
36
29
38
BD01D314
BD01D296
Identify, tag, and disconnect transmission wiring

harness connectors from filter maintenance switch
(28 ) a nd ou tp ut sp eed se nso r (2 9). Mo ve
transmission wiring harness away from transmission.
At front of transmission, identify, tag, and disconnect

parking brake hose (34) from parking brake (35).
Move hose away from transmission. Remove four
bolts (36) and two straps (37) securing center drive
shaft (38) to transmission output flange. Disconnect
center drive shaft from transmission.
STEP 13
STEP 16
30
39
31
32
41
BD01D333
40
Connect lifting equipment to hydraulic pump (30);

take care not to damage pump tube assembly (31).
Take up all slack in lifting equipment. Remove two
bolts (32) and washers securing pump to
transmission.
Remove four bolts (39) and two straps (40) securing

rear drive shaft (41) to transmission output flange.
Disconnect rear drive shaft from transmission.
STEP 14
STEP 17
BD01D323
43
42
33
44
BD01D335
BD01D324
Pull hydraulic pump from transmission and remove

from loader. Remove and discard O-ring (33).
Remove two bolts (42) securing hose bracket (43) to

transmission. Remove bracket from transmission
and lay on rear axle brake hose (44).
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-6
STEP 18
STEP 21
46
50
45
BD01D322
BD01D339
Remove two bolts (45). Remove fill tube (46), with

cap and oil gauge assembled, two seals, and metal
strainer. Discard seals.
Remove fitting (50). Remove and discard O-ring from

fitting.
STEP 22
STEP 19
51
52
48
47
BD01D340
BD01D329
Remove two bolts (47) and washers securing hose

retainer (48) to front of rear chassis. Move hose
retainer towards front of machine.
Repeat Steps 20 and 21 to remove cooler hose (51)

and fitting (52).
STEP 20
50
49
BD01D318
Identify, tag, and disconnect cooler hose (49) from

fitting (50) installed in LH side of transmission.
Remove and discard O-ring face seal from fitting
(50).
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-7
STEP 23
STEP 25
57
63
53
56
53
62
64
BD01D338
BD01D326
At bottom center of fuel tank, loosen clamp (62).

Disconnect fuel supply hose (63) and remove clamp.
Plug fuel supply hose and cap fuel tank fitting (64).
STEP 26
65
55
55
66
54
54
BD01D341
Remove fo ur bolts (5 3) and washe rs securin g

mounting brackets (54), spacers (55), parking brake
accumulator (56), and brake accumulators (57) to
rear chassis. Move assembled parts away from
transmission as shown.
67
BD01D328
Remove lock nut (65), washers, and bolt. Remove

vent cover (66) and breather valve installed in vent
hose (67). Route vent hose with breather valve down
to fuel tank.
STEP 24
59
STEP 27
60
61
58
BD01D335
Place a container large enough to hold fuel in fuel

tank under drain valve (58). Open drain valve (58)
and drain fuel tank. Close drain valve after fuel has
drained. Loosen clamp (59) and disconnect fuel
return hose (60). Remove clamp. Plug fuel return
hose and cap fuel tank fitting (61).
Bur 6-42451
68
BD01D330
Identify, tag, and disconnect wiring harness wires

from fuel level sender (68).
Revised 2-03
Printed in U.S.A.
Copyright
6001-8
STEP 28
STEP 30
73
72
74
75
70
75
A
76
BD01D332
69
69
69
BD01D342
In area between rear of transmission and front of

engine, remove four bolts (72) and two straps (73).
Discard bolts (72) and straps (73). Use pry bar to
disconnect engine drive shaft (74) from transmission.
Using 3/4 inch drive socket, extensions, and impact
wrench, remove four bolts (75) and washers securing
transmission to top mounting bracket (76).
69
69
STEP 31
69
BD01D327
Position a hydraulic jack (A) under fuel tank plate

(70) to support fuel tank and plate. Jack must be at
center of plate and as far rearward as possible.
Loosen and remove six bolts (69) and washers. With
an assistant, slowly lower hydraulic jack and carefully
move fuel tank and plate from under machine.
79
80
77
78
STEP 29
BD01D337
Loosen two bolts (77) securing RH and LH mounting

brackets (78) to transmission. Remove bolts (79) and
washers (80) securing RH and LH mounting brackets
(78) to rear chassis.
71
71
BD01D343
Connect lifting equipment to transmission lifting eyes

(71). Take up all slack in lifting equipment.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-9
STEP 32
STEP 34
82
81
78
76
77
BD01D344
BD01D361
Raise transmission just enough to enable removal of

RH and LH mounting brackets (78). Remove two
b o lt s ( 7 7 ) a n d w a s h e r s s e cu ri n g R H a n d L H
mounting brackets (78) to transmission. Remove RH
and LH mounting brackets.
If top mounting bracket (76) requires removal,

remove bolt (81) and washer (82) then remove
bracket.
STEP 33
BD01D345
Slowly and carefully raise transmission from loader

while checking that all hoses, electrical connectors,
and wires have been disconnected and nothing
interferes with transmission. Remove transmission
from loader.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-10
Transmission Mounting
79
79 81
80 82
C
80
83
83
77
ISOLATOR
INSTALLATION
81
77
82
78
83
79
76
80
75
77
83
75
A
77
78
BS01E012
75.
76.
77.
78.
79.
80.
Bur 6-42451
BOLT
TOP MOUNTING BRACKET
BOLT
MOUNTING BRACKET
BOLT
WASHER
81.
82.
83.
A.
B.
C.
BOLT
WASHER
ISOLATOR
REAR CHASSIS TRUNNION
BRACKET (76 OR 78)
SMALLER PIECE ON TOP
Revised 2-03
Printed in U.S.A.
Copyright
6001-11
STEP 38
Installation
STEP 35
C he c k is ola t o rs ( 8 3 ) fo r d e te r io ra tio n , te a r s,
deformation, or other damage. Replace as
necessary: refer to Page 10.
STEP 36
78
82
81
77
BD01D344
Ins tall R H a nd L H mou n tin g br ac ket s (7 8 ) o n

transmission using two washers and bolts (77). Do
not tighten bolts.
STEP 39
76
BD01D361
If top mounting bracket (76) was removed, position

bracket on rear chassis trunnion and secure using
washer (82) and bolt (81). Do not tighten bolt.
79
80
STEP 37
77
78
BD01D337
Loosely install washers (80) and bolts (79) to secure

RH and LH mounting brackets (78) to rear chassis.
Tighten bolts (77) securing RH and LH mounting
brackets to transmission to a torque of 481 to 590
Nm (355 to 435 lb-ft).
BD01D345
Move transmission into position above loader. Slowly

lower transmission into loader.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-12
STEP 40
STEP 42
NOTE: In this step, new straps (73) and bolts (72)

must be installed whenever these parts are removed.
Bolts have a nylon patch to maintain torque which
requires new bolts.
73
71
72
71
81
74
75
BD01D343
Disconnect lifting equipment from transmission lifting

eyes (71).
75
76
BD01D342
STEP 43
Using 3/4 inch drive socket, extensions, and impact

wrench, install four washers and bolts (75) to secure
top mounting bracket (76) to transmission. Then
tighten bolts (75) to a torque of 251 to 319 Nm (185
to 235 lb-ft). If bracket (76) had been removed,
tighten bolt (81) to a torque of 890 to 1000 Nm (655
to 735 lb-ft). Connect engine drive shaft (74) to
transmission. Install two new straps (73) and four
new bolts (72). Tighten bolts (72) to a torque of 34 to
41 Nm (25 to 30 lb-ft).
70
A
STEP 41
BD01D332
69
69
79
69
69
69
69
BD01D337
Tighten bolts (79) securing RH and LH mounting

brackets to a torque of 890 to 1000 Nm (655 to 735
lb-ft).
Bur 6-42451
BD01D327
Put fuel tank and plate (70) on hydraulic jack (A) and,
with an assistant, move into position beneath loader.
Make sure vent hose (67, Step 45) with breather
installed is routed up into engine compartment when
fuel tank is raised. Raise fuel tank and plate, align
mounting holes, and secure using six washers and
bolts (69). Lower and remove hydraulic jack (A) from
under fuel tank plate.
Revised 2-03
Printed in U.S.A.
Copyright
6001-13
STEP 44
STEP 47
59
60
61
68
58
BD01D330
BD01D335
Connect wiring harness wires to fuel level sender

(68) following tags installed during removal. Remove
and discard tags.
Remove plug from fuel return hose (60) and cap from
fitting (61). Put clamp (59) on fuel return hose.
Connect hose to fitting (61) and tighten clamp to a
torque of 3.4 Nm (30 lb-inch). Check that drain valve
(58) is closed.
STEP 45
STEP 48.
65
66
67
55
55
54
BD01D328
54
Route vent hose (67) with breather valve up towards

RH side of fan shroud. Put breather valve in vent
cover (66). Install washer and bolt, then washer and
nut (65) to secure vent cover and breather valve.
BD01D338
57
STEP 46
63
62
53
56
53
BD01D341
64
BD01D326
Mo v e m o u nt in g b r a ck e ts ( 5 4 ), p a r kin g b ra k e
accumulator (56), and brake accumulators (57) into
position. Secure to rear chassis using four spacers
(55), washers, and bolts (53).
Remove plug from fuel supply hose (63) and cap

from fuel tank fitting (64). Put clamp (62) on hose
(63). Connect fuel supply hose and tighten clamp to
a torque of 3.4 Nm (30 lb-inch).
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-14
STEP 49
STEP 52
51
46
52
45
BD01D340
BD01D322
Install new O-ring on fitting (52) and install fitting in

transmission. Install new O-ring face seal in fitting
then connect cooler hose (51) to fitting following tag
Position fill tube (46), two new seals, and metal

strainer on transmission; metal strainer is installed
between seals. Secure using two bolts (45). Tighten
bolts to a torque of 17 to 33 Nm (12 to 24 lb-ft).
STEP 50
STEP 53
50
43
49
42
44
BD01D318
BD01D324
Install new O-ring on fitting (50) and install fitting in

transmission. Install new O-ring face seal in fitting
then connect cooler hose (49) to fitting following tag
Position hose bracket (43) with rear axle brake hose

(44) on transmission. Install two bolts (42) to secure
hose bracket to transmission.
STEP 54
STEP 51
39
41
48
47
BD01D323
BD01D329
Position hose retainer (48) on front of rear chassis

and secure using two washers and bolts (47).
Bur 6-42451
40
Connect rear drive shaft (41) to transmission then

install two straps (40) and four bolts (39). Tighten
Revised 2-03
Printed in U.S.A.
Copyright
6001-15
STEP 55
STEP 58
34
37
28
35
36
29
38
BD01D296
BD01D314
Connect center drive shaft (38) to transmission and

install two straps (37) and four bolts (36). Tighten
Connect parking brake hose (34) to parking brake
(35) following tag installed during removal. Remove
and discard tag.
Connect transmission wiring harness connectors to

output speed sensor (29) and filter maintenance
switch (28) following tags installed during removal.
Remove and discard tags.
STEP 59
STEP 56
27
31
33
30
BD01D316
BD01D335
Install new O-ring (33) on hydraulic pump (30). Move

pump into position taking care not to damage pump
tube assembly (31) and install pump in transmission.
Install socket head bolt to secure wiring harness

clamp (27).
STEP 60
STEP 57
24
26
25
BD01D312
32
BD01D333
Install two washers and bolts (32) to secure pump to

transmission. Disconnect lifting equipment from
pump.
Bur 6-42451
Connect transmission wiring harness connectors to

turbine speed sensor (26), intermediate speed
sensor (25), and engine speed sensor (24) following
tags installed during removal. Remove and discard
tags.
Revised 2-03
Printed in U.S.A.
Copyright
6001-16
STEP 61
STEP 64
15
17
22
18
23
16
BD01D310
BD01D306
Install two socket head bolts to secure transmission

wiring harness clamps (23 and 22).
At brake valve, install new O-ring face seals in fittings

(18 and 17). Connect brake to hydraulic reservoir
hose (16) and brake pump pressure hose (15)
following tags installed during removal. Remove and
discard tags.
STEP 62
STEP 65
21
11
13
14
10
BD01D317
Connect transmission wiring harness connector (21)

to torque converter output sender following tag
12
BD01D308
At hydraulic pump, remove cap from fitting (11) and

plugs from hoses (14 and 10) and pump port. Install
new O-ring face seal in flange head of hose (14).
Position pump pressure hose (14) on pump port and
secure using two split flanges (13) and four washers
and bolts (12). Install new O-ring face seal in fitting
(11). Connect pump load sensing hose (10) to fitting
discard tag.
STEP 63
19
20
BD01D315
Install socket head bolt to secure wiring harness

clamp (20). Connect transmission wiring harness
connector (19) to control valve connector.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-17
STEP 66
STEP 68
9
6
1
BD01D304
Remove plugs from hoses and caps from fittings.

Install new O-ring face seal in fitting (9). Connect
hydraulic pump case drain hose (6) to fitting (9).
Position suction hose (5) between reservoir port and
hydraulic pump inlet port. Connect suction hose (5)
to hydraulic reservoir. Tighten clamp (8).
BD01D321
Check that transmission drain plug (1) is tight.
STEP 69
STEP 67
4
2
5
7
BS00M474A
Fill transmission with MS-1209 Hy-Tran Ultra oil

until oil level is up to the arrow. Fill fuel tank with fuel
drained in Step 24.
3
BD01D303
At hydraulic pump, remove plug from hoses (6 and 4)

and pump port and cap from fitting (7). Install new
O-ring face seal in fitting (7). Connect pump case
drain hose (6) to fitting (7) following tag installed
during removal. Install new O-ring face seal in flange
head of tube assembly (4). Position tube assembly
(4) with hose (5) on hydraulic pump port. Install two
split flanges (3) and secure using four washers and
bolts (2).
Bur 6-42451
STEP 70
Refer to Section 9007 and install ROPS cab or
ROPS canopy.
STEP 71
Start and run engine at idle speed with transmission
in neutral. If transmission oil level is at or below
bottom of crosshatch region, put articulation lock in
LOCKED position and add MS-1209 Hy-Tran Ultra
oil until oil level is up to crosshatch region. Shut down
engine and put articulation lock in OPERATING
position.
Revised 2-03
Printed in U.S.A.
Copyright
6001-18
FRONT AXLE
STEP 75
Removal
STEP 72
3
1
1
BD01D370
BD00M030
Park machine on level surface. Have assistant put

articulation lock in LOCKED position.

front drive shaft (3) to front axle.
STEP 76
4
STEP 73
8
5
7
9
5
6
BD01D368
BD00M048
Raise bucket and have assistant install safety link.

L o w e r lo a d e r a r ms slo w ly u n til s a fe t y lin k is
supporting loader arms.
STEP 74
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
Bur 6-42451
Remove clamp securing lubrication hose (4) to

machine and nut securing opposite end of hose (4).
center drive shaft (7) to front drive shaft (3). Use a
pry bar to separate drive shafts. While supporting
center bearing (9) and front drive shaft (3), remove
four nuts and bolts (8) and eight washers. Lower
center bearing and front drive shaft from mounting
plate and remove from machine.
Revised 2-03
Printed in U.S.A.
Copyright
6001-19
STEP 77
STEP 80
11
10
BD01D371
Disconnect brake hose (10) from fitting (11). Remove

and discard O-ring face seal from fitting.
BD01D412
Use an acceptable jack to hold front axle.
STEP 81
STEP 78
12
13
BD01D391
BD01D393
Remove 10 bolts (12) and washers from front wheels

(13). Remove both wheels from front axle.
STEP 82
14
BD01D392
Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand
under machine.
BD01D394
STEP 79
Remove eight nuts and bolts (14) and 16 washers

securing front axle to machine.
Repeat Step 78 to raise other front axle tire from

ground.
STEP 83
Carefully lower front axle and remove from under
machine.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-20
Front Axle Mounting
14
14
15
15
18
16
16
17
17
BS01E054
14. BOLT
15. WASHER
16. WASHER
Bur 6-42451
17. NUT
18. FRONT AXLE
Revised 2-03
Printed in U.S.A.
Copyright
6001-21
STEP 87
Installation
STEP 84
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 85
14
BD01D412
Remove jack from front axle.
STEP 88
BD01D394
Install eight washers (15), bolts (14), washers (16),

and nuts (17) to secure front axle to machine. For
machines P.I.N. JEE0135500 and below, tighten
bolts to a torque of 845 to 950 Nm (625 to 700 lb-ft);
for machines P.I.N. JEE0135501 and above, tighten
STEP 86
BD01D393
12
13
BD01D391
BD01D392
Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.
STEP 89
Repeat Step 88 to remove other jack stand from
under machine.
BS00J104
Install both wheels (13) on front axle and secure

using 10 washers and bolts (12). Tighten bolts to a
preliminary torque of 298 Nm (220 lb-ft) in sequence
indicated; then tighten to a torque of 640 to 720 Nm
(475 to 530 lb-ft) in same sequence.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-22
STEP 90
STEP 92
2
11
1
10
3
1
BD01D371
BD01D370
Install a new O-ring face seal in fitting (11). Connect

brake hose (10) to fitting.
Secure drive shaft (3) to front axle using two straps

(2) and four bolts (1). Tighten bolts (1) to a torque of
61 to 81 Nm (45 to 60 lb-ft).
STEP 91
STEP 93
If necessary, fill axle with gear lubricant specified in

Section 1002.
STEP 94
Refer to Section 7002 and bleed brakes.
STEP 95
9
5
6
BD01D368
Position and support center bearing (9) and front

drive shaft (3) and install eight washers and four
bolts (8) and nuts. Tighten bolts (8) to a torque of 99
to 128 Nm (73 to 94 lb-ft). Install two straps (6) and
four bolts (5). Tighten bolts (5) to a torque of 61 to 81
Nm (45 to 60 lb-ft). Secure lubrication hose (4) to
machine using clamp; secure opposite end of hose
using nut.
BD00M048
Start eng ine and raise b ucket. Have assistant

remove safety link. Lower bucket to ground and stop
engine.
STEP 96
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-23
REAR AXLE
STEP 102
Removal
STEP 97
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. Note amount of fuel
in fuel tank then put key switch in OFF position.
STEP 98
BD01D369
Disconnect brake hose (4) from fitting (5). Remove

and discard O-ring face seal from fitting.
STEP 103
BD00M030
STEP 99
Remove fuel tank (Steps 24 through 28).
BD01D410
STEP 100
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.
Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.
STEP 104
STEP 101
2
3
BD01D414
BD01D362
Use an acceptable jack to hold rear axle.
Remove four bolts (1) and two straps (2). Use a pry
bar to disconnect rear drive shaft (3) from rear axle.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-24
STEP 105
STEP 106
6
8
10
A
A
10
12
BD01D391
BD01D363
Remove 10 bolts (6) and washers (7) from rear

wheels (8). Remove both wheels from rear axle.
At front of trunnion (9), remove two Allen head bolts

(10) and washers (11). Remove front cap (12): 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
(15) from cap. Repeat this step at rear of trunnion
except remove and retain shim(s) (14) after removal
of rear cap (13). Remove pivot shaft (16) using
acceptable sleeve or rod if necessary.
STEP 107
Carefully lower rear axle and remove through side of
machine.
STEP 108
Remove and discard two seals (17) from rear axle
pivot point.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-25
Rear Axle Mounting
10
9
12
11
17
15
10
11
7
14
16
11
18
15
10
17
11
13
10
BS01E055
6.
7.
9.
10.
Bur 6-42451
BOLT
WASHER
TRUNNION
BOLT
11.
12.
13.
14.
WASHER
FRONT CAP
REAR CAP
SHIM(S)
15.
16.
17.
18.
O-RING
PIVOT PIN
SEAL
REAR AXLE
Revised 2-03
Printed in U.S.A.
Copyright
6001-26
STEP 110
Installation
NOTE: If shim(s) (14) have been lost or pivot pin
(16) has been replaced, do Step 109 to determine
required shim(s) otherwise go to Step 110.
STEP 109
10
16
13
10
12
BD01D482A
A
B
BS01E091A
Install pivot pin (16) and caps (12 and 13) in trunnion
(9) without rear axle or shim(s). Install washers (11)
a n d b o lt s (1 0 ) . Tig h t e n b o l ts se cu re ly. P u s h
assembled pivot pin and caps to rear of machine as
far as possible. Measure and record gap (A) between
rear cap (13) and trunnion. Select shims from the
following:
NOTE: Shims are available in following sizes: 0.50
mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm
(0.059 inch).
MEASURED
GAP (mm)
SHIM(S) REQUIRED
(mm)
0.07 to 0.55
None
0.56 to 1.09
0.50
1.10 to 1.59
1.0
1.60 to 2.09
1.50
2.10 to 2.59
0.50 plus 1.50
2.60 to 3.02
1.0 plus 1.50
BD01D499
Clean front (A) and rear (B) pivot area of rear axle
where seals (17) will be installed.
STEP 111
A
17
12
13
15
BS01E092
Lubricate two new seals (17) and new O-rings (15)

using Case Molydisulfide Grease. Install seals,
smooth side out, into front and rear of axle housing
(A) until flush with housing or recessed 2.0 mm
(0.079 inch). Install an O-ring in each cap (12 and
13).
STEP 112
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.
Bur 6-42451
Revised 2-03
Printed in U.S.A.
Copyright
6001-27
STEP 113
14
13
10
STEP 115
12
Remove hydraulic jack supporting rear axle and jack

stands supporting loading.
10
STEP 116
5
9
16
9
BS01E091
Lubricate pivot pin (16) using Case Molydisulfide

Grease. At rear of trunnion (9), install pivot pin into
trunnion and axle (A). Install shim pack (14), rear cap
(13) with O-ring installed, and two washers and bolts
(10). At front of trunnion install front cap (12) with
O-ring installed, and two washers and bolts (10).
Tighten bolts (10) to a torque of 251 to 280 Nm (185
to 205 lb-ft).
4
BD01D369
Install a new O-ring face seal in fittings (5). Connect

brake hose (4) to fitting.
STEP 117
STEP 114
1
2
BD01D362
BD01D391
Connect rear drive shaft (3) to rear axle. Install two

straps (2) and four bolts (1). Tighten bolts to a torque
of 61 to 81 Nm (45 to 60 lb-ft).
STEP 118
Install fuel tank (Steps 43 through 47). Fill fuel tank
with fuel drained in Step 24.
STEP 119
If necessary, fill axle with gear lubricant specified in
Section 1002.
BS00J104
Install both wheels (8) on front axle and secure using

1 0 w a sh e rs a n d b o lts ( 6 ) . Tig h te n b o l ts t o a
preliminary torque of 298 Nm (220 lb-ft) in sequence
indicated; then tighten to a torque of 640 to 720 Nm
(475 to 530 lb-ft) in same sequence.
Bur 6-42451
STEP 120
Refer to Section 7002 and bleed brakes.
STEP 121
Revised 2-03
Printed in U.S.A.
Copyright
6001-28
NOTES
Bur 6-42451
Revised 2-03
Printed in U.S.A.
6002
Copyright
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE
CHECKS, AND TROUBLESHOOTING
CASE CORPORATION
700 State Street
Bur 6-40800

Printed in U.S.A.
March, 2001
Copyright
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONSUMPTION TEST PROCEEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . .
Bur 6-40800
Issued 3-01
3
3
9
9
9
10
10
10
11
12
14
16
17
17
17
17
17
18
18
18
18
18
18
18
18
18
18
19
20
20
20
Printed in U.S.A.
Copyright
6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit.
Includes: CAS-2324 special 90 degree adapter and
CAS-2325 plug and cap set.
CAS-1804 Master pressure test kit
CAS-1808 Flowmeter kit

CAS-2702 Flowmeter adapter
CAS-2278 Flow 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........................................................................................................ 2.5 bar (36 psi) minimum
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm)
521D...................................................................................................................................52 L/min (14 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)
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-4
1
3
12
9
6
8
11
14
7
13
10
BS01A190
1.
2.
3.
4.
5.
6.
7.
TRANSMISSION ELECTRONIC CONTROL MODULE

DOWNSHIFT BUTTON
DECLUTCH ROCKER SWITCH
MANUAL/AUTOMATIC ROCKER SWITCH
SHIFTER
SUPPLY SYSTEM CONNECTIONS B+ AND RETURN
TRANSMISSION
8.
9.
10.
11.
12.
13.
14.
INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR

INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
HALL SENSOR - OUTPUT SPEED SENSOR
TRANSMISSION CONTROL VALVE CABLE
DECLUTCH LIMIT SWITCH
PLUG
FIGURE 1. COMPONENT LOCATIONS SYSTEMS
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-5
BS01B049
1.
2.
3.
4.
5.
6.
7.
8.
CLUTCH SHAFT KR
POWER TAKE OFF
CLUTCH SHAFT KV
CLUTCH SHAFT K2
CLUTCH SHAFT K3
OUTPUT FLANGE REAR
OUTPUT FLANGE CONVERTER SIDE
OUTPUT SHAFT
9.
10.
11.
12.
13.
14.
15.
TRANSMISSION PUMP
DRIVE SHAFT
CONVERTER
INDUCTIVE TRANSMITTER FOR ENGINE SPEED
CLUTCH SHAFT K4
CONVERTER RELIEF VALVE
CLUTCH SHAFT K1
FIGURE 2. COMPONENT LOCATIONS TRANSMISSION LAYOUT
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-6
BS01A191
1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK

2. TRANSMISSION SUSPENSION BORES
3. OUTPUT FLANGE CONVERTER

SIDE
4. OIL DRAIN PLUG
FIGURE 3. COMPONENT LOCATIONS FRONT VIEW
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-7
5
9
10
8
BS01A192
1.
2.
3.
4.
5.
CONVERTER BELL HOUSING

BREATHER
TRANSMISSION CASE COVER
FILTER HEAD
FILTER
6.
7.
8.
9.
10.
OUTPUT FLANGE REAR

OIL DRAIN PLUG
OUTPUT FLANGE CONVERTER SIDE
TRANSMISSION CASE
PARKING BRAKE
FIGURE 4. COMPONENT LOCATIONS SIDE VIEW
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-8
BS01B048
1.
2.
3.
4.
LIFTING LUGS
POWER TAKE OFF
TRANSMISSION CONTROL VALVE
TRANSMISSION SUSPENSION BORES
5. OUTPUT FLANGE REAR

6. FILTER
7. FILTER HEAD
FIGURE 5. COMPONENT LOCATIONS REAR VIEW
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-9
TRANSMISSION OPERATION
General
A. Determines which clutches to engage in the

transmission.
The transmissions for the D series equipment is

equipped with a Transmission ECM (Electronic
Control Module). This module controls modulation
and shifting that were normally associated with
hydraulically modulated transmissions, providing
smoother shifts and enhanced clutch life.
The Transmission ECM relies on signals from several
solenoids that are incorporated into the design.
These solenoids measure the speed of several
components, as well as other sensors that measure
temperature. These solenoids and sensors are
further defined in the following paragraphs.
In a ddi ti on , th e tran s mi ss i on i nc o r po rat es a
two-piece transmission case for ease of transmission
maintenance, helical cut gears that help reduce
noise, and all external hoses have been eliminated
(all oil passages are internal).
Transmission ECM
Modulation and shifting are controlled by the
Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e
(Transmission ECM). This module replaces the oil
and springs that are found in hydraulically modulated
transmissions.
T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h
e n g a ge m e n t , p r ov i d i n g s m o o t h e r s h i f ts a n d
enhanced clutch life, whether the transmission is set
to the automatic or manual shift mode.
The Transmission ECM also informs the Information
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:
B. Protects the engine and transmission turbine

fr om overspeed conditions dur ing
downloading.
C. Receives speed information from the engine
speed sensor, the turbine speed sensor, the
intermediate clutch speed sensor and the
transmission output speed sensor. These
speed sensors are checked to determine if
normal sensor operation is present. The data
is also used to control modulation during
shifting and to determine the appropriate shift
patterns.
D. Detects system failures and determines the
appropriate alternative actions.
E. Provides various diagnostic messages to the
Information Center.
F. Provides other information to the information
center, which in turn displays engine speed,
wheel speed, gear shift selection, and actual
gear selection.
G. Provides a method to
transmission clutch control.
calibrate
the
H. Establishes clutch modulation pressure during

transmission shifts.
Transmission Sensor Data Collection.

The Transmission ECM collects and uses information
from four sensors to accurately shift the transmission
and determine if any clutches are slipping. These
sensors are:
Engine (Speed) Sensor - monitors engine speed to
determine the load on the engine for shift points and
sends the engine rpm to the Transmission ECM,
which sends the information to the tachometer in the
Information Center.
oil
Turbine (Speed) Sensor - assists the engine speed

sensor in deter mining the load going into the
transmission and helps determine shift points.
B. The Transmission ECM times the rate the

solenoid energizes and de-energizes.
Intermediate (Shaft Speed) Sensor - determines

differential gear speed in the transmission to check
for clutch slippage.
A. A temperature sensor relays the

temperature to the Transmission ECM.
C. As the transmission changes gears, there is

reduced hesitation from one gear to the next.
Transmission ECM Tasks

The Transmission ECM performs a variety of tasks in
the overall system. The Transmission ECM:
Bur 6-40800
Output (Speed) Sensor - monitors transmission

output shaft speed to help determine the load on the
transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM
which sends the information to the speedometer in
Issued 3-01
Printed in U.S.A.
Copyright
6002-10
T he tra ns m i s s io n E CM al s o r ev i ews vol ta g e
infor mation from the shifter and transmission
solenoids to determine if there are any short circuits
or open circuits in the system.
Automatic Problem Modes

If the Transmission ECM detects an error condition in
the transmission system, it will generate a service
code in the Information Center and will enter one of
three modes:
A. Clutch Modulation Substitute Mode
B. Limp-Home Mode
C. Transmission/Transmission ECM Shutdown
Mode
Clutch Modulation Substitute Mode
In this mode, the transmission clutch modulation is
time dependant rather than load dependant. The
transmission will go into the Clutch Modulation
Substitute Mode if any of the four speed sensors fail.
If the output speed sensor is working and the
transmission is in gear, the shift points in Automatic
mode will be speed dependant but the modulation
will be a predetermined amount of time.
If the output speed sensor is not working and the
transmission is in gear, the shift points will be load
d ep e n d a nt bu t th e m o du l a t i o n w i l l s t i l l b e a
predetermined amount of time.
If the transmission is shifted from neutral into a
direction in the Clutch Modulation Substitute Mode in
automatic, the transmission will shift into 4th gear
and shift down until it gets the correct output speed
from the turbine.
If the Transmission ECM generates a code, the

wre nch over the ser v ic e manual ic on wil l b e
displayed on the Information Center.
Transmission Clutch Calibration

The Transmission ECM has the capability to find the
optimal adjustment of the clutch filling parameters for
each individual transmission, providing the ability to
individually adjust the optimum fill time for the
individual transmission in the machine. Clutch Filling
Parameter Calibration is performed on each machine
at the plant and should be repeated at the first 250
hours of use and every 1000 hours thereafter.
Gear Selections
The transmission in all D Series models provides 4
fo r wa r d a n d 3 r eve r s e g e a r s e l e c t i o n s. Th e
transmission ratios were designed to give optimized
speed and torque for each gear selection. The torque
converter is a single stage torque converter (one
locking unit in the torque converter).
Automatic/Manual Modes
The automatic/manual switch is located on the right
control panel. The transmission is in automatic mode
when the top of the automatic/manual switch is
depressed. The Transmission Display Center
indicates when the machine is in the automatic
mode.
Limp-Home Mode
In this mode, the transmission will go into second
gear, forward or reverse, no matter what gear is
selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
g e a r s u n t i l a n o p e r a bl e g e a r i s fo u n d . T h e
transmission will go into the Limp Home Mode if
there is a fault on one clutch, a fault on one clutch
valve, or a fault on more than one speed sensor.
Transmission/Transmission ECM Shutdown
Mode
In this mode, the Transmission ECM has detected a
s ev e r e fa i l u r e t h a t d i s a b l e s c o n t r o l o f t h e
transmission. The transmission will go into Shutdown
Mode if there is a fault on more than one clutch, a
fault on the solenoid power supply, or invalid voltage.
In this mode, the Transmission ECM will shut off all
solenoid valves and the power supply and the
transmission shifts into and stays in neutral.
Bur 6-40800
RD98K308
FIGURE 6. AUTO/MANUAL TRANSMISSION SWITCH
Upshifting in Automatic Mode

Upshifting is determined by machine speed and the
torque on the transmission.
The transmission will shift from first or second gear
up to the highest gear selected as the accelerator is
depressed, machine speed increases, and required
torque is reduced.
Issued 3-01
Printed in U.S.A.
Copyright
6002-11
If the machine speed is increasing, but the operator
is not depressing the accelerator (such as when
going down a hill), the transmission will not upshift.
As the operator depresses the accelerator and the
torque on the transmission is lowered, the
transmission will upshift.
Downshifting in Automatic Mode

Downshifting is determined directly by machine
speed and transmission torque. The transmission will
downshift to first or second gear as machine speed
decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
and the machine speed decreases, as the torque
requirement incr eases, the trans mission will
downshift into third, then second, and down to first
gear, if necessary.
BS00M472
1. DOWNSHIFT BUTTON/SINGLE LEVER CONFIGURATION

FIGURE 7
Upshifting in Manual Mode
In the manual mode, the transmission starts out in

the selected gear and stays in that gear until the
operator selects another gear or direction. The
transmission can be upshifted without reducing
engine speed or machine speed.
If the gear selected is two or more gears higher than
the present gear, the transmission will shift up
through the gears at 2.5 second intervals until the
selected gear has been reached.
Downshifting in Manual Mode

The transmission can be downshifted in the manual
mode without reducing engine speed or machine
speed.
If 1st gear is selected from 3rd or 4th gear, the
transmission will downshift into 2nd gear for 1.2
seconds and then will shift into 1st gear.
Downshift Button
The downshift button is located on front of the
joystick control lever in machines with a single lever
configuration, and on top of the control tower in
machines with a two lever configuration.
With the number of different ways the downshift
button functions, the operator can tailor the use of the
machine to the application at hand.
Bur 6-40800
409
1. DOWNSHIFT BUTTON/TWO LEVER CONFIGURATION

FIGURE 8
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.
Issued 3-01
Printed in U.S.A.
Copyright
6002-12
The transmission will retur n to the full range
automatic mode when:
A. Another gear is selected.
B. The shifter is moved into neutral and then into
forward or reverse.
C. The autoshift switch is recycled.
Manual Mode
In the manual mode, the downshift button toggles
between 1st and 2nd gear. The manual mode is
useful in short haul operations. In this mode, the
downshift button functions in two ways in 1st and 2nd
gear.
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 operator is in 2nd gear and pushes the

downshift button, the transmission instantly shifts into
1st gear. When the operator pushes the downshift
button again, the transmission upshifts into 2nd gear.
If the machine is in 2nd gear and the downshift
button is pushed, the transmission instantly shifts into
1st gear. When the operator shuttles the shifter, the
transmission upshifts back into 2nd gear.
Cold Start Protection System

The transmission has a cold start protection system.
When the transmission sump temperature is minus
10 C (14 F), the Transmission ECM will keep the
transmission in neutral.
When the transmission sump temperature warms up
to minus 10 C (14F) (within approximately one
minute), the machine will operate in all gears.
RD98K308
FIGURE 9. TRANSMISSION DECLUTCH SWITCH
When the transmission declutch switch is in the on

po s i ti o n a nd th e b rake p ed al i s p u s he d, th e
Transmission ECM reduces the pressure to the
transmission forward or reverse clutch.
T h e Tr a n s m i s s i o n E C M w i l l n o t c o m p l e t e l y
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.
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-13
NOTES
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-14
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

No.
IDENTIFICATION/LOCATION
CONNECTION
DESIGNATION ON
VALVE BLOCK
H
Measuring Points for Pressure Oil and Temperature

51
Before the Converter - Opening Pressure 8 bar (116 psi)
M10x1
52
Behind the Converter - Opening Pressure 2.5 bar (36 psi)
M14x1.5
53
Clutch Forward 16+2 bar (232 + 29 psi)
KV M10x1
55
Clutch Reverse 16+2 bar (232 + 29 psi)
KR M10x1
56
Clutch 16+2 bar (232 + 29 psi)
K1 M10x1
57
K2 M10x1
58
K3 M10x1
60
K4 M10x1
63
Behind the Converter Temperature 100 C, Short Time 120 C
M14x1/5
65
System Pressure 16+2 bar (232 + 29 psi)
M10x1
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 n Turbine
34
M18x1.5
Speed Sensor n Output and Speedometer
47
Inductive Transmitter n Central Gear Train
M18x1.5
48
Inductive Transmitter n Engine
M18x1.5
Connections
49
Plug Connection on the Hydraulic Control Unit
68
System Pressure
M16x1.5
69
Pilot Pressure
M16x1.5
NOTE: See Figure 10 for Measuring Point, Transmitter, Sensor and Connection locations.
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-15
BC01B047
FIGURE 10. MEASURING POINTS AND CONNECTIONS
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-16
CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.
P.I.N. Number:
Date:
TEST POINTS
Shift
Speed
P
65
V
53
R
55
1
56
2
57
3
58
4
60
5
51
6
52
LP
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
V= FORWARD CLUTCH
2= SECOND GEAR CLUTCH
5= CONVERTER IN
R= REVERSE CLUTCH
3= THIRD GEAR CLUTCH
6= CONVERTER OUT
Bur 6-40800
LP= LUBE PRESSURE
Issued 3-01
Printed in U.S.A.
Copyright
6002-17
PRESSURE TEST RESULTS

All or Most Pressures Low and/or
Flow Test Low
Possible causes include:
1. Oil level not correct.
2. Oil type and grade not correct.
3. Oil operating temperature high.
4. Screen for suction tube plugged.
5. Suction tube or gaskets leak.
6. Main pressure valve, springs, or valve bore.
7. Reduction valve, springs, or valve bore.
Not Enough Power

1. Check Electrical Troubleshooting in this Section
to verify actual gear selected.
2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
A. Check engine and fuel system for problem.
B. Check that torque converter installation is
correct.
3. Engine RPM above Stall Test specified RPM.
(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.
Some Pressures Low

1. Circuit isolation does not correct low pressure.
A. Control valve or gasket.
B. Channel plate or gasket.
2. Circuit isolation corrects low pressure.
A. Clutch shaft or seals.
B. Clutch drum or piston.
Bur 6-40800
Machine Stops or Hesitates While

Shifting - Intermittent
1. Check orifice and O-ring. (See Section 6007 for
replacing.)
2. Check for foreign material plugging orifices or
sticking valves.
3. Check for reduced pressure at test pressure
points.
4. See Electrical Troubleshooting in this Section for
electrical system problem.
Issued 3-01
Printed in U.S.A.
Copyright
6002-18
CONVERTER OUT PRESSURE CHECK

Test Equipment Required
2. Apply the parking brakes.
0 to 28 bar (400 psi) gauge with hose long enough to

take readings in the cab and CAS-2324 Special
Adapter.
3. Install the pressure gauge.
Test Procedure
5. While in the cab, put the transmission in

NEUTRAL. Run the engine at full throttle. Record
the reading in the char t on page 6002.16.
Pressure must be a minimum of 2.5 bar (36 psi).
1. Block the machine tires.
4. Heat the oil to an operating temperature of 80 to

100 C (176 to 212 F).
LUBRICATION PRESSURE CHECK

3. Install the pressure gauge in the cooler return

line at the transmission.
0 to 7 bar (100 psi) gauge.

100 C (176 to 212 F).
Test Procedure
5. While in the cab, run the engine at full throttle.

Put the transmission in each gear and record the
reading in the chart on page 6002.16. Pressure
must be 0.2 to 1.2 bar (3 to 18 psi).

FLOWMETER TEST
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter.
Flowmeter Test Procedure


100 C (176 to 212 F).
4. Remove the filter and install the CAS-2702
adapter.
5. Install the flowmeter between the adapter and
the filter.
Put the transmission in NEUTRAL and record the
flow measurement. The correct flow for 521D
machines is 52 L/min (14 U.S. gpm) at 2000 rpm.
CONSUMPTION TEST PROCEEDURE

100 C (176 to 212 F).
4. Install the flowmeter to converter outlet line (line
to cooler) in series.
6. Repeat the procedure with the transmission in

FORWARD in third gear. The flow must be 9.1
L/min (2 U.S. gpm).
7. Repeat the procedure with the transmission in
REVERSE in third gear. The flow must be 9.1
L/min (2 U.S. gpm).

Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 L/min
(2 U.S. gpm).
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
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 56C (100F) 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 operators 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.
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6002-20
ERROR CODES
In case of possible errors in the system, a wrench appears on the display, combined with indication of the error
number. See section 4005 for error code retrieval procedures and definitions.
TRANSMISSION SHIFTER LOGIC INFORMATION

Function
Shifter
Shifter Wire
Color
Shifter Tower
Connector
Shifter Shroud
Connector
Harness
Wire #
Harness
ped/cab #
Trans. ECM #
power
B+
red/black
19A
43
45
forward
yellow
25F
44
43
reverse
pink
25R
45
64
neutral
gray
25T
46
67
gear2(3-4)
B2
green
25W
48
65
gear1(1-2)
B1
blue
25Z
49
63
downshift
DS
purple
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
Function
Transmission
ECM Pin #
Transmission
Valve
Clutch #
Transmission
Valve Pin #
Wire #
Trans/Cab
Pin #
A1P1
56
Y1
K4
25K
16
A1P2
10
Y2
KR
25L
17
A1P3
32
Y3
K1
25M
18
A1P4
55
Y4
K3
25N
19
A1P5
Y5
KV
25P
20
A1P6
51
Y6
K2
25J
21
VPSI
12,13
all Y
all K
25S
22
TEMP
39
TEMP
none
36T
TEMP
46
TEMP
none
36R
12
Bur 6-40800
Issued 3-01
Printed in U.S.A.
Copyright
6003
Section
6003
TRANSMISSION
CASE CORPORATION
700 State Street
Bur 6-42460

Printed in U.S.A.
June, 2002
Copyright
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42460
Issued 6-02
3
3
4
5
16
Printed in U.S.A.
Copyright
6003-3
SPECIAL TOOLS
CAS2885 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
CAS2807 TRANSMISSION
INPUT/OUTPUT SHAFT SEAL
INSTALLATION TOOL
OUTPUT SHAFT SEAL
INSTALLATION TOOL
(521D AND 621 MODELS
ONLY)
TORQUE CONVERTER SEAL
INSTALLATION TOOL
BS02C093 THRU 096
CAS40075 TRANSMISSION TOOL KIT
CAS2802 ALIGNMENT
DOWEL SET
CAS2799 CLUTCH PACK

H0LDER AND SPRING
COMPRESSOR TOOLS
MOUNTING BRACKETS
CAS2796 NESTING
PLATE
CAS2798 GEAR
PULLER COLLET SET
CAS2800 CLUTCH
ASSEMBLY HOLDING
KNOB SET
CAS2797 LIFTING
EYEBOLT SET
CAS2868 CLUTCH
SPRING COMPRESSOR
(521D AND 621 MODELS
ONLY)
BS02C097 THRU 104
CAS40079 TRANSMISSION OVERHAUL KIT
SPECIAL TORQUES
Oil pipes
Studs .............................................................................................................................................. 9 Nm (80 lb-in)
Socket head screw ..................................................................................................................... 23 Nm (204 lb-in)
Screw plug .................................................................................................................................... 51 Nm (38 lb-ft)
Clutch K1, K2, K3, K4 Stud ............................................................................................................ 17 Nm (150 lb-in)
Plugs................................................................................................................................................ 25 Nm (221 lb-in)
Output shaft
Output shaft screws (apply Loctite 243 to threads) .................................................................... 23 Nm (204 lb-in)
Housing cover screws (apply Loctite 574 to threads)................................................................. 46 Nm (407 lb-in)
Output flange screws ................................................................................................................. 34 Nm (301 lb-in)
Oil feed housing and transmission pump
Transmission pump screws ........................................................................................................ 46 Nm (407 lb-in)
Oil feed housing screws ............................................................................................................. 25 Nm (221 lb-in)
Engine connection and converter
Input shaft screws ....................................................................................................................... 115 Nm (85 lb-ft)
Converter housing screws............................................................................................................. 68 Nm (50 lb-ft)
Cover........................................................................................................................................... 23 Nm (204 lb-in)
Converter cover.......................................................................................................................... 46 Nm (407 lb-in)
Input flange ................................................................................................................................. 34 Nm (301 lb-in)
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-4
SPECIAL TORQUES (CONTINUED)

Duct plate
Screws ....................................................................................................................................... 25 Nm (221 lb-in)
Screw plug ................................................................................................................................. 30 Nm (265 lb-in)
Hydraulic control unit ....................................................................................................................... 9.5 Nm (84 lb-in)
Filter
Filter head screws ...................................................................................................................... 25 Nm (221 lb-in)
Oil distribution cover screws ...................................................................................................... 25 Nm (221 lb-in)
Speed sensor and inductive transmitter
Speed sensor screw................................................................................................................... 23 Nm (204 lb-in)
Inductive transmitter ................................................................................................................... 30 Nm (265 lb-in)
Cover plate ................................................................................................................................. 23 Nm (204 lb-in)
Screw plug ................................................................................................................................ 140 Nm (103 lb-ft)
SPECIFICATIONS
Clutch KV and KR plate clearance ......................................................................... 2.5 to 2.7 mm (0.098 to 0.106 in)
Clutch K1, K2,K3 plate clearance........................................................................... 2.1 to 2.3 mm (0.083 to 0.090 in)
Clutch K4 Plate Clearance ..................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)
NOTE: The J I Case Company reserves the right to make improvements in design or changes in specifications at
any time without incurring any obligation to install them on units previously sold.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-5
DISASSEMBLY
STEP 1
STEP 4
GD98M833
GD98M837
Fasten transmission on an assembly stand using

CAS2801 transmission mounting brackets.
R e m o v e tw o s o c k e t h e a d s cr e w s a n d i n s ta l l
CAS2885 transmission valve adjustment tool set.
Remove remaining 21 socket head screws securing
control valve. Loosen and remove hex rods (part of
CAS2885) from studs then remove control valve.
STEP 2
STEP 5
GD98M835
Remove and discard oil filter.
STEP 3
GD98M838
Remove both gaskets and the intermediate plate.
STEP 6
GD98M836
Remove hex head screws securing filter head.

Remove filter head from transmission.
GD98M839
Remove socket head screws and hex nuts. Remove

duct plate. Remove flat gasket.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-6
STEP 7
STEP 10
GD98M844
Be nd loc k p late a wa y fr om he x h e ad sc re ws.

Remove two hex head screws, lock plate, and
washer. Remove input flange from shaft.
GD98M847
U sin g p r o p er siz e r o d, p r e ss in p u t sh a ft a n d
converter from cover.
STEP 11
STEP 8
GD98M845
Pu t alig n me n t ma rk s on co n ve r te r co ve r a n d
housing to aid in assembly. Remove 12 nuts and
hex head screws.
GD98M848
Remove retaining ring then remove bearing.
STEP 12
STEP 9
GD98M849
GD98M846
C o n n e c t s u i t a b l e l if t i n g e q u ip m e n t t o s h a f t.
R e m o v e c o v e r, s h a f t , a n d c o n v e r t e r f r o m
transmission and place in hydraulic press.
Bur 6-42460
Rem ove f our hex head sc rews and rem ov e

diaphragm and input shaft.
Issued 6-02
Printed in U.S.A.
Copyright
6003-7
STEP 13
STEP 16
GD98M853
GD98M850
Put input shaft and diaphragm in vise as shown.

Remove 12 hex head screws to separate
diaphragm and input shaft.
Remove the socket head screws for removal of the

transmission pump.
STEP 17
STEP 14
GD98M854
GD98M851
Remove the inductive transmitter.
STEP 15
Apply a bearing separator on the splines shoulder of

the stator shaft and pull the pump out of the housing
bores, using two-leg puller.
NOTE: If traces of wear should be encountered in
the pump housing or the cam disk, the complete
pump has to be replaced.
STEP 18
GD98M852
Remo ve the h ex head scre ws and remo ve the

converter housing.
GD98M855
Se p ar at e th e tra n smiss ion p u mp fr om st ato r.

Separate the cam plate from pump.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-8
STEP 19
STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 24
GD98M856
Remove the hex head screws and remove the oil

feed housing. Remove the flat gasket.
STEP 20
GD98M862
Remo ve the spe ed se nso r and bo th in ductive

transmitters.
STEP 25
GD98M860
Remove the hex head screws, cover, and flat gasket.
STEP 21
GD98M863
Remove the hex nuts and the two covers.
STEP 26
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 22
Pry the shaft seal out of the housing bore.
GD98M864
Install CAS2802 alignment dowel set.

NOTE: The following steps describe the common
removal of all clutches.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-9
STEP 27
STEP 30
Remove CAS2800 clutch assembly holding knob
set and lift cover free.
STEP 31
BK00D029
Install CAS2800 clutch assembly holding knob set.

With knobs installed on all clutches in housing cover,
install CAS2797 lifting eyebolt set and lifting device
to transmission cover.
GD98M867
Remove the socket head screws and remove the

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

transmission housing, using lifting device.
GD98M872
Remove clutch K2.
STEP 29
STEP 33
BK00D026
Place clutch disc carriers onto CAS2796 nesting

plate.
Bur 6-42460
GD98M873
Remove clutch K1 while lifting clutch K4.
Issued 6-02
Printed in U.S.A.
Copyright
6003-10
STEP 34
STEP 37
GD98M877
GD98M874
Remove the bearing outer race and pull output shaft

out of the housing bore.
Remove clutch K3.
STEP 35
STEP 38
GD98M875
GD98M878
Remove clutch K4 while lifting input shaft slightly.
STEP 36
Remove the rectangular ring and separate ball

bearing from the shaft.
NOTE: The following steps are for the disassembly
of the clutch KV. The disassembly of the clutch KR is
similar.
STEP 39
GD98M876
Remove clutches KV and KR together with input

shaft.
GD98M979
Remove the sealing ring. Pull the tapered roller

bearing from the shaft. Remove the opposite tapered
roller bearing.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-11
STEP 40
STEP 43
GD98M881
BK00D020
Separate the clutch disc carrier from the shaft.
Remove snap ring.
STEP 41
STEP 44
GD98M882
Remove the snap ring and remove the clutch disc

pack.
BK00D019
Remove the compression spring.
STEP 45
STEP 42
GD98M885
BK00D018
Preload compression spring using CAS2799 clutch

pack holder and spring compressor tool.
Bur 6-42460
Remove piston from clutch pack holder. Remove and

discard the O-rings from piston.
Issued 6-02
Printed in U.S.A.
Copyright
6003-12
STEP 46
STEP 48
GD98M886
GD98M889
Remove the snap ring.
Remove the snap ring and remove the ball bearing.
STEP 47
NOTE: The following steps are for disassembly of

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

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

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

washer.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-13
STEP 51
STEP 54
GD98M893
Remove the idler gear.
BK00D018

STEP 52
STEP 55
GD98M894
Remove the needle bearings and thrust bearing.
BKOOD020
STEP 53
STEP 56
GD98M895

pack.
Bur 6-42460
BK00D019
Issued 6-02
Printed in U.S.A.
Copyright
6003-14
STEP 57
STEP 59
BS00G001
GD98M800
Remove the sealing ring. Remove bearing using

bearing puller. Tap assembly until piston drops out of
the clutch pack carrier. Then, remove and discard
O-rings from piston.
Remove and discard two sealing rings. Pull two

bearings from shaft using bearing puller. Remove the
snap ring and separate the clutch disc carrier from
the shaft.
STEP 58
STEP 60
GD98M801
BK00D022
Remove the clutch disc carrier from the shaft.

NOTE: The following steps are for the disassembly
of the clutch K4.

pack.
STEP 61
BK00D018

Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-15
STEP 62
NOTE: The following two steps are for disassembly

of the input shaft.
NOTE: A snap ring is used to lock turbine shaft in
input shaft. Snap ring will be destroyed when turbine
shaft is pressed from input shaft.
STEP 64
BK00D020
STEP 63
GD98M803
If turbine shaft is to be removed from input shaft, use

proper size diameter sleeve or rod and press turbine
shaft out of input shaft.
STEP 65
Remove bearings from input shaft using a bearing
puller.
BK00D019
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-16
ASSEMBLY
NOTE: The following steps are for the reassembly of
the oil pipes.
STEP 69
STEP 66
2
3
GD98M607
Install a new O-ring on plug. Tighten the plug to a

torque of 51 Nm (38 lb-ft).
STEP 70
GD98M603
Install suction tube (1), pressure pipes (2), and

lubrication pressure pipe (3) in housing.
STEP 67
Secure suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 lb-in)
STEP 68
GD98M608
Install all bearing outer races in housing bores.
STEP 71
GD98M605
Tilt the cover 180 degrees. Install the suction tubes

and pressure pipes into the housing bores using a
rolling tool.
NOTE: Pipe end of the pressure pipes must be
slightly below the housing plane face.
GD98M609
Install both oil pipes into the housing cover. Tilt the
cover 180 degrees and install pipes into the housing
bores using a rolling tool.
NOTE: The pipe end must be slightly below the
housing plane face.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-17
STEP 72
STEP 75
GD98M610
BK00D019
Install the studs. Tighten the studs to a torque of 9

Nm (80 lb-in).
NOTE: The following steps are for the assembly of
clutches KV and KR, starting with assembly of the
clutch disc carrier.
STEP 73
BK00D018
Install compression spring and two spring cups in

clutch disc carrier. Preload compression spring
using CAS2 799 clutch pack h older and spring
compressor tool.
STEP 76
GD98M612
Check that drain hole is clear and free of foreign

matter. Install both O-rings in recesses of the piston
and apply oil.
STEP 74
BK00D020
Install the snap ring.

NOTE: The following steps are for the KV and KR
clutch disc packs. The disc stacking of clutches KV
and KR is identical.
GD98M613
Install piston in clutch disc carrier.

Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-18
STEP 77
STEP 79
GD98M617
Install end shim and snap ring.

BS02C134
1.
2.
3.
4.
5.
6.
7.
A
PLATE CARRIER
PISTON
OUTER PLATE - ONE-SIDED COATED
INNER PLATES
OUTER PLATES - COATED ON BOTH SIDES
SNAP RING
END SHIM
RUNNING CLEARANCE 2.5 TO 2.7 MM (0.098 TO 0.106
IN)
STEP 80
Install clutch disc plates in KV and KR clutch disc

carriers in position and sequence shown above.
Install outer plates (3) with steel faced side facing
piston and end shim (7). Install two inner plates (4)
on the end shim side.
NOTE: Snap rings of different thickness are
available for adjustment of the running clearance. To
ensure correct adjustment, do not apply oil to clutch
discs until after adjustment is completed.
STEP 78
GD98M618
Adjust running clearance to 2.5 to 2.7 mm (0.098 to

0 . 1 0 6 in ) . P r e s s d o w n o n t h e e n d s h i m w it h
approximately 10 kg (20 lb). Measure and record
dimension (A) from carrier face to end shim using
depth gauge as shown.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
GD98M616
Install the clutch disc pack.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-19
STEP 81
STEP 84
GD98M619
GD98M621
Use tools to lift the end shim against snap ring

(upward) until contact is obtained. Measure and
record dimension (B) from carrier face to end shim
using depth gauge as s hown. S ubtrac t this
measurement from the measurement of Step 80. The
difference is the running clearance.
Apply Loctite 243 to stud. Tighten stud to a torque of

17 Nm (150 lb-in).
STEP 85
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
Dimension B . . . . . . . . . . . . . . . . . 4.75 mm (0.19 in)
Difference = Running . . . . . . . . . . . 2.50 mm (0.10 in)
Clearance
Required running clearance is 2.5 to 2.7 mm (0.098
to 0.106 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
STEP 82
GD98M622
Remove clutch disc pack, apply oil to discs, and

install clutch disc pack, end shim, and snap ring as
determined in Step 81.
Install ball bearing until contact is obtained. Secure

using snap ring.
STEP 83
STEP 86
GD98M623
GD98M620
Install idler gear to align and engage all inner discs,

then remove idler gear.
Bur 6-42460
Install needle bearing.
Issued 6-02
Printed in U.S.A.
Copyright
6003-20
STEP 87
STEP 90
GD98M624
Support the idler gear on the bearing inner race.

Press the idler gear against the shoulder.
BP00G020
Install gear and shaft into heated bore.
STEP 91
STEP 88
BK00D024
GD98M625
Secure idler gear using snap ring.
Heat bearing.
STEP 92
STEP 89
WARNING: Always wear heat protective

gloves to prevent burning your hand when
handling heated parts.
SM121A
BK00D023
Use heat gun to heat assembled clutch disc carrier

inner bore.
BK00D025
In st a ll h e at e d b ea r in g o n s ha f t a g a in st sh a ft
shoulder.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-21
STEP 93
STEP 96
Check operation of the clutch using compressed air.

NOTE: The following steps are for assembly of
clutch K1, K2, and K3.
STEP 94
GD98M632

matter. Install both O-rings in recesses of piston and
apply oil.
GD98M630
STEP 97
Press bearing against shoulder of shaft. Apply

Loctite 243 to the stud and install the stud. Tighten
the stud to a torque of 17 Nm (150 lb-in).
STEP 95
GD98M633
Install piston in clutch disc carrier.
STEP 98
GD98M631
Install the clutch disc carrier until contact is obtained.
GD98M634
Install the compression spring and spring cup.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-22
STEP 99
STEP 101
A
BK00D019
BS02C130
1.
2.
3.
4.
5.
6.
7.
A.
BK00D018

compressor tool.
STEP 100
PLATE CARRIER
PISTON
INNER PLATES
SNAP RING
END SHIM
IN)
Install clutch disc plates in K1, K2, and K3 clutch disc

carriers in position and sequence shown above.
Install outer plate (3) with steel faced side facing
piston. Install two outer and inner plates each on the
end shim side.
STEP 102
BK00D020
Install the snap ring.

NOTE: The following steps are for K1, K2 and K3
clutches. The assembly of clutches K1, K2, and K3 is
identical.
Bur 6-42460
GD98M636
Install the clutch disc pack.
Issued 6-02
Printed in U.S.A.
Copyright
6003-23
STEP 103
STEP 105
GD98M637
Install the end shim and snap ring.
GD98M639

measurement from the measurement of Step 104.
The difference is the running clearance.
STEP 104
Example
Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in)
Difference = Running . . . . . . . . . . . .2.1 mm (0.08 in)
Clearance
GD98M638
Adjust running clearance for K1, K2, and K3 to 2.1 to

2.3 mm (0.083 to 0.090 in). Press down on the end
shim with approximately 10 kg (20 lb). Measure and
record dimension (A) from carrier face to end shim
using depth gauge as shown.
STEP 106
STEP 107
Example
Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)
3
2
1
GD98M640
Install the thrust washer (1), thrust bearing (2), and

thrust washer (3).
NOTE: Install the thrust washer (1) with the chamfer
facing the thrust bearing.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-24
STEP 108
STEP 111
GD98M641
BK00D024
Install both needle bearings.
Heat bearing.
STEP 109
STEP 112
SM121A
GD98M642
Install idler gear until all inner discs are engaged.
STEP 110
BK00D025
Place heated bearing on the shaft.
STEP 113
GD98M643
Install the thrust washer (3), thrust bearing (2), and

thrust washer (1). Install the thrust washer (1) with
the chamfer facing the thrust bearing.
NOTE: Ensure the thrust washer (1) is overlapping
with the chaff collar to accommodate all the inner
discs.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-25
NOTE: The following steps are for assembly of
clutch K4.
STEP 116
STEP 114
SM121A
GD98M649
Apply Loctite 243 to the stud and install the stud.

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

until seated in position.
STEP 115
GD98M650

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

bottoms out.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-26
STEP 119
STEP 121
A
BK00D019
BS02C131
1.
2.
3.
4.
5.
6.
7.
A.
PLATE CARRIER
PISTON
INNER PLATES
SNAP RING
END SHIM
IN)
Install clutch disc plates in K4 clutch disc carrier in

position and sequence shown above. Install outer
plate (3) with steel faced side facing piston.
BK00D018

compressor tool.

STEP 122
STEP 120
GD98M653
Install clutch disc pack.

BK00D020
Install snap ring.

NOTE: The following steps are for installing the
clutch disc pack in clutch K4.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-27
STEP 123
STEP 125
GD98M654
Install end shim and snap ring.
GD98M656

measurement from the measurement of Step 124.
The difference is the running clearance.
STEP 124
Example
Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in)
Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in)
Clearance
GD98M655
Adjust running clearance to 1.2 to 1.4 mm (0.047 to

0 . 0 5 5 in ) . P r e s s d o w n o n t h e e n d s h i m w it h
approximately 10 kg (20 lb). Measure and record
dimension (A) from carrier face to end shim using
depth gauge as shown.
STEP 126
STEP 127
Example
Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-28
STEP 128
STEP 131
1
2
3
GD98M658
Assemble two thrust washers and thrust bearing.

NOTE: Upper and lower thrust washers are the
same thickness.
GD98M661
Assemble thrust washer (3), thrust bearing (2), and

thrust washer (1). Install the thrust washer (1) with
the chamfer facing the thrust bearing.
STEP 132
STEP 129
GD98M662
GD98M659
Install the assembled clutch disc carrier until all the

inner discs are engaged.
Install both needle bearings.
STEP 130
STEP 133
GD98M660
GD98M663
Install the idler gear.
Bur 6-42460
Install snap ring to secure clutch disc carrier.
Issued 6-02
Printed in U.S.A.
Copyright
6003-29
STEP 134
STEP 138
SM121A
BK00D024
Heat bearing.
STEP 135
GD98M666
Heat gear to about 120 C (248 F) and install on

input shaft until contact is obtained.
SM121A
STEP 139
BK00D025
Install heated bearing on the shaft shoulder.
STEP 136
Repeat Steps 134 and 135 to install bearing on
opposite end of shaft.
GD98M667
Secure gear with snap ring.
STEP 140
STEP 137
the input shaft.
GD98M668
Install snap ring into recess of turbine shaft.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-30
STEP 141
STEP 144
GD98M669
GD98M672
Install the turbine shaft until the snap ring snaps into
the recess of the input shaft.
Install output shaft into housing bore until contact is

made.
STEP 142
NOTE: The following steps are for the installation of

the output shaft and clutches. All clutches have a
common installation.

STEP 145
SM121A
K1
AB
K3
K4
AN
KR
K2
KV
GD98M673
BK00D024
Heat bearings and install on turbine shaft until

bearings are against shoulder.
Install bearing outer races into housing cover until

contact is obtained.
STEP 146
STEP 143
BK00F003
GD98M671
Install the clutches onto CAS2796 nesting plate.
Install bearing then install rectangular ring.

Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-31
STEP 147
STEP 150
BK00D029
GD98M681
Using CAS2797 lifting eye bolt set and acceptable

lif tin g e q u ip m e n t , in s ta ll h o u s in g c o v e r o n t o
clutches. Install CAS2800 clutch assembly holding
knob set to secure clutch shafts to cover.
Install the sealing rings and insert rings in their

respective grooves. Apply grease to the sealing rings
and align the rings centrally.
STEP 151
STEP 148
KR
KV
K4
K2
K3
K1
GD98M692
GD98M679
The above photo shows the position of the single

clutches in the housing cover.
Install both the O-rings into the annular groove of the

oil pipes and apply grease.
STEP 152
STEP 149
AN
KV
K2
Tilt the housing cover 180 degrees.
KR
K4
K1
K3
AB
GD98M866
The above shows the position of the single clutches

and the input and output clutches.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-32
STEP 153
STEP 156
GD98M683
GD98M686
Install output gear and shaft in transmission housing.

Install alignment screws. Carefully lower the cover
and clutches into the gear box housing.
Install screen sheet on output shaft. Press front and

rear bearings on output shaft until contact with
shoulder of output shaft is made.
STEP 154
STEP 157
Remove CAS2800 clutch assembly holding knob set.
STEP 155
GD98M688
Install the screening plate.

GD98M685
STEP 158
Separate the housing cover from the gearbox, using

a lifting device.
the output shaft.
GD98M689
Install the output shaft.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-33
STEP 159
STEP 162
GD98M690
GD98M697
Apply Loctite 243 to the socket head screws and

install the screws. Tighten the screws to a torque of
23 Nm (204 lb-in).
Heat the output flange to about 90 C (194 F). Apply

Loctite 574 to the contact area and assemble the
flange with the washers and hex head screws.
Tighten the screws to a torque of 34 Nm (301 lb-in).
Bend corner of lock plate over hex head screws.
STEP 160
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
the oil feed housing and transmission pump.
STEP 164
GD98M691
Install rectangular rings in grooves of clutch shafts.

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

Apply grease to sealing lip. Use CAS286 9
transmission output shaft seal installation tool to
install seal.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-34
STEP 165
STEP 168
GD98M703
Install the oil feed housing with washers and hex

head screws. Screw the hex head screws in only
until contact is obtained, do not tighten.
GD98M706
Install transmission pump.
STEP 169
STEP 166
GD98M707
GD98M704
Install the two alignment screws and install the stator

shaft.
Apply grease to new O-rings. Install the O-rings on

the socket head screws.
STEP 170
STEP 167
GD98M708
GD98M705
Apply oil and install the O-ring.
Bur 6-42460
Secure the transmission pump with the socket head

screws. Tighten screws to a torque of 46 Nm (407
lb-in).
Issued 6-02
Printed in U.S.A.
Copyright
6003-35
STEP 171
STEP 173
GD98M709
GD98M712
Install the oil feed housing with the hex head screws
and flat washers. Tighten the screws to a torque of
25 Nm (221 lb-in).
Position converter housing. Secure with hex head

screws. Tighten the screws to a torque of 68 Nm (50
lb-ft).
STEP 172
STEP 174
GD98M711
GD98M713
Position the gasket and cover. Secure the cover with

the hex head screws. Tighten the screws to a torque
of 23 Nm (204 lb-in).
P u t i n p u t s h a ft in a v i se a s s h o w n . P o s it io n
diaphragm on input shaft and secure using 12 hex
head screws. Tighten screws to a torque of 115 Nm
(85 lb-ft).

the engine connection and converter.
STEP 175
GD98M714
Position diaphragm and input shaft on converter.

Apply Loctite 262 to threads of hex head screws.
Install screws and tighten to a torque of 115 Nm (85
lb-ft).
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-36
STEP 176
STEP 178
GD98M715
GD98M718
Position converter cover on converter housing. Make

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

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

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

against shoulder in cover. Secure using retaining
ring.
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-37
STEP 180
NOTE: The following steps are for installation of

STEP 183
GD98M720
Tighten input flange hex head screws to a torque of

34 Nm (301 lb-in). Lock screws by bending corners
of lock plate over screws.
STEP 181
258
Install CAS2885 transmission valve adjustment tool

set. Be sure hex rods (part of tool set) are not
installed on studs. Mount the gasket (1), intermediate
plate (2), and gasket (3).
STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 lb-in).
STEP 185
GD98M724
Install new sealing rings and both plugs in duct plate.
STEP 182
GD98M727
Install control valve on duct plate and CAS2885

studs. Install hex rods on studs and tighten against
control valve. Install 21 socket head screws. Tighten
screws to a torque of 9.5 Nm (84 lb-in). Remove
CAS2885 transmission valve adjustment tool set.
Install remaining two socket head screws. Tighten
screws to a torque of 9.5 Nm (84 lb-in).
GD98M725
NOTE: The following steps are for the installation of

the filter.
Install the gasket and place the duct plate against

shoulder. Install socket head screws and hex nuts.
Tighten to a torque of 25 Nm (221 lb-in).
Bur 6-42460
Issued 6-02
Printed in U.S.A.
Copyright
6003-38
STEP 186
STEP 189
GD98M729
GD98M735
Install new O-rings in recesses of oil filter head.

Position filter head on transmission and secure using
two socket head screws. Tighten screws to a torque
of 25 Nm (221 lb-in).
Apply grease to the new O-ring and install the speed

sensor with the socket head screw. Tighten the
screw to a torque of 23 Nm (204 lb-in).
STEP 190
STEP 187
GD98M736
Install a new transmission filter.
With new O-rings, install the inductive transmitters.

Tighten to a torque of 30 Nm (265 lb-in).
STEP 188
STEP 191
GD98M730
Install the breather.
STEP 192
GD98M733
Install new O-rings in oil distribution covers. Install

the two oil distribution covers on the housing with hex
nuts and flat washers. Tighten to a torque of 25 Nm
(221 lb-in).
Bur 6-42460
GD98M737
Install the gasket and the cover plate. Tighten to a

torque of 23 Nm (204 lb-in). With a new O-ring, install
the screw plug. Tighten to a torque of 140 Nm (103
lb-ft).
Issued 6-02
Printed in U.S.A.
Copyright
6004
Section
6004
FRONT AND REAR AXLE
CASE CORPORATION
700 State Street
Bur 6-42470

Printed in U.S.A.
June, 2002
Copyright
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wheel End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wheel End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cleaning, Inspection, and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear Axle Pivot Pin Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Determining Pinion Shaft Shim Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pinion Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly - Open Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly - Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Assembly - Open Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assembly - Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-3
SPECIFICATIONS
Type of Lubricant ....................................................................................................... Case 135H EP (SAE 85W-140)
Capacity.................................................................................................................................. 20.3 liters (21.5 quarts)
Pinion Shaft Rolling Torque (Without Seal Installed) ................................................................... 2.4 Nm (21.23 lb-in)
Pinion Shaft and Differential Combined Rolling Torque
(Without Seal Installed) ................................................................................... 2.9 to 3.2 Nm (25.66 to 28.32 lb-in)
Ring Gear and Pinion Shaft Backlash .............................................................0.25 to 0.33 mm (0.010 to 0.013 inch)
SPECIAL TORQUES
Bolts Securing Retainer and Flange to Hub (Loctite 270 Applied to Threads) ................................. 114 Nm (84 lb-ft)
Bolts Securing Gears to Planetary Carrier Shafts (Loctite 270 Applied to Threads) ........................ 114 Nm (84 lb-ft)
Socket Head Bolts Securing Wheel End to Axle Housing (Loctite 270 Applied to Threads) ..........226 Nm (167 lb-ft)
Bolt Securing Axle Flange (Loctite 270 Applied to Threads) ....................................................... 139 Nm (102.5 lb-ft)
Bolts Securing Differential Carrier (Loctite 270 Applied to Threads) ............................................. 226 Nm (167 lb-ft)
Ring Gear Mounting Bolts (Loctite 270 Applied to Threads) ..........................................................190 Nm (140 lb-ft)
SPECIAL TOOLS
BD01D644
PINION NUT REMOVAL TOOL CASXXXX
BDXXXXXXX
PINION DEPTH GAUGE CASXXXXXX
BD01D646
FALSE PINION TOOL CASXXXXX
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-4
WHEEL END AND BRAKE

Removal
STEP 5
STEP 1
IMPORTANT: In this step, brake plates (4) and axle

shaft (5) may stay in axle housing or stay with wheel
end.
Remove drain plugs and drain oil from wheel ends

and axle housing. Drain oil into a container having a
capacity large enough to hold 20.3 liters (21.5
quarts).
STEP 2
Install axle in an axle stand if available. If axle stand
is not available, secure the axle to a suitable work
bench.
STEP 3
5
BD01D687
4. BRAKE PLATE
5. AXLE SHAFT
Remove wheel end from axle housing. Put wheel end

on suita ble work b en ch an d discon ne ct liftin g
equipment from wheel end.
STEP 6
4
BD01D506
1. SOCKET HEAD BOLT
Remove 12 socket head bolts (1).
STEP 4
BD01D681
4. BRAKE PLATE
5. AXLE SHAFT
Remove brake plates (4) from axle shaft (5).
BD01D685
2. HUB
3. FLANGE
Connect suitable lifting equipment to hub (2) and

flange (3). Using a pry bar, separate hub from axle
housing taking care not to damage mating surfaces
of housing and hub.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-5
STEP 7
STEP 9
A
8
6
7
BD01D680
5. AXLE SHAFT
BD01D627
6. BRAKE FRICTION PLATE

7. SEPARATOR PLATE
8. GRIPPING RING
Pull axle shaft (5) from axle housing.
9. PIN
A. TOOL
Release pressure. Remove pressing tool (A) from

brake friction plate (6). Turn brake plates over as
shown and put pressing tool on brake friction plate.
Apply pressure to press brake friction plate (6),
separator plate (7), and gripping rings (8) down pins
(9).
Disassembly
Brake Plates
STEP 8
STEP 10
9
A
8
9
7
BD01D626

7. SEPARATOR PLATE
8. GRIPPING RING
9. PIN
A. TOOL
Put brake plates in a press. Put a large diameter

sleeve or other suitable tool (A) on center of brake
friction plate (6). Apply pressure to press brake
friction plate (6), separator plate (7), and gripping
rings (8) down pins (9).
Bur 6-42470
BD01D628

7. SEPARATOR PLATE
8. GRIPPING RING
9. PIN
A. TOOL
Using punch and hammer, remove two gripping rings

(8) from each of the four pins (9). Release pressure.
Remove pressing tool (A) from brake friction plate
(6). Remove separator plate (7) and brake friction
plate.
Issued 6-02
Printed in U.S.A.
Copyright
6004-6
STEP 11
STEP 14
10
BD01D622
10. BELLEVILLE SPRING
Remove five Belleville springs (10) from each of the

four pins. Remove two gripping rings from each pin
then remove four pins from separator plate.
BD01D520

COMPRESSED AIR. Apply compressed air to port
from which bleeder valve (12) was removed to free
brake piston and carrier.
STEP 15
Wheel End
STEP 12
13
14
11
BD01D522
13. BRAKE PISTON

BD01D518
11. O-RING
14. BRAKE CARRIER
Remove brake piston (13) and brake carrier (14).
STEP 16
Remove and discard O-ring (11).
STEP 13
16
15
12
BD01D523
BD01D519
12. BLEEDER VALVE
15. O-RING
16. O-RING
Remove brake piston (13) from brake carrier (14).

Remove and discard two O-rings (15 and 16).
Remove bleeder valve (12).

Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-7
STEP 17
STEP 20
20
17
BD01D524
BD01D505
17. O-RING
20. O-RING
Remove and discard O-ring (17) from brake piston

(13).
STEP 21
STEP 18
18
18
21
BD01D503
BD01D525
18. BOLT
21. RETAINING RING
Remove retaining ring (21).
Loosen, but do not remove, three bolts (18).
STEP 22
STEP 19
22
19
BD01D504
BD01M018
19. CAP
Reposition wheel end to gain access to cap (19).

Using a screwdriver, remove cap.
22. WASHER
Remove washer (22).
STEP 23
Remove planetary carrier (32) and associated parts
from hub (2).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-8
IMPORTANT: When disassembling planetary carrier,
do not intermix parts. Keep parts associated with a
planetary gear together in one container. Identify
container and associated shaft to ensure that parts
are installed on same shaft as removed.
STEP 27
26
STEP 24
18
25
BD01D633
25. PLANETARY GEAR
BD01D629
26. NEEDLE BEARING
Put a pan beneath planetary gear (25) to catch

needle bearings (26) when gear is removed. Remove
planetary gear and let needle bearings fall into pan.
Be careful not to lose any needle bearings.
18. BOLT
STEP 28
Remove bolt (18).
STEP 25
27
26
23
BD01D6634
26. NEEDLE BEARING

BD01D631
23. RETAINER
27. WASHER
Remove washer (27). Remove remaining needle

bearings (26).
Remove retainer (23).
STEP 29
STEP 26
28
24
BD01D635
BD01D632
24. WASHER
Remove washer (24).

Bur 6-42470
28. WASHER
Remove washer (28).

Issued 6-02
Printed in U.S.A.
Copyright
6004-9
STEP 30
STEP 33
Do Steps 24 through 32 to remove remaining two
planetary gears and associated parts from planetary
carrier (32). Be sure to keep parts in separate
containers. Mark containers and shafts to ensure
parts are installed on same shaft as removed from.
29
STEP 34
33
BD01D638
29. SLEEVE
Using slide hammer and puller, remove sleeve (29).
STEP 31
BD01D655
33. BOLT
Remove eight bolts (33).
STEP 35
34
30
BD01D639
30. THRUST WASHER
Remove thrust washer (30).
STEP 32
BD01D657
34. RETAINER
Remove retainer (34).
31
BD01D640
31. SPACER
Remove spacer (31).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-10
STEP 36
STEP 39
35
BD01D658
BD01D661
2. HUB
35. SEAL
Connect lifting equipment to hub (2) as shown.
Remove and discard seal (35).
STEP 37
STEP 40
2
36
A
3
BD01D659
2. HUB
3. FLANGE
BD01D662
A. HYDRAULIC RAM
36. OUTER BEARING
Install hydraulic ram (A) as shown. Raise hub (2) and

flange (3) two inches from bench top. Apply pressure
to ram while at the same time tapping on flange to
separate flange and hub.
Remove outer bearing (36) using slide hammer and

puller.
STEP 41
37
STEP 38
38
2
BD01D663
37. INNER BEARING

BD01D660
2. HUB
38. INNER BEARING CUP
Remove inner bearing (37) from hub. Remove inner

bearing cup (38) using slide hammer and puller.
Remove hub (2) from flange.

Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-11
STEP 42
STEP 47
Check brake friction plate (6) and separator plates
(7) with a straight edge. If a plate is not flat, install a
new friction plate and new separator plates.
39
STEP 48
Inspect brake friction plate (6) for excessive wear.
discoloration, scoring, and flaking of material over
large areas. Replace if any of these conditions are
seen.
STEP 49
BD01D665
Remove outer bearing cup (39) using suitable puller.

IMPORTANT: Do not use compressed air to dry or
spin bearings. Allow bearings to air dry.
Check separator plates (7) for pitting, scoring, and

other damage. Replace as necessary.
STEP 50
Inspect piston (13) and carrier (14) for cracks,
breaks, or deformation. Check O-ring grooves in
piston and carrier for foreign matter and chipping.
Replace if any of these conditions are seen.
STEP 43
Clean all parts except brake friction plate (6) in
cle aning s olve nt. WEAR FACE PROTEC TION
WH EN U SIN G CO MPRESSED AIR. U se
compressed air to clear passages in hub (2).
STEP 51
STEP 44
STEP 52
Check hub (2) and flange (3) for cracks, breaks,

deep pitting, erosion, and other damage. Check bolt
holes in flange for crossed or stripped threads.
Replace part if any of these conditions are seen.
Inspect needle bearings (26) for flat spots indicating

wear. Replace as necessary.
STEP 45
Check planetary ring gear in hub (2) for broken,
chipped, or deformed gear teeth. Replace hub if any
of these conditions are seen.
STEP 46
Inspect axle shaft (5) splines for breaks, cracks,
chipping, twisting, or deformation. Replace axle shaft
as necessary.
NOTE: If brake friction plate (6) or separator plate
(7) is damaged, install a new friction plate and new
set of separator plates. Do not mix old and new parts
in a brake.
Bur 6-42470
Check gears (25) for broken, chipped, or deformed

gear teeth. Replace if any of these conditions are
seen.
STEP 53
Check planetary carrier (32) for cracks, breaks, or
pitting. Check splines for cracks, breaks, chipping,
twisting, or deformation. Replace planetary carrier if
any of these conditions are seen.
STEP 54
Inspect bearings (36 and 37) for rough spots or
binding by holding bearing and rotating. If bearing
binds or action is not smooth, replace the bearing.
Visually inspect outer race for cracks, bent condition,
and deformation. Check associated bearing cups for
scratches and grooves, If a bearing or bearing cup
requires replacement, the associated bearing or
bearing cup must also be replaced.
Issued 6-02
Printed in U.S.A.
Copyright
6004-12
26
28
27
18
31
23
24
29
25
26
30
32
38
37
33
34
12
2
39
11
35
PLANETARY RING GEAR

(PART OF HUB; NOT SERVICED SEPARATELY)
21
19
20
36
22
BS01M002
1.
2.
3.
11.
12.
18.
19.
20.
21.
Bur 6-42470
SOCKET HEAD BOLT

HUB
FLANGE
O-RING
BLEEDER VALVE
BOLT
CAP
O-RING
RETAINING RING
22.
23.
24.
25.
26.
27.
28.
29.
30.
WASHER
RETAINER
WASHER
GEAR
NEEDLE BEARING
WASHER
WASHER
SLEEVE
THRUST WASHER
31.
32.
33.
34.
35.
36.
37.
38.
39.
SPACER
PLANETARY CARRIER
BOLT
RETAINER
SEAL
OUTER BEARING
INNER BEARING
INNER BEARING CUP
OUTER BEARING CUP
Issued 6-02
Printed in U.S.A.
Copyright
6004-13
5
4
8
10
9
8
7
6
7
13
17
15
14
16
BS01M001
4.
5.
6.
7.
Bur 6-42470
BRAKE PLATES
AXLE SHAFT
BRAKE FRICTION PLATE
SEPARATOR PLATE
8.
9.
10.
13.
GRIPPING RING
PIN
BELLEVILLE SPRING
BRAKE PISTON
14.
15.
16.
17.
BRAKE CARRIER
O-RING
O-RING
O-RING
Issued 6-02
Printed in U.S.A.
Copyright
6004-14
STEP 57
Assembly
Wheel End
STEP 55
38
35
BD01D632
35. SEAL
Position new seal (35), seal lips down, in hub (2).

BD01D664
STEP 58
Using proper size sleeve, press new inner bearing

cup (38) into hub (2) until flush against shoulder in
hub.
STEP 56
39
BD01D668
Using proper size driver, press seal (35) into hub (2)
until seated against shoulder in hub.
STEP 59
BD01D665
39. OUTER BEARING CUP
36
Using proper size sleeve, press new outer bearing

cup (39) into hub (2) until flush against shoulder in
hub.
BD01D662
36. OUTER BEARING
Install outer bearing (36) using suitable size sleeve

pushing on inner race of bearing. Press bearing on
flange (3) until bearing stops moving.
STEP 60
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-15
STEP 63
32
31
37
BD01D669
BD01D641
37. INNER BEARING
Put hub (2) and flange (3) in a hydraulic press.

Position inner bearing (37) on hub. Using suitable
size driver pushing on inner race of bearing, press
bearing on flange until bearing stops moving.
31. SPACER
32. PLANETARY CARRIER
Install spacer (3 1), chamfer down, on shaft of

planetary carrier (32).
STEP 64
STEP 61
34
30
BD01D639
BD01D657
34. RETAINER
30. THRUST WASHER
Install thrust washer (30).
Put retainer (34) in position in hub (2) on flange (3).
STEP 65
STEP 62
29
33
BD01D648
BD01D655
33. BOLT
Apply Loctite 270 to threads of eight bolts (33). Install

bolts. Tighten bolts to a torque of 114 Nm (84 lb-ft).
Bur 6-42470
29. SLEEVE
Put planetary carrier in press. Press sleeve (29) on

shaft until sleeve stops moving. Repeat Steps 63
through 65 to install other sleeves if necessary.
Issued 6-02
Printed in U.S.A.
Copyright
6004-16
STEP 66
STEP 69
29
26
24
28
BD01D649
26. NEEDLE BEARINGS
28. WASHER
BD01D653
29. SLEEVE
Install washer (28). Apply petroleum jelly to bottom

portion of sleeve (29). Install 39 needle bearings (26)
on periphery of sleeve.
24. WASHER
Install washer (24).
STEP 70
STEP 67
25
27
BD01D654
25. GEAR
BD01D650
27. WASHER
Install gear (25). Do Steps 66 through 70 to install the

remaining washers, roller bearings, and gears.
STEP 71
STEP 68
18
26
23
BD01D631
BD01D652
26. NEEDLE BEARING
Apply petroleum jelly to upper portion of sleeve (29).

Install 39 needle bearings (26) on periphery of
sleeve.
Bur 6-42470
18. RETAINER
23. BOLT
Install retainers (23). Apply Loctite 270 to threads of

three bolts (18) and install bolts.
Issued 6-02
Printed in U.S.A.
Copyright
6004-17
STEP 72
STEP 76
20
18
18
BD01D630
BD01D505
18. BOLT
20. O-RING
Tighten three bolts (18) to a torque of 114 Nm (84

lb-ft).
Install new O-ring (20).
STEP 77
STEP 73
Install planetary carrier (32) in hub (2).
STEP 74
19
22
BD01M019
19. CAP
Install cap (19).

BD01D504
STEP 78
22. WASHER
Tip wheel end down. Install washer (22).
STEP 75
17
BD01D524
17. O-RING
21
Install a new O-ring (17) in brake piston (13).

BD01D503
21. RETAINING RING
Install retaining ring (21).

Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-18
STEP 79
STEP 82
13
14
16
15
BD01D523
15. O-RING
BD01D677
13. BRAKE PISTON

14. BRAKE CARRIER
A. PUSHER
16. O-RING
Install two new O-rings (16 and 15) in brake carrier

(14) and brake piston (13). Put brake piston on brake
carrier.
STEP 80
Using a large diameter pusher (A), push brake piston

(13) and carrier (14) into hub (3).
STEP 83
14
12
13
BD01D675
13. BRAKE PISTON
BD01D519
14. BRAKE CARRIER
Put brake piston (13) and brake carrier (14) in press.

Using a large diameter pusher (A), push brake piston
onto brake carrier.
12. BLEEDER VALVE
Install bleeder valve (12).
STEP 84
STEP 81
13
14
11
BD01D518
BD01D676
13. BRAKE PISTON
14. BRAKE CARRIER
11. O-RING
Put assembled brake piston (13) and carrier (14) in

hub (3). Put hub and flange in press.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-19
Brake Plates
STEP 86
STEP 85
A
9
10
7
BD01D622
BD01D620
10
9
A
8
C
BS01M088
10. BELLEVILLE SPRING

BS01M087
7. SEPARATOR PLATE
8. GRIPPING RING
9. PIN
A.
B.
C.
D.
SHOULDER OF PIN
GAP 180 DEGREES APART
20.8 MM (0.82 INCH)
NO GAP BETWEEN PIN
SHOULDER AND PLATE
Install pins (9) in separator plate (7); shoulder (A) of

pin must be positioned as shown. Using a press and
suitable size sleeve, install two gripping rings (8) on
ea ch p in . End s of g rip ping rin gs mu st be 18 0
degrees opposite (B) each other when installed.
When gripping rings are installed, there must be no
gap (D) between shoulder of pin and separator plate.
Dimension (C) between end of pin and gripping ring
should be 20.8 mm (0.82 inch).
Install five Belleville springs (10) on each of the four

pins. Position Belleville springs as shown.
STEP 87
7
BD01D624
7. SEPARATOR PLATE
Install brake friction plate (6) and separator plate (7).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-20
STEP 88
Installation
STEP 89
8
5
BD01D625
BD01D680
5. AXLE SHAFT
Install axle shaft (5) in axle housing.
A
STEP 90
A
4
C
7
A
BS01M041
7. SEPARATOR PLATE
8. GRIPPING RING
9. PIN
A. GAP 180 DEGREES APART

B. 12.5 MM (0.49 INCH)
C. GRIPPING RINGS
Using a press and suitable size sleeve, install two

gripping rings (8) on each pin (9). Ends of gripping
rings must be 180 degrees opposite (A) each other
when installed. Press gripping rings on pin until 12.5
mm (0.49 inch) (B) is obtained between gripping ring
and top of pin. Remove brake plates from press.
Check that pins cannot be rotated in their mounting
holes. If pins can be rotated, gripping rings (C) are
not completely against separator plate (7). Put brake
plates in press and press gripping rings (C) on pin
until rings are completely against separator plate (7).
Bur 6-42470
BD01D681
4. BRAKE PLATE
5. AXLE SHAFT
A. AXLE HOUSING HOLES
IMPORTANT: Brake plates must be installed in axle

housing with short pin side of brake plates inside axle
housing: long pin side of brake plates must be facing
outward.
Install brake plates (4) on axle shaft (5). Install pins
on short pin side of brake plates in holes (A) in axle
housing.
Issued 6-02
Printed in U.S.A.
Copyright
6004-21
STEP 91
STEP 93
A
A
BD01D682
A. STUD
BD01D684
1. SOCKET HEAD BOLT
Install two studs (A) in axle housing wheel end.
STEP 92
A. STUD
Apply Loctite 270 to threads of 12 socket head bolts

(1). Install bolts finger tight and remove two studs
(A).
STEP 94
BD01D683
Connect lifting equipment to wheel end and move

into position. Turn flange as necessary to mesh
planetary gears with axle shaft gear teeth.
BD01D692
1. SOCKET HEAD BOLT
Disconnect lifting equipment from wheel end. Tighten

socket head bolts (1) to a torque of 226 Nm (167
lb-ft).
STEP 95
Remove axle from axle stand or work bench.
STEP 96
Fill axle with amount and type of oil specified in
Section 1002.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-22
DIFFERENTIAL CARRIER
STEP 100
Removal
STEP 97
Remove both wheel ends, brakes, and axle shafts
(Steps 1 through 7).
STEP 98
2
1
BD01D533
Remove differential carrier from axle housing and

install in suitable stand.
Disassembly
1
BD01D527
1. BOLT
STEP 101
2. DIFFERENTIAL CARRIER
Remove 14 bolts (1) securing differential carrier (2)

to axle housing.
STEP 99
2
A
9
BD01D617
2
A
BD01D531
9. AXLE FLANGE
A. STRAP
Install two straps (A) in axle flange (9). Connect lifting

equipment to straps as shown. Raise differential
carrier from axle housing. If necessary, use prybar to
break seal between differential carrier and axle
housing and move carrier off housing dowel pins.
BD01D616
2. DIFFERENTIAL CARRIER A. MATCH MARKS

4. CARRIER
Using a suitable markers, make match marks (A) on

differential carrier (2) and carriers (4) to aid in
assembly.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-23
STEP 102
STEP 105
5
3
4
BD01D534
3. LOCKING PIN
4. CARRIER
5. DIFFERENTIAL
Position differential carrier on stand so differential (5)

is at top. Using suitable tool, push locking pin (3) up
into collar out of notch in carrier (4). Do the same on
other side of differential.
BD01D539
Carefully remove differential from differential carrier.

Put differential on clean work bench. Go to Step 180
to disassemble open differential or Step 194 to
disassemble limited slip differential.
STEP 106
STEP 103
A
7
BD01D540
BD01D536
5. DIFFERENTIAL
Connect lifting equipment to differential (5) and take

up all slack.
STEP 104
6. BOLT
7. WASHER
9. AXLE FLANGE
A. PRYBAR
Reposition differential carrier so axle flange (9) is at

top. Using prybar (A) to prevent axle flange from
turning, remove bolt (6) and washer (7).
STEP 107
4
BD01D538
8
BD01D542
4. CARRIER
Remove carrier (4). Remove carrier from opposite

side of differential carrier.
Bur 6-42470
8. O-RING

Issued 6-02
Printed in U.S.A.
Copyright
6004-24
STEP 108
STEP 111
9
A
12
10
BD01D543
9. AXLE FLANGE
BD01D555
10. COVER
12. NUT
A. TOOL CASXXXX
Re mov e a xle flan ge (9 ) a nd co ver (10 ) a s a n

assembly.
Install tool CASXXXX (A) on nut (12).
STEP 109
STEP 112
11
BD01D556
BD01D544
Loosen nut (12).
11. SEAL
Remove and discard seal (11).
STEP 113
STEP 110
12
12
BD01D557
12. NUT
BD01D546
12. NUT
Remove nut (12).
Using a hammer and suitable size punch, move

projection staked in nut (12) during assembly away
from notch in pinion shaft.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-25
STEP 114
STEP 117
13
15
BD01D558
BD01D560
13. TAB WASHER
15. WASHER
Remove tab washer (13).
Remove washer (15) from pinion shaft.
STEP 115
STEP 118
20
16
A
14
BD01D559
14. OUTER BEARING
20. PINION SHAFT
BD01D561
A. HAMMER
Using a brass hammer (A), push pinion shaft (20) out

of differential carrier just enough to free outer bearing
(14).
16. SPACER
Remove and discard spacer (16).
STEP 119
STEP 116
14
17
20
BD01D562
17. WASHER
BD01D563
14. OUTER BEARING
Remove washer (17).
20. PINION SHAFT
Remove outer bearing (14) from differential carrier

then remove pinion shaft (20) with washers (15 and
17), spacer (16), inner bearing (18), and shim (19)
installed.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-26
STEP 120
STEP 123
20
18
21
BD01D564
18. INNER BEARING
20. PINION SHAFT
BD01D567
A. COLLAR
Put pinion shaft (20) and inner bearing (18) in

hydraulic press. Install collar (A). Put a support under
pinion shaft to prevent it from falling on floor. Press
pinion shaft from bearing.
If outer bearing cup (21) requires replacement, use a

slide hammer and suitable puller to remove.
STEP 124
STEP 121
22
19
BD01D568

BD01D565
19. SHIM
If inner bearing cup (22) requires replacement, use a

slide hammer and suitable puller to remove.
Remove shim (19) from pinion shaft.
STEP 122
A
10
BD01D673
9. AXLE FLANGE
10. COVER
A. COLLAR
To remove axle flange (9) from cover (10), install

collar (A) as shown and press flange from cover.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-27
Cleaning, Inspection, and Repair

STEP 125
STEP 128
Check pinion shaft (20) for broken, chipped, or
deformed gear teeth. Inspect splines for breaks,
cracks, chipping, twisting, or deformation. Replace
pinion shaft if any of these conditions are seen.
Clean all parts in cleaning solvent. WEAR FACE

Compressed air may be used to dry parts.
NOTE: If the pinion shaft is replaced, the differential

ring gear must also be replaced. These parts, pinion
shaft and ring gear, are supplied as a matched set.
STEP 126
STEP 129
Check differential carrier (2) for cracks, breaks, deep

pitting, erosion, and other damage. Replace if any of
these conditions are seen.
Inspect outer bearing (14) and inner bearing (18) for

rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth,
replace the bearing. Visually inspect outer race for
cracks, bent condition, and deformation. Check
associated bearing cups for scratches and grooves,
If a bearing or bearing cup requires replacement, the
associated bearing or bearing cup must also be
replaced.
STEP 127
Inspect axle flange (9) for cracks, breaks, and
damaged threads. Check splines for breaks, cracks,
chipping, twisting, or deformation. Replace axle
flange if any of these conditions are seen.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-28
Rear Axle Pivot Pin Bushings
STEP 132
STEP 130
A
23 24
23
BD01D495
BD01D482
A
A
23 24
24
BD01D499
23. DIFFERENTIAL CARRIER PIVOT PIN BUSHING

24. AXLE HOUSING PIVOT PIN BUSHING
A. GROOVE
BD01D499

A. THRUST SURFACE
Inspect pivot pin bushings in differential carrier and

axle housing for cracks, breaks, deformation, or
other damage. Check oil splash grooves for scoring
or chipping. Check for scoring on thrust surface (A).
If bushing (23 or 24) requires replacement, do Steps
131 and 132.
STEP 131
WARNING: Always wear insulated gloves

or mittens when handling frozen parts.
Freeze new bushing in dry ice for several hours.

Install bushing in axle housing or differential carrier
with groove (A) on circumference of bushing facing
center of housing or carrier. Install bushing against
shoulder in housing or carrier.
BD01D491
Put axle housing or differential carrier in hydraulic

press. Make sure housing or carrier is properly
supported. Using a 66.6 mm (2.625 inches) diameter
by suitable length rod, press bushing out of housing
or carrier.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-29
STEP 137
Assembly
Determining Pinion Shaft Shim
Thickness
STEP 133
18
If bearing cups (21 and 22) were removed, do Steps

146 and 147.
STEP 134
14
BD01D571
Install pinion tool (A) and inner bearing (18) in

differential carrier then install outer bearing (14) on
pinion tool.
STEP 138
BD01D569
12
Measure and record thickness (A) of head of pinion

tool CASXXXX.
STEP 135
Measure differential housing diameter, then calculate
and record its radius.
STEP 136
BD01D572
Install nut (12) on pinion tool shaft.
STEP 139
18
BD01D570
Install inner bearing (18) on pinion tool CASXXXX

(A).
BD01D573
Using tool CASXXXX (A), tighten nut (12) securely.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-30
STEP 140
STEP 143
BD01D614
BD01D600
Install bolt (14) in shaft. Using a lb-in torque wrench,

measure rolling torque of pinion shaft. Rolling torque
must be 1.6 to 2.4 Nm (14.16 to 21.23 lb-in). If rolling
torque is too high, loosen nut (12); if too low, tighten
nut then recheck pinion shaft rolling torque.
Using inside micro me ter, me asure and re cord

distance (A) between surface of pinion tool and mark
indicating halfway point on differential housing.
STEP 141
5
4
2
BD01D601
Install differential (5) in differential carrier (2) and

install two carriers (4) to secure differential. Tighten
carriers until there is no play and some resistance is
felt when differential is rotated.
STEP 144
Record the number stamped on pinion shaft. Add the
measurements recorded in Step 134 (pinion tool
head thickness), Step 135 (differential housing
radius), and Step 143 (distance between pinion tool
head and differential housing). Subtract the number
stamped on the pinion shaft from the sum of the
measurements of Steps 134, 135, and 143. The
remainder is the required shim thickness.
NOTE: Shims are available in the following
thicknesses: 2.5 mm (0.098 inch), 2.6 mm (0.102
inch), 2.7 mm (0.106 inch), 2.8 mm (0.110 inch), 2.9
mm (0.114 inch), 3.0 mm (0.118 inch), 3.1 mm (0.122
inch), 3.2 mm (0.126 inch), 3.3 mm (0.130 inch), and
3.4 mm (0.134 inch).
STEP 145
Remove differential, pinion tool, and bearings from
differential carrier. Go to Step 146.
STEP 142
BD01D597
Mo unt d ial in dicator to in dicate off differentia l

housing. Rotate differential while observing dial
indicator. Mark zero point and maximum reading
point on differential. Determine and mark halfway
point between zero and maximum reading points on
differential housing.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-31
Pinion Shaft
6.
7.
8.
9.
10.
11.
12.
13.
14.
BOLT
WASHER
O-RING
AXLE FLANGE
COVER
SEAL
NUT
TAB WASHER
OUTER BEARING
15.
16.
17.
18.
19.
20.
21.
22.
A.
WASHER
SPACER
WASHER
INNER BEARING
SHIM
PINION SHAFT
OUTER BEARING CUP
INNER BEARING CUP
RING GEAR
22
19
20
17
15
16
21
10
11
12
13
18
14
8
7
6
BS01M166
STEP 146
STEP 147
21
22
BD01D568
BD01D567

If inner bearing cup (22) was removed, freeze new

bearing cup in dry ice for several hours. Install
bearing cup in differential carrier against shoulder in
carrier.
Bur 6-42470

If outer bearing cup (21) was removed, freeze new

bearing cup in dry ice for several hours. Install
bearing cup in differential carrier against shoulder in
carrier.
Issued 6-02
Printed in U.S.A.
Copyright
6004-32
STEP 148
STEP 151
10
17
BS01D674
9. AXLE FLANGE
BD01D562
17. WASHER
10. COVER
Press axle flange (9) into cover (10) as shown.
STEP 149
STEP 152
19
16
BD01D561
BD01D565
16. SPACER
19. SHIM
Install correct thickness shim (19) (as determined in

Steps 133 through 144) on pinion shaft.
Install new spacer (16).
STEP 153
STEP 150
18
15
20
BD01D560
BD01D506
18. INNER BEARING
20. PINION SHAFT
15. WASHER
Install washer (15) on pinion shaft.
Install inner bearing (18) on pinion shaft (20). Put

pinion shaft and inner bearing in hydraulic press.
Press bearing on pinion shaft using proper diameter
sleeve pushing on inner race of bearing.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-33
STEP 154
STEP 156
13
BD01D612
Install pinion shaft (20) with washers (15 and 17),

spacer (16), inner bearing (18), and shim (19) in
differ e ntia l ca r rier. Po sitio n a me ta l blo ck o n
differential as shown and secure using two C-clamps.
BD01D558
13. TAB WASHER
Install tab washer (13).
STEP 157
STEP 155
12
BD01D557
12. NUT
BD01D511
Apply Case 135H EP (SAE 85W-140) oil to pinion

shaft where outer bearing (14) will be installed. Install
outer bearing (14) on pinion shaft in differential
carrier. Using suitable size sleeve pushing on outer
bearing inner race press outer bearing on pinion
shaft until threads of pinion shaft are accessible.
Remove C-clamps and metal block installed in Step
154 from differential carrier.
Apply Case 135H EP (SAE 85W-140) oil to tab

washer face and nut (12) threads. Install nut.
STEP 158
A
12
BD01D555
12. NUT
A. TOOL CASXXXX
Install tool CASXXXX (A) on nut (12).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-34
STEP 159
STEP 162
4
BD01D556
Tighten nut (12). Do not overtighten nut to where

r o l lin g t o r q u e ( c h e c k e d i n f o ll o w i n g s t e p ) is
exceeded.
STEP 160
BD01D538
4. CARRIER
Install carrier (4). Install carrier in opposite side of

differential carrier. When installing carriers, be sure to
follow match marks made during assembly.
STEP 163
5
BD01D614
Install bolt (6) in pinion shaft. Using a lb-in torque

wrench, measure rolling torque of pinion shaft.
Rolling torque must be 2.4 Nm (21.23 lb-in). If rolling
torque is too high, loosen nut (12); if too low, tighten
nut then recheck pinion shaft rolling torque.
BD01D536
5. DIFFERENTIAL
Disconnect lifting equipment from differential (5).
STEP 164
STEP 161
BD01D671
BD01D539
Move differential into position and carefully position

in differential carrier.
Bur 6-42470
Tighten carriers (4) evenly and check rolling torque

(Step 165).
Issued 6-02
Printed in U.S.A.
Copyright
6004-35
STEP 165
STEP 167
BD01D614
Install bolt (6) in pinion shaft. Using a lb-in torque

wrench, measure rolling torque of pinion shaft and
differential. Rolling torque must be between 2.9 and
3.2 Nm (25.66 to 28.32 lb-in). If rolling torque is too
high, loosen carriers (4); if too low, tighten carriers
then recheck pinion shaft rolling torque. Remove bolt
(6) when correct rolling torque is obtained.
BD01D618
Check that notch in carrier (4) is directly under

locking pin (3). If necessary turn carrier slightly to
align locking pin and notch. Using hammer, drive
locking pin into notch of carrier. Repeat at opposite
side of differential.
STEP 168
STEP 166
12
BD01D546
12. NUT
BD01D615
Setup a dial indicator to indicate off one tooth of ring

gear. Turn pinion shaft so that teeth of ring gear and
pinion shaft touch in both directions. Backlash as
indicated on dial indicator must be 0.25 to 0.33 mm
(0.010 to 0.013 inch). If backlash is too high, adjust
carriers (4) to move ring gear away from pinion shaft.
If backlash is too low, adjust carriers to move ring
gear closer to pinion shaft. Repeat Step 165 to check
rolling torque. If rolling torque must be adjusted,
repeat Step 166 to check backlash.
Using a hammer and suitable size punch, stake nut

(12) in notch in pinion shaft.
STEP 169
11
BD01D544
11. SEAL
Install seal (11).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-36
STEP 170
STEP 172
10
BD01D543
9. AXLE FLANGE
10. COVER
BD01D541
6. BOLT
7. WASHER
Install cover (10) and axle flange (9).
9. AXLE FLANGE
A. PRYBAR
Reposition differential carrier. Apply Loctite 270 to

threads of bolt (6). Install washer (7) and bolt. Using
prybar (A) to prevent axle flange from turning, tighten
bolt to a torque of 139 Nm (102.5 lb-ft).
STEP 171
8
BD01D542
8. O-RING
Installation
2
1. BOLT
3. LOCKING PIN
FRONT AXLE
3
BS01M168
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-37
24
2
1
3
REAR AXLE
23
BS01M167
1. BOLT
3. LOCKING PIN

STEP 173
STEP 174
BD01D678
BD01D679
Remove all traces of old gasket material from axle

housing differential carrier mounting surface. Do the
same on associated mating mounting surface of
differential carrier.
Apply Loctite 515 to axle housing differential carrier

mounting surface.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-38
STEP 175
STEP 177
2
1
1
BD01D533
Connect suitable lifting equipment to differential

carrier. Remove differential carrier from repair stand.
STEP 176
BD01D528
1. BOLT
Apply Loctite 270 to threads of bolts (1). Secure

differential carrier (2) using 14 bolts (1). Tighten bolts
to a torque of 226 Nm (167 lb-ft).
STEP 178
Install both axle shafts, brakes, and wheel ends
(Steps 89 through 96).
BD01D531
9. AXLE FLANGE
A. STRAP
L o w e r d if fe r e n t ia l c a r r ie r in t o a x le h o u s in g .
Disco nn e ct lifting e qu ipme nt fr om s tra ps ( A).
Remove two straps (A) from axle flange (9).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-39
DIFFERENTIAL
STEP 182
Removal
STEP 179
Refer to Steps 97 through 104 to remove differential
from differential carrier.
Disassembly - Open Differential

STEP 180
19
5
BD01D577
7. HOUSING COVER
19. HOUSING
Using two putty knives or other suitable tools inserted

between housing cover (7) and housing (19), pry
cover up and remove from housing.
STEP 183
BD01D574
5. BOLT
Remove 14 bolts (5).
STEP 181
BD01D591
8. COUNTER PLATE
Remove counter plate (8).
STEP 184
6
9
BD01D576
6. RING GEAR
Using a prybar, carefully remove ring gear (6).
BD01D592
9. SIDE GEAR
Remove side gear (9).

Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-40
STEP 185
STEP 188
13
10
10
11
BD01D584
10. PIN
BD01D587
11. LONG SHAFT
13. SHAFT RETAINER
Remove three pins (10) securing long shaft (11) and

two short shafts (12).
Remove shaft retainer (13).
STEP 189
STEP 186
14
15
11
BD01D588
BD01D586
11. LONG SHAFT
14. PINION GEAR
15. THRUST WASHER
Remove long shaft (11).
Remove four pinion gears (14) and four thrust

washers (15).
STEP 187
STEP 190
16
12
BD01D585
12. SHORT SHAFT
Remove two short shafts (12).
Bur 6-42470
BD01D593
16. SIDE GEAR
Remove side gear (16).
Issued 6-02
Printed in U.S.A.
Copyright
6004-41
STEP 191
STEP 193
17
BD01D594
BD01D578
17. COUNTER PLATE
Remove counter plate (17).
STEP 192
3
4
BD01D595
4. BEARING CUP
If bearing cup (4) requires replacement, remove

bearing cup using slide hammer and puller.
BD01D608
3. BEARING
I f i n s p e c t io n i n d i c a t e s b u s h i n g ( 2 ) r e q u ir e s
replacement, remove bushing using proper size
pusher and sleeve. If inspection indicates bearing (3)
re q u ir e s r e p la ce m e n t, r e mo v e b e a r in g u s in g
hydraulic press and collar.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-42
STEP 197
Disassembly - Limited Slip

Differential
11
STEP 194
8
5
9 10
BD01D579
8. SEPARATOR PLATE
9. FRICTION PLATE
BD01D574
5. BOLT
Remove 14 bolts (5).
10. FRICTION PLATE

11. SIDE GEAR
Remove side gear (11) with separator plates (8) and

friction plates (9 and 10) as an assembly from
housing.
STEP 198
STEP 195
6
BD01D580
BD01D576
8. SEPARATOR PLATE
6. RING GEAR
Using a prybar, carefully remove ring gear (6).
Remove one separator plate (8).
STEP 196
STEP 199
7
9
8
22
BD01D577
BD01D581
Using two putty knives or other suitable tools inserted

between housing cover (7) and housing (22), pry
cover up and remove from housing.
Remove three friction plates (9) and three separator

plates (8).
7. HOUSING COVER
Bur 6-42470
22. HOUSING
8. SEPARATOR PLATE
9. FRICTION PLATE
Issued 6-02
Printed in U.S.A.
Copyright
6004-43
STEP 200
STEP 203
14
10
11
BD01D583
10. FRICTION PLATE
BD01D585
11. SIDE GEAR
14. SHORT SHAFT
Remove friction plate (10) from side gear (11).
Remove two short shafts (14).
STEP 201
STEP 204
15
12
12
13
BD01D584
12. PIN
BD01D587
13. LONG SHAFT
15. SHAFT RETAINER
Remove three pins (12) securing long shaft (13) and

Remove shaft retainer (15).
STEP 205
STEP 202
16
17
13
BD01D588
BD01D586
13. LONG SHAFT
Remove long shaft (13).
Bur 6-42470
16. PINION GEAR
17. THRUST WASHER
Remove four pinion gears (16) and four thrust

washers (17).
Issued 6-02
Printed in U.S.A.
Copyright
6004-44
STEP 206
STEP 209
21
20
21
18 19 20
BD01D590
18. SEPARATOR PLATE

19. FRICTION PLATE
20. FRICTION PLATE

21. SIDE GEAR
Remove side gear (21) with separator plates (18)

and friction plates (19 and 20) as an assembly from
housing.
BD01D583
20. FRICTION PLATE
21. SIDE GEAR
Remove friction plate (20) from side gear (21).
STEP 210
STEP 207
3
18
BD01D608
3. BEARING
BD01D580
18. SEPARATOR PLATE
Remove one separator plate (18).
I f i n s p e c t io n in d i c a t e s b u s h i n g ( 2 ) r e q u ir e s
replacement, remove bushing using proper size
pusher and sleeve. If inspection indicates bearing (3)
re q u ir e s r e p la ce m e n t, r e mo v e b e a r in g u s in g
hydraulic press and collar.
STEP 208
19
18
BD01D581
18. SEPARATOR PLATE 19. FRICTION PLATE
Remove three friction plates (19) and three separator

plates (18).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-45
STEP 211

4
STEP 212
Clean all parts in cleaning solvent. WEAR FACE
Compressed air may be used to dry parts other than
bearings.
STEP 213
BD01D578
Check bushing (2) for cracks, grooves, or other

damage. Replace bushing if any of these conditions
are seen.
STEP 214
Inspect bearing (3) for rough spots or binding by
holding bearing and rotating. If bearing binds or
action is not smooth, replace the bearing. Visually
inspect outer race for cracks, bent condition, and
deformation. Check associated bearing cups (4) for
scratches and grooves, If a bearing or bearing cup
requires replacement, the associated bearing or
bearing cup must also be replaced.
4
BD01D595
4. BEARING CUP
If bearing cup (4) requires replacement, remove

bearing cup using slide hammer and puller.
STEP 215
Check ring gear (6), side gears, and pinion gears for
broken, chipped, or deformed gear teeth. Check
internal splines in side gears for cracks, breaks,
chipping, twisting, or deformation. Replace part if any
of the above conditions are seen.
NOTE: If the ring gear (6) is replaced, the pinion
shaft must also be replaced. These parts, ring gear
and pinion shaft, are supplied as a matched set.
STEP 216
Inspect remaining parts for cracks, bent condition, or
damaged or deformed threads. Replace parts as
necessary.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-46
Assembly - Open Differential
6
1
4
18
15
2
14
14
10
15
12
17
16
13
11
15
5
1
12
10
10
14
14
3
15
BS01M177
1.
2.
3.
4.
5.
CARRIER
BUSHING
BEARING
BEARING CUP
BOLT
6.
7.
8.
9.
10.
RING GEAR
HOUSING COVER
COUNTER PLATE
SIDE GEAR
PIN
STEP 217
11.
12.
13.
14.
15.
LONG SHAFT
SHORT SHAFT
SHAFT RETAINER
PINION GEAR
THRUST WASHER
16. SIDE GEAR

17. COUNTER PLATE
18. HOUSING
STEP 218
1
BD01D610
1. CARRIER
If bushing (2) was removed for replacement, press

new bushing into carrier (1) using proper size pusher
and sleeve. Press bushing into carrier until it stops
moving.
Bur 6-42470
BD01D609
1. CARRIER
3. BEARING
If bearing (3) was removed for replacement, press

new bearing onto carrier (1) until bearing is flush
against shoulder.
Issued 6-02
Printed in U.S.A.
Copyright
6004-47
STEP 219
STEP 221
16
4
BD01D578
BD01D593
16. SIDE GEAR
Install side gear (16).
4
STEP 222
14
15
BD01D595
4. BEARING CUP
If bearing cup (4) was removed for replacement,

press new bearing cup into housing or cover until
flush against shoulder.
BD01D588
14. PINION GEAR
STEP 220
15. THRUST WASHER
Install four thrust washers (15) and pinion gears (14).
STEP 223
17
13
BD01D594
17. COUNTER PLATE
Install counter plate (17) in housing.
BD01D587
13. SHAFT RETAINER
Install shaft retainer (13).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-48
STEP 224
STEP 227
9
A
12
BD01D592
BD01D585
12. SHORT SHAFT
9. SIDE GEAR
A. HOLE (FOR PIN)
Install two short shafts (12) through thrust washer

(15), pinion gear (14), and into shaft retainer (13).
Make sure hole (A) in shaft is facing up.
Install side gear (9).
STEP 228
STEP 225
8
11
BD01D591
8. COUNTER PLATE
BD01D586
11. LONG SHAFT
Install counter plate (8).
STEP 229
Install long shaft (11).
STEP 226
7
18
10
6
10
BD01D596
6. RING GEAR
7. HOUSING COVER
11
BD01D584
12. PIN
13. LONG SHAFT
Install three pins (10) to secure long shaft (11) and

Bur 6-42470
18. HOUSING
A. STUDS
Put ring gear (6) on wood blocks. Wood blocks must

be high enough to let housing (18) be put in ring
gear. Install two studs (A) in ring gear. Put housing
(18) and assembled parts on studs then install
housing cover (7). Use a soft hammer to move
housing down onto ring gear.
Issued 6-02
Printed in U.S.A.
Copyright
6004-49
STEP 230
STEP 232
1
BD01D575
BD01D609
5. BOLT
1. CARRIER
Apply Loctite 270 to threads of 14 bolts (5). Install 12

bolts finger tight. Remove two studs then install
remaining two bolts. Remove wood blocks. Tighten
14 bolts (5) to a torque of 190 Nm (140 lb-ft).
3. BEARING
If bearing (3) was removed for replacement, press

new bearing onto carrier (1) until bearing is flush
against shoulder.
STEP 233
Assembly - Limited Slip Differential

STEP 231
4
BD01D578
1
4
BD01D610
1. CARRIER
If bushing (2) was removed for replacement, press

new bushing into carrier (1) using proper size pusher
and sleeve. Press bushing into carrier until it stops
moving.
BD01D595
4. BEARING CUP
If bearing cup (4) was removed for replacement,

press new bearing cup into housing or cover until
flush against shoulder.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-50
22
18
17
18
16
16 12
17
14
11
10
20
21
19
15
5
12
4
9
3
12 13 16
16
14
17
17
BS01M176
1.
2.
3.
4.
5.
6.
CARRIER
BUSHING
BEARING
BEARING CUP
BOLT
RING GEAR
7.
8.
9.
10.
11.
12.
COVER
SEPARATOR PLATE
FRICTION PLATE
FRICTION PLATE
SIDE GEAR
PIN
STEP 234
13.
14.
15.
16.
17.
LONG SHAFT
SHORT SHAFT
SHAFT RETAINER
PINION GEAR
THRUST WASHER
18.
19.
20.
21.
22.
SEPARATOR PLATE
FRICTION PLATE
FRICTION PLATE
SIDE GEAR
HOUSING
STEP 235
21
20
19
18
A
A
BD01D582
20. FRICTION PLATE
21. SIDE GEAR
A. HOLES
Install friction plate (20) on side gear (21). Make sure

circular cutouts in friction plate are aligned with holes
(A) in side gear.
Bur 6-42470
BD01D581
18. SEPARATOR PLATE
19. FRICTION PLATE
Install three separator plates (18) and three friction

plates (19) alternating between separator plates and
friction plates. The first plate installed must be a
separator plate (18); the last plate installed must be a
friction plate (19). Circular cutouts in friction plates
must be aligned.
Issued 6-02
Printed in U.S.A.
Copyright
6004-51
STEP 236
STEP 239
18
15
BD01D580
BD01D587
18. SEPARATOR PLATE
15. SHAFT RETAINER
Install one separator plate (18).
Install shaft retainer (15).
STEP 237
STEP 240
21
A
14
18 19 20
BD01D590
18. SEPARATOR PLATE

19. FRICTION PLATE
20. FRICTION PLATE

21. SIDE GEAR
BD01D585
14. SHORT SHAFT
A. HOLE (FOR PIN)
Install side gear (21) with separator plates (18) and

friction plates (19 and 20) as an assembly in housing.
Install two short shafts (14) through thrust washer

(17), pinion gear (16), and into shaft retainer (15).
Make sure hole (A) in shaft is facing up.
STEP 238
STEP 241
16
17
13
BD01D588
16. PINION GEAR
17. THRUST WASHER
Install four pinion gears (16) and four thrust washers

(17).
Bur 6-42470
BD01D586
13. LONG SHAFT
Install long shaft (13).
Issued 6-02
Printed in U.S.A.
Copyright
6004-52
STEP 242
STEP 244
12
12
13
BD01D584
12. PIN
13. LONG SHAFT
BD01D581
8. SEPARATOR PLATE
Install three pins (12) to secure long shaft (13) and

STEP 243
11
9. FRICTION PLATE
Install three separator plates (8) and three friction

plates (9) alternating between separator plates and
friction plates. The first plate installed must be a
separator plate (8); the last plate installed must be a
friction plate (9). Circular cutouts in friction plates
must be aligned.
STEP 245
10
A
A
BD01D582
10. FRICTION PLATE
11. SIDE GEAR
A. HOLES
Install friction plate (10) on side gear (11). Make sure

circular cutouts in friction plate are aligned with holes
(A) in side gear.
BD01D580
8. SEPARATOR PLATE
Install one separator plate (8).
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-53
STEP 246
STEP 248
11
8
5
9 10
BD01D579
8. SEPARATOR PLATE
9. FRICTION PLATE
10. FRICTION PLATE

11. SIDE GEAR
Install side gear (11) with separator plates (8) and

friction plates (9 and 10) as an assembly in housing.
STEP 247
BD01D575
5. BOLT
Apply Loctite 270 to threads of 14 bolts (5). Install 12

bolts finger tight. Remove two studs then install
remaining two bolts. Remove wood blocks. Tighten
14 bolts (5) to a torque of 190 Nm (140 lb-ft).
Installation
STEP 249
Do Steps 161 through 172 to install differential.
7
22
6
BD01D596
6. RING GEAR
7. HOUSING COVER
18. HOUSING
A. STUDS
Put ring gear (6) on wood blocks. Wood blocks must

be high enough to let housing (22) be put in ring
gear. Install two studs (A) in ring gear. Put housing
(22) and assembled parts on studs then install
housing cover (7). Use a soft hammer to move
housing down onto ring gear.
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
6004-54
Bur 6-42470
Issued 6-02
Printed in U.S.A.
Copyright
FRONT AND REAR AXLE

CASE CORPORATION
700 State Street
Bur 6-48970

Printed in U.S.A.
February, 2003
6004
Section
6004
Copyright
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIFFERENTIAL CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DRIVE PINION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REAR AXLE PIVOT PIN BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE TUBES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BRAKE TUBES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIFFERENTIAL CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Determine Shim Thickness for Correct Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Open Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Limited Slip Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-3
SPECIFICATIONS
Lubricant Capacity........................................................................................................22.1 Liters (23.5 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ...................................... 10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim .........................................................................4.5 to 5.0 mm (0.18 to 0.20 inch)
Sun Gear Shaft End Play ....................................................................................0.5 to 2.0 mm (0.020 to 0.079 inch)
Drive Pinion Rolling Torque ...................................................................................... 1.1 to 4.5 Nm (9.7 to 40 lb-inch)
Differential Carrier Bevel Gear End Play .......................................................... Zero to 0.15 mm (zero to 0.006 inch)
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing....................................................................................390 Nm (288 lb-ft)
Locknut Securing Planetary Carrier........................................................................ 700 to 1000 Nm (516 to 737 lb-ft)
Vent Valve Fitting ............................................................................................................................140 Nm (103 lb-ft)
Vent Valve...........................................................................................................................................80 Nm (59 lb-ft)
Axle Housing Connector for Brake Tube ........................................................................................140 Nm (103 lb-ft)
Nut Securing Brake Tube to Connector..........................................................................................140 Nm (103 lb-ft)
Brake Tube Fitting to Wheel End Fitting ............................................................................................. 80 Nm (60 lb-ft)
Breather Plug..................................................................................................................................140 Nm (103 lb-ft)
Nut Securing Input Flange (Apply Loctite 262 to Threads).............................................................600 Nm (442 lb-ft)
Bolts Securing Differential Ring Gear
M12 Bolts ..................................................................................................................................... 120 Nm (88 lb-ft)
M16 Bolts ...................................................................................................................................300 Nm (221 lb-ft)
Bolts Securing Differential Bearing Caps (Apply Loctite 262 to Threads) ......................................185 Nm (136 lb-ft)
Differential Carrier Mounting Bolts (Apply Loctite 262 to Threads) ................................................390 Nm (288 lb-ft)
SPECIAL TOOLS
Brake housing seal installer. . . . . . . . . . . . CAS2880
Differential bearing cone puller collet set. . CAS2871
Brake housing inner bearing cup installer . CAS2877
Brake housing outer bearing cup installer . CAS2878
Wear ring installer adapter . . . . . . . . . . . . CAS2875
Pinion depth gauge set . . . . . . . . . . . . . . CAS(*TBS)
Support bracket . . . . . . . . . . . . . . . . . . . . . CAS2883
Slide hammer puller adapter . . . . . . . . . CAS10846-3
Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252
Replacer . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2297
Dial indicator with magnetic base . . . . . CAS10066A
Heat gun . . . . . . . . . . . . . . . . . . . . . . . . . CAS10810
Engine stand . . . . . . . . . . . . . . . . . . . . . . . OEM4135
Snap ring pliers . . . . . . . . . . . . . . . . . . . . . OEM6484
Alignment Studs . . . . . . . . . . . . . . . . . . . . CAS2861
Step plate set (includes 8061, 8067,
and 8073) . . . . . . . . . . . . . . . . . . . . . . . OEM4288
Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8061

Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8067
Step plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8073
Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2876
Planetary Gear Puller . . . . . . . . . . . . . . . . . CAS2848
Brake Housing Puller Bridge . . . . . . . . . . . CAS2850
Pressure Ring Installer . . . . . . . . . . . . . . . . CAS2860
Holding Bracket . . . . . . . . . . . . . . . . . . . . CAS2847
Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS2848
Pulling Attachment . . . . . . . . . . . . . . . . . . .OEM4175
Puller Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103
Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8065
Holding Wrench . . . . . . . . . . . . . . . . . . . . CAS1579A
Pinion Inner Bearing Cup Installer . . . . . CAS2293-1
Pinion Outer Bearing Cup Installer . . . . . .CAS(*TBS)
Pinion Seal Installer . . . . . . . . . . . . . . . . .CAS(*TBS)
Pinion Seal Installer . . . . . . . . . . . . . . . . .CAS(*TBS)
Pulling Attachment . . . . . . . . . . . . . . . . . . .OEM4054
*TBS: To Be Supplied
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern
Pinion Distance Must Be Increased
BS01D011
BS01D009
COAST SIDE (CONCAVE)
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010
DRIVE SIDE (CONVEX)
BS01D015
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-6
LUBRICATION
5
6
5
4
2
3
1
2
BS02D084
REAR AXLE SHOWN

1. OIL DRAIN PLUG (AXLE HOUSING)
2. OIL DRAIN PLUG (OUTPUTS)
3. OIL FILL PLUG
4. OIL DIPSTICK
5. BRAKE BLEEDER
6. BLEEDER
NOTE: Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE

A
BS02D085
BD02D001
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 70 Nm (52 lb-ft).
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-7
WHEEL END AND BRAKE

STEP 3
Disassembly
NOTE: The following photographs show the rear
axle; dissassembly/assembly procedures are the
same for either axle. 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 axles are the
same regardless of appearance.
STEP 1
BD02D005
Using two pry bars, remove cover from output shaft.

Remove and discard O-ring from cover.
STEP 4
BD02D002
Fasten axle on a stand.
STEP 2
BD02D006
Remove pin from lock nut using OEM4252 slide

hammer and CAS10846-3 adapter.
STEP 5
BD02D003
BD02D007
BD02D004
Remove lock nut using CAS2883 support bracket

and CAS2876 socket and nuts.
Remove drain plugs and drain oil from axle housing.

Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-8
STEP 6
STEP 9
BD02D008
Use acceptable lifting equipment to hold wheel end in

place. Loosen and remove the bolts and washers.
BD02D011
Remove the shim(s) from the sun gear shaft.
STEP 10
STEP 7
BD02D012
BD02D009
Carefully pull the wheel end from the axle housing.

Remove and discard O-ring from axle housing wheel
end.
Pull the sun gear shaft out of the planetary gears and
remove.
STEP 11
STEP 8
BD02D013
BD02D010
Using two pry bars, remove ring gear from brake

housing.
Pull the stub shaft out of the sun gear shaft. Be

careful not to lose shim(s) that may be installed in
sun gear shaft.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-9
STEP 12
STEP 15
BD02D014
Remove and discard O-rings from ring gear.
BD02D017
Using CAS2848 planetary gear puller and step plate

8061, remove planetary gear and outer bearing from
planetary carrier shaft. Using a suitable puller,
remove the inner bearing from carrier shaft.
STEP 13
STEP 16
Repeat Steps 14 and 15 to remove the remaining
two re ta in ing ring s, pla neta ry gea rs, a nd fo ur
bearings.
STEP 17
BD02D015
Using OEM4054 pulling attachment, remove the

planetary carrier.
STEP 14
BD02D018
Remove and discard O-ring from brake housing port.
BD02D016
Remove retaining ring.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-10
STEP 18
STEP 21
BD02D019
Remove the brake disc pack from brake housing.
STEP 19
BD02D022
W E A R FA C E P R O T E C T I O N W H E N U S I N G
COMPRESSED AIR. Apply compressed air to brake
ho using por t to pus h br ake pis to n fro m bra ke
housing.
STEP 22
BD02D020
Using suitable tool, push the three pins down until

pins are even with top surface of shim.
BD02D023
Remove the support shim from the brake piston.
STEP 20
STEP 23
BD02D021

BD00M258
Remove three pins from support shim.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-11
STEP 24
STEP 27
BD00M259
Put support shim in a press and compress Belleville

washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.
BD02D024
Lift and remove the piston from the brake housing.
STEP 28
STEP 25
BD02D025
BD00M260
Remove seven Belleville washers from each pin.
STEP 26
BS02D086
BD00M261
Using a press, remove four gripping rings from each

pin.
Bur 6-48970
1.
2.
3.
4.
BRAKE HOUSING
GUIDE RING
SUPPORT RING
U-RING
5. U-RING
6. SUPPORT RING
7. WHEEL END SHAFT
Remove the guide ring (2), support rings (3 and 6),

and U-rings (4 and 5) from the grooves of the brake
housing.
Issued 2-03
Printed in U.S.A.
Copyright
6004-12
STEP 29
STEP 32
BD02D029
BD02D026
Using the CAS2850 brake housing puller bridge and

8073 step plate, pull the brake housing from the
wheel end shaft and remove the inner bearing.
Remove the face seal from the brake housing.
STEP 33
Using a puller, remove the outer bearing from the
wheel end shaft.
STEP 30
STEP 34
BD02D027
Use acceptable lifting equipment and lift the brake

housing from the wheel end shaft.
BD02D030
Remove and discard the face seal metal ring from

the wheel end shaft.
STEP 31
BD02D028
If replacement of bearing cups is necessary, drive

both bearing cups out of the brake housing.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-13
Assembly
IMPORTANT: Do not use compressed air to dry

bearings. Allow bearings to air dry.
STEP 40
STEP 35
Clean all parts except friction plates in brake disc
p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FA C E
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 36
I n s p e c t b e a r i n g r o l l e r s f o r p i t t i n g , s c o r in g ,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
d a m a g e . C h e c k a s s o c ia te d b e a r in g c u p s f o r
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.
BD02D031
Apply Loctite 574 to inside diameter of a new face

seal metal ring. Install face seal metal ring on wheel
end shaft.
STEP 41
STEP 37
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
NOTE: If a bearing or bearing cup requires
replacement, the associated part must also be
replaced.
STEP 38
Check planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of
these conditions are seen. Check planetary carrier
sh a f t sp lin e s f o r b r ok e n , c ra c ke d , o r t w ist e d
condition. Replace if necessary.
BD01F107
STEP 39
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
BD01F105
Install CAS2875 pressure ring installer adapter on

wheel end shaft. Press the face seal metal ring over
the collar of the wheel end shaft using CAS2860
pressure ring installer.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-14
STEP 42
STEP 45

SM121A
BD02D034
A
A
BD02D032
Heat the wheel end shaft outer bearing to 100 C

(212 F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the shoulder on
the wheel end shaft.
A
1
STEP 43
BS00M073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
Wet the outer diameter of the face seal with a

solution of 50% water and 50% mineral spirits. Use
CAS2880 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to
seal as indicated by (A) above.
BD02D033
STEP 46
Using CAS2877 inner bearing cup installer, press the

inner bearing cup into the brake housing until seated
against the shoulder in the brake housing.
STEP 44
Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
against the shoulder in the brake housing.
BD02D027
Use acceptable lifting equipment and install the

brake housing on the wheel end shaft.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-15
STEP 47
STEP 48

SM121A
BD02D025
BD02D035
Heat the wheel end shaft inner bearing to 100 C

gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the bearing cup
in the brake housing.
BS02D086
GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION

1.
2.
3.
4.
BRAKE HOUSING
GUIDE RING
SUPPORT RING
U-RING
5. U-RING
6. SUPPORT RING
7. WHEEL END SHAFT
Install the support rings and U-rings in the grooves of

the brake housing.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-16
STEP 49
STEP 51
A
BD02D036
Clean the groove of the brake housing with cleaning

solvent. Install the guide ring in the groove. Make
sure the ends (A) of the guide ring are facing up
towards the top (B) of the brake housing and the
guide ring is installed completely in its groove in the
brake housing. Apply Loctite 415 to ID of guide ring
to secure guide ring in its groove.
BD00M282
1. GRIPPING RINGS
Press the four gripping rings on the pins. Ends of

gripping rings must be 180 opposite from each
other.
STEP 52
STEP 50
BD00M283
BD02D037
Apply oil on the sliding surface of the piston, support

rings, U-rings and guide ring. Carefully install piston
in the brake housing.
3
A
2
1
BS00M074
1. PIN
4. SUPPORT SHIM
2. GRIPPING RINGS
5. RETAINING RING
3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43
INCH)
Install the Belleville springs on the pins. Make sure

dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-17
STEP 53
STEP 56
BD00M259
BD02D020
Put the assembled pins into the support shim and

install the snap ring.
STEP 54
BS02D087
1. BRAKE HOUSING
2. SNAP RING
3. PIN
BD02D038
Put the assembled support shim in the piston.
4. SUPPORT SHIM
5. PISTON
A. 4.5 TO 5.0 MM (0.18 TO 0.20
INCH)
Install the three pins (3) in the support shim (4) to

lock the snap ring (2). Dimension (A) between top of
pins (3) and top of support shim (4) must be 4.5 to
5.0 mm (0.18 to 0.20 inch).
STEP 55
STEP 57
BD02D039
Install the snap ring to secure the support shim.
1
BD02D040
1. SPLINE
If removed, drive the stop bolt into the planetary

carrier until contact. Then coat the spline with Loctite
No. 767 antiseize lubricant.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-18
STEP 58
STEP 61
BD02D041
BD02D014
Install the planet carrier into the spline of the wheel

end shaft.
Apply grease to new O-rings and install on planetary

ring gear.
STEP 59
STEP 62
BD02D042
Apply oil to the clutch discs. Install the outer and

inner clutch discs alternately starting with an outer
clutch disc.
STEP 60
BD02D044
Install two alignment studs in the brake housing.

Pos ition the plan eta ry r in g g ea r o n th e b ra ke
housing. Make sure alignment marks made during
disassembly are aligned. Press planetary ring gear
into brake housing.
BD02D043
Install a new O-ring in the brake housing port.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-19
STEP 63
STEP 65


SM121A
SM121A
BD02D045
BD02D047
Heat the planetary gears inner bearings to 100 C

gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft.
Heat the planetary gears outer bearings to 100 C

gloves or mittens, install the bearings on the shafts
until the bearing is against the gear.
STEP 64
STEP 66
BD02D046
Install the planetary gears on the bearings.
Bur 6-48970
BD02D048
Install the retaining rings on the planetary gear

shafts.
Issued 2-03
Printed in U.S.A.
Copyright
6004-20
Sun Gear Shaft End Play Adjustment
STEP 69
STEP 67
BD02D051
BD02D049
Using two M18 bolts of suitable length, secure

p la n e t a r y r in g g e a r to b r a k e h o u s in g . Th e n ,
d e te r min e di me n si on A, f ro m t h e fa c e of t h e
planetary carrier stop bolt to the mounting face of the
planetary ring gear.
Install the sun gear shaft in the stub shaft. Make sure
the stub shaft is installed all the way into the sun gear
shaft.
STEP 70
Example:
Dimension A . . . . . . . . . . . . . 35.60 mm (1.40 inch)
STEP 68
BD02D052
Determine dimension B from the face of the sun gear

shaft to the mounting face of the axle housing.
Example:
Dimension B . . . . . . . . . . . . . . 31.40 mm (1.24 inch)
BD02D050
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 71
Subtract dimension B from dimension A. Then
subtract 1 mm (0.04 inch) from the difference. The
difference is the required shim size.
Example:
Dimension A
Dimension B
Difference
Required end play
Difference = shim
size
Bur 6-48970
+ 35.60 mm (1.40 inch)

31.40 mm (1.24 inch)
4.20 mm (0.16 inch)
1.00 mm (0.04 inch)
3.20 mm (0.12 inch)
Issued 2-03
Printed in U.S.A.
Copyright
6004-21
STEP 72
STEP 75
BD02D012
Install the sun gear shaft in the planet carrier.
BD02D154
Install the washers and bolts to secure the wheel end

to the axle housing. Tighten the bolts to a torque of
390 Nm (288 lb-ft).
STEP 73
STEP 76
BD02D011
Install the shim set (size as determined in Step 71

above) into the sun gear shaft with grease.
BD02D155
Install the lock nu t by ha nd a nd tig hten usin g

CAS2883 support bracket and CAS2876 locknut
socket and nuts. Tighten the lock nut to a torque of
700 to 1000 Nm (516 to 737 lb-ft).
STEP 74
STEP 77
BD02D009
Apply grease to a new O-ring and install O-ring in

brake port. Use acceptable lifting equipment and
install the assembled wheel end o nto the axle
housing.
BD02D156
Install a new slotted pin into the wheel end lock nut.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-22
STEP 78
STEP 79
1
BD00M303
1. O-RING
BD02D153
Install the cover into the wheel end.
Install a new O-ring on the wheel end cover.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-23
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450
PSI) PRESSURE IN THE FOLLOWING STEPS. If
the maximum pressure of 100 bar (1450 psi) is
exceeded, the piston will move too much changing
the gripping rings adjustment. If the gripping rings
adjustment changes, the wheel end must be
removed and disassembled and the gripping rings
adjusted to the correct dimension (Step 52).
STEP 80
High Pressure Test

STEP 81
Operate the hand pump to increase pressure to 100
bar (1450 psi) maximum. Close connection to hand
pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 2 bar (29
psi).
Low Pressure Test

STEP 82
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
BD02D157
Connect a hand pump with pressure gauge to the

brake port as shown above. Fill the hand pump with
Case MS-1209 Hy-Tran Ultra. Build up pressure in
the axle internal brake lines then bleed air from the
lines. After air is bled, actuate the brakes a minimum
of 10 times by operating the hand pump.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-24
DIFFERENTIAL CARRIER DISASSEMBLY

STEP 83
STEP 85
BD02D002
Fasten the axle to a stand.
BD02D008
Use acceptable lifting equipment to hold wheel end in

place. Remove the bolts and washers.
STEP 84
STEP 86
BD02D003
BD02D054
Carefully pull the wheel end from the axle housing.

Remove and discard O-ring from axle housing wheel
end.
BD02D004
Remove drain plugs and drain oil from axle.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-25
STEP 87
STEP 91
BD02D010
Pull the stub shaft out of the sun gear shaft. Be

careful not to lose shim(s) that may be installed in
sun gear shaft.
BD02D057
Mount differential carrier in OEM4135 engine stand

using one CAS2847 holding bracket.
STEP 92
STEP 88
Do Steps 85 to 87 to remove the other wheel end.
STEP 89
BD02D058
Drive out the roll pins from the bearing caps.
STEP 93
BD02D055
Remove 15 bolts securing differential carrier.
STEP 90
BD02F158
Remove both adjusting nuts.

BD02D056
Connect lifting equipment to flange and remove the

differential carrier from axle housing.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-26
STEP 94
STEP 96
BD02D059
Heat the differential carrier using a hot air blower.

NOTE: Bolts are installed with Loctite.
BD02D061
Remove both bearing cups.
STEP 97
STEP 95
IMPORTANT: Do not use an air ratchet or wrench to
remove bolts.
1
BD02D062
Remove the differential from the differential carrier.
BD02D060
1. ALIGNMENT MARK
M a k e a li g n m e n t m a r k s o n b e a r in g c a p s a n d
differential housing to aid in assembly. Remove four
bolts then remove both bearing caps.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-27
DIFFERENTIAL DISASSEMBLY
STEP 98
STEP 101
BD01F059
Remove the bearing from the differential housing

using CAS2848 puller, OEM4175 pulling attachment,
1103 puller legs, and 8065 step plate.
BD02D064
Remove the differential cage half and remove all

parts from the differential housing.
STEP 102
STEP 99
Repeat Step 98 to remove the bearing from the
housing cover.
STEP 100
BD02D065
Press the ring gear from the differential cage.
BD02D063
Place the differential in a press to prevent it from

turning. Remove the bolts.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-28
DRIVE PINION DISASSEMBLY

STEP 103
STEP 106
Heat nut securing flange with a hot air blower to

loosen Loctite.
STEP 104
BD02D067
Remove the shaft seal from the differential carrier.
STEP 107
BD01F091
Install CAS1579A holding wrench on input flange.

Hold flange using holding wrench and remove nut
and washer. Remove holding tool from flange.
Put the differential carrier in a press. Press the drive

pinion from the differential carrier. Remove the pinion
outer bearing.
STEP 108
STEP 105
Remove the spacer ring and inner bearing from the

drive pinion.
STEP 109
BD02D066
Remove the input flange from the drive pinion.

BD02D068
If necessary drive out both bearing cups from the

Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-29
REAR AXLE PIVOT PIN BUSHINGS

STEP 110
STEP 112
A
A
BD01D482
BD01D495
BD01D499
BD01D499

A. THRUST SURFACE
Inspect pivot pin bushings in differential carrier and

axle housing for cracks, breaks, deformation, or
other damage. Check oil splash grooves for scoring
or chipping. Check for scoring on thrust surface (A).
If bushing (1 or 2) requires replacement, do Steps
111 and 112.
STEP 111

A. GROOVE

Freeze new bushing in dry ice for several hours.

Install bushing in axle housing or differential carrier
with groove (A) on circumference of bushing facing
center of housing or carrier. Install bushing against
shoulder in housing or carrier.
BD01D491
Put axle housing or differential carrier in hydraulic

press. Make sure housing or carrier is properly
supported. Using a 66.6 mm (2.625 inches) diameter
by suitable length rod, press bushing out of housing
or carrier.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-30
BRAKE TUBES REMOVAL

STEP 113
STEP 116
BD02D069
BD02D072
Remove the plug with the breather installed from the

axle housing.
Loosen the fitting on the opposite end of the brake

tube then remove the brake tube from the axle
housing.
STEP 114
STEP 117
BD02D070
Remove the nut securing the brake tube to the axle

housing.
Remove the vent valve from the fitting.
STEP 115
STEP 118
BD02D073
BD02D071
Loosen and remove the connector from the axle.
BD02D074
Remove the fitting. Remove and discard O-ring and

rectangular ring from fitting.
NOTE: Do Steps 114 to 118 on other wheel end.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-31
BRAKE TUBES INSTALLATION

STEP 119
STEP 121
2
3
4
BD00M340
1.
2.
3.
4.
VENT VALVE
FITTING
O-RING
RECTANGULAR RING
BD02D116
Tighten the vent valve to a torque of 80 Nm (59 lb-ft).
STEP 122
Install new O-ring and rectangular ring on fitting.

Install and tighten vent valve in fitting.
STEP 120
BD02D117
Install a new O-ring on the connector. Install the

connector in the axle and tighten to a torque of 140
Nm (103 lb-ft).
BD02D115
Install the assembled vent valve and fitting in the

axle. Tighten the fitting to a torque of 140 Nm (103
lb-ft).
STEP 123
BD00M343
1. O-RING
Install a new O-ring in the groove of the brake tube

fitting.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-32
STEP 124
2
STEP 126
3
BD02D118
1. BRAKE TUBE
2. FITTING
3. CONNECTOR
Install th e bra ke tube (1) in the axle ho using,

inserting the fitting (2) through the connector (3).
STEP 125
BD02D120
Connect fitting on opposite end of brake tube to

fitting installed in wheel end. Tighten brake tube
fitting to a torque of 80 Nm (60 lb-ft).
NOTE: Do Steps 119 to 126 on other wheel end.
STEP 127
1
2
3
BD00M347
BD02D119
Install the nut to secure the brake tube fitting. Tighten

the nut to a torque of 140 Nm (103 lb-ft).
1. O-RING
2. PLUG
3. BREATHER
Remove and discard O-ring (1) from plug (2) and

install a new O-ring. Install breather (3) in plug.
STEP 128
BD02D121
Install the plug in axle housing. Tighten plug to a

torque of 140 Nm (103 lb-ft)
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-33
DIFFERENTIAL CARRIER ASSEMBLY

NOTE: The ring gear and the drive pinion are a
matched gear set and cannot be serviced separately.
STEP 131
Determine Shim Thickness for

Correct Tooth Contact Pattern
NOTE: Make the following measurements at
maximum accuracy. Inaccurate measurements will
result in a faulty tooth contact pattern causing
disassembly of the drive pinion and differential.
STEP 129
Install the CAS(*TBS) pinion depth gauge set on the
BD02D122
Determine dimension C (bearing width).

Dimension C (Example) . . . . 33.65 mm (1.325 inch)
STEP 130
STEP 132
1
BD01F076
Determine dimension B (gap between the measuring

shaft and the measuring pin) using a thickness
gauge.
Dimension B (Example) . . . . . . 1.00 mm (0.039 inch)
Example A:
171.75 mm
Dimension A (tool constant)
------(6.762 inch)
+ 1.00 mm
Dimension B (gap)
------(0.039 inch)
172.75 mm
Results in Dimension X
-----(6.801 inch)
BD02D123
1. 138.00 MM (+/-0 MM)
Read dimension D (dimension for pinion).

Dimension D (Example) . . . 138.00 mm (5.433 inch)
Example B:
33.65 mm
Dimension C
------(1.325 inch)
+ 138.00 mm
Dimension D
------(5.433 inch)
171.65 mm
Results in Dimension Y
-----(6.758 inch)
STEP 133
Bur 6-48970
Su btr ac t dime ns io n Y fr om dime ns io n X. Th e

difference is the required shim thickness.
Example C:
Dimension X
172.75 mm (6.801 inch)
Dimension Y
171.65 mm (6.758 inch)
Difference = Shim
1.10 mm (0.043 in)
Issued 2-03
Printed in U.S.A.
Copyright
6004-34
STEP 136
Install Drive Pinion
WARNING: Always wear insulated gloves or

mittens when handling frozen parts.
STEP 134
BD02D124
Install the shim set determined in Step 133 in the

bearing bore on the differential carrier.
STEP 135
WARNING: Always wear insulated gloves or
mittens when handling frozen parts.
BD01F062
Freeze new outer bearing cup in dry ice for several

hours. Install bearing cup in differential carrier using
CAS(*TBS).
STEP 137
BD02D125
BD01F064
Freeze new inner bearing cup in dry ice for several

hours. Install bearing cup in differential carrier using
CAS2293-1.
Press the inner bearing on drive pinion shaft using

suitable size slee ve p re ssing on inne r race of
bearing.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-35
STEP 140
Drive Pinion Bearing Rolling

Torque Adjustment
STEP 138
BD02D128
Using CAS(*TBS) puller tube, press the dust shield

on the input flange.
BD02D126
Install an 16.90 mm (0.665 inch) thick spacer on the

pinion shaft.
STEP 141
STEP 139
SM121A
BD02D129
Install the input flange on the pinion shaft.
STEP 142
BD02D127
Install the assembled pinion shaft in the differential

carrier. Heat the pinion shaft outer bearing to 100 C
(212 F) in a bearing oven. Wearing heat resistance
gloves or mittens, install the bearing on the pinion
shaft until contact.
BD02D130
Put the washer in place on the pinion shaft.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-36
STEP 143
STEP 146
BD01F091
BD02D132
Install CAS1579A holding wrench on input flange.

Hold flange using holding tool and tighten nut to a
torque of 600 Nm (442 lb-ft). Remove CAS1579A.
Using the CAS(*TBS) and CAS(*TBS) pinion seal

installers, install the shaft seal with the seal lip down.
NOTE: When tightening rotate the pinion shaft in

both directions several times.
NOTE: Just before installation, wet the outer

diameter of the shaft seal with a solution of 50%
water and 50% mineral spirits. Fill the space between
the sealing and dust lip with grease.
STEP 144
STEP 147
BD02D131
Check the rolling torque of the drive pinion bearing.

The rolling torque should be 1.1 to 4.5 Nm (9.7 to 40
lb-inch). If rolling torque is too low, install a thinner
spacer (Step 138); if rolling torque is too high, install
a thicker spacer (Step 138).
STEP 145
BD01F091
Install the input flange. Install CAS1579A 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 600 Nm (442 lb-ft). Remove
CAS1579A.
Remove the nut and input yoke from the drive pinion
shaft.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-37
DIFFERENTIAL ASSEMBLY
STEP 148
STEP 149
BD02D133
BD02D134
Install two slotted pins (2 and 3)in each of the four

blind holes in the differential cage half (1). Install
slotted pins so that slots are 180 from center of
differential cage and slots of pins are 180 offset to
each other.
Using suitable size sleeve press the ring gear (4)

onto the slo tted pins until rin g gear is a gainst
differential cage half (1).
Open Differential Assembly

8
11
3
2
13
6
10
14
7
5
12
1
4
8
8
BS01D140
1.
2.
3.
4.
DIFFERENTIAL CAGE HALF

SLOTTED PIN
SLOTTED PIN
RING GEAR
5.
6.
7.
8.
THRUST WASHER
BEVEL GEAR
BEVEL GEAR
THRUST WASHER
9.
10.
11.
12.
SHAFT
BEVEL GEAR
THRUST WASHER
13. BOLT
14. BOLT
STEP 150
STEP 152
Install thrust washer (5) then bevel gear (6) in

differential cage half (1).
Install shaft (9) with bevel gears (7) and thrust

washers (8) on differential cage half (1). Check that
teeth of bevel gears (7 and 6) mesh.
STEP 151
Install bevel gears (7) and thrust washers (8) on shaft
(9).
Bur 6-48970
STEP 153
Install and mesh bevel gear (10) with gears (7) and
install thrust w asher (11 ) o n gea r (1 0). Install
differential cage half (12). Go to Step 163.
Issued 2-03
Printed in U.S.A.
Copyright
6004-38
Limited Slip Differential Assembly
STEP 157
10
STEP 154
9
7
7
8
11
5
1
6
BD02D137
6
BD02D135
Install the thrust washer (5), coated surface to clutch

discs, and outer and inner clutch discs (6 and 7) on
bevel gears (8) in the sequence shown above.
Install assembled shafts (11) with gears (9) and

thrust washers (10) in differential cage (1) making
sure gear teeth mesh. Check that tabs on thrust
washers (10) are positioned as shown above.
STEP 158
STEP 155
8
1
BD02D138
Put the bevel gear (8) with installed parts (5 through

7) in the differential cage half (1).
Carefully assemble the differential cage halves.

Make sure the manufacturers markings (A) on both
halves are aligned.
STEP 156
STEP 159
BD02D142
8
1
BD02D139
BD02D136
Put the other bevel gear (8) with installed parts (5

through 7) in differential cage half (12).
Bur 6-48970
Secure the differential cage halves together using

two bolts.
Issued 2-03
Printed in U.S.A.
Copyright
6004-39
13
2
6
10
10
6
9
8
11
9
5
11
10
12
14
10
6
BS01D141
1.
2.
3.
4.

SLOTTED PIN
SLOTTED PIN
RING GEAR
5.
6.
7.
8.
THRUST WASHER
SEPARATOR PLATE
FRICTION PLATE
BEVEL GEAR
STEP 160
9.
10.
11.
12.
BEVEL GEAR
13. BOLT
THRUST WASHER
14. BOLT
SHAFT
STEP 161
After obtaining the required end play, disassemble
the differential. Install the adjusted clutch pack that
was in the differential cage half (12) in the other
differential cage half (1). Repeat Step 160 to check
the end play. After both clutch packs have been
adjusted, go to Step 162.
12
STEP 162
BD02D140
Check the end play (zero to 0.15 mm (0.006 inch)) of

th e b evel gear (8). Do this by mounting a dia l
indicator as shown set to indicate from the top
separator plate through one of the top holes in
differential cage half (12). Zero the dial indicator.
Using screwdrivers or other suitable tools inserted in
holes in side of cage half, move the bevel gear up.
Record the dial indicator reading. Dial indicator
sho u ld in d ica te z ero to 0.1 5 mm (0.0 06 inch )
(required end play).
If required end play of zero to 0.15 mm (0.006 inch)
is not obtained, install new outer clutch discs of
thickness necessary to obtain required end play.
Bur 6-48970
BD02D141
After adjustment is completed, separate the cage

halves, and remove the parts. Keep clutch packs
together and identify which side they are installed.
Ap ply o il to all pa rts. Do Step s 1 5 4 to 15 8 to
assemble the differential, then go to Step 163.
Issued 2-03
Printed in U.S.A.
Copyright
6004-40
STEP 163
STEP 166
BD02D143
Put the differential in a press to prevent it from

turning. Apply Loctite 262 to threads of bolts (13 and
14). Tighten M16 bolts (13), to a torque of 300 Nm
(221 lb-ft); tighten M12 bolts (14) to a torque of 120
Nm (88 lb-ft).
BD02D146
Install both bearing cups and adjusting nuts.
STEP 167
STEP 164
BD02D147
BD02D144
Using proper size sleeve pushing on inner race of

bearing, press bearing on differential housing until
bearing is against housing. Repeat to install other
bearing.
STEP 165
Position bearing brackets; make sure threads of

bearing brackets and adjusting nuts are not crossed.
Put Loctite 262 on threads of four bolts. Install bolts
and tighten to a torque of 185 Nm (136 lb-ft).
STEP 168
Using a spanner wrench, tighten the two adjusting
nuts evenly until there is a light pressure against the
bearings on each side of the differential.
BD02D145
Install differential in differential carrier.

Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-41
STEP 174
Adjust Backlash and Bearing

Preload
STEP 169
BD02D149
BD02D148
Place CAS10066A dial indicator right-angled at the

outer diameter of the tooth flank (ring gear). Adjust
the pinion to ring gear backlash to the low side of
specifications (see numbers etched on the outer
diameter of the ring gear) by alternately turning each
of the adjusting nuts to move the ring gear closer to
or further away from the pinion.
Apply marking ink on several teeth of the ring gear

and rotate it in both directions. Compare the obtained
tooth contact pattern with the examples on pages 4
and 5.
NOTE: If the tooth contact pattern differs, the wrong
shim size was selected in Step 133. Remove
differential and repeat Steps 129 though 133.
STEP 175
STEP 170
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release
pressure on the bearing. It should be very noticeable
that pressure is released on the bearing, as the
adjusting nut will turn much easier.
STEP 171
Tighten the bearing adjusting nut slowly until firm
contact is made with the bearing.
NOTE: As the adjusting nut makes firm contact with
the bearing, the adjusting nut will immediately begin
to turn with more effort.
BD02D150
Install pins to secure both adjusting nuts.
STEP 176
STEP 172
To adjust the differential bearing preload, note the
position of the adjusting nut. Now tighten the nut two
additional notches.
STEP 173
Apply sealing compound (Three Bond Type 1215) to

differential mounting surface on axle housing. Install
two CAS2861 alignment studs in axle housing to aid
installation of differential carrier. Using suitable lifting
equipment, install the differential carrier in the axle
housing then remove alignment studs.
When the bearing preload is adjusted the backlash

may increase slightly. Check pinion backlash to
confirm that it is within specifications as marked on
the ring gear. If within specifications, install the
adjusting nut locking roll pins. If backlash is outside
of specified range, repeat Step 169 through 173
again.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
6004-42
STEP 177
STEP 180
BD02D151
BD02D054
Using new bolts, secure the differential carrier to the

axle housing. Tighten bolts to a torque of 390 Nm
(288 lb-ft).
Apply grease to a new O-ring and install O-ring in

brake port. Position the wheel end on the axle
housing.
STEP 178
STEP 181
BD02D050
BD02D154
Install the stub shaft into the spline of the differential

bevel gear.
Install the washers and bolts on the wheel end.

Tighten the bolts to a torque of 390 Nm (288 lb-ft)
STEP 179
NOTE: Repeat Steps 178 through 181 for the other

wheel end.
NOTE: Refer to Section 1002 of this service manual
for proper lubricant.
BD02D011
Install the thrust washer removed at disassembly.

Use grease to keep it in the sun gear.
Bur 6-48970
Issued 2-03
Printed in U.S.A.
Copyright
DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL

JOINTS
CASE CORPORATION
700 State Street
Bur 6-42480

Printed in U.S.A.
August, 2001
6005
Section
6005
Copyright
6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42480
Issued 8-01
3
4
4
5
5
6
6
7
7
8
8
8
9
9
9
10
10
12
12
14
14
14
Printed in U.S.A.
Copyright
6005-3
SPECIAL TORQUES
Coupler to Flywheel Bolts ................................................................................................. 53 to 62 Nm (39 to 46 lb ft)
Engine Drive Shaft to Coupler Bolts ................................................................................. 53 to 62 Nm (39 to 46 lb ft)
Engine Drive Shaft to Transmission Bolts ........................................................................ 34 to 41 Nm (25 to 30 lb ft)
Center, Rear and Front Drive Shaft Bolts ......................................................................... 61 to 81 Nm (45 to 60 lb ft)
Carrier Bearing Bolts ...................................................................................................... 99 to 128 Nm (73 to 94 lb ft)
Lock Nut for Yoke on Front Drive Shaft .................................................................... 339 to 375 Nm (250 to 275 lb ft)
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-4
FRONT DRIVE SHAFT

Removal
STEP 4
STEP 1
Use an acceptable puller and remove the yoke from

the end of the front drive shaft.
STEP 5
Loosen the set screws that secure the center bearing
to the front drive shaft.
STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD01D368
Loosen and remove the bolts and straps that fasten

the center drive shaft to the yoke of the front drive
shaft.
STEP 2
BD01D370

the front drive shaft to the front axle.
STEP 8
BD01D715
Remove the lock nut that fastens the yoke to the front
drive shaft.
STEP 3
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.
Make an alignment mark on the yoke and the end of

the front drive shaft to make sure that the yoke is
installed correctly.
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-5
FRONT DRIVE SHAFT

STEP 14
Installation
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11
BD01D715
Install the lock nut that fastens the yoke to the front
drive shaft. Tighten the lock nut to a torque of 339 to
375 Nm (250 to 275 lb ft).
STEP 15
Tighten the set screws, that secures the center
bearing to the front drive shaft, alternately until they
stop turning and the hex head socket wrench starts
to spring.
BD01D370
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
61 to 81 Nm (45 to 60 lb ft).
STEP 16
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed,
make sure the yoke being installed is 90 to the yoke
on the other end of the front drive shaft.
Bur 6-42480
BD01D368
Install the bolts and straps that fasten the front drive
shaft to the center drive shaft. Tighten the bolts to a
torque of 61 to 81 Nm (45 to 60 lb ft).
Issued 8-01
Printed in U.S.A.
Copyright
6005-6
CENTER BEARING
Removal
STEP 20
STEP 17
Make an alignment mark on the yoke and the front

drive shaft to be sure that the yoke is installed
correctly.
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD01D368
STEP 23

the center drive shaft to the front drive shaft.
Loosen the set screws that secure the center bearing

STEP 18
STEP 24
BD01D715
BD01D715
Loosen and remove the lubrication hose from the

center bearing
Loosen and remove the bolts, washers and nuts that

fasten the bearing housing to the front frame.
STEP 19
STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD01D715
Loosen and remove the lock nut that fastens the yoke
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-7
CENTER BEARING
STEP 31
Installation
NOTE: The center bearing and the bearing housing
are not serviced separately. If the center bearing is
worn or damaged or if the bearing housing is
cracked, a new center bearing and bearing housing
must be used.
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 27
Install the bearing housing so that the lubrication
fitting is at the top.
STEP 28
BD01D715
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 lb ft).
STEP 32
BD01D715
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 lb ft).
STEP 29
Apply antiseize compound to the splines on the front
drive shaft.
STEP 30
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
BD01D368
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 61 to 81 Nm (45 to 60
lb ft).
STEP 33
Install the lubrication hose into the fitting on the
bearing housing.
STEP 34
L ub r ic a te th e c en te r b ea r ing w ith t he g r ea s e
specified in Section 1002.
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-8
CENTER DRIVE SHAFT

Removal
Installation
STEP 35
STEP 39
BD01D368
BD01D331

the center drive shaft to the yoke of the front drive
shaft.
Hold the center drive shaft in position and install the

bolts and straps that fasten the center drive shaft to
the transmission. Tighten the bolts to a torque of 61
to 81 Nm (45 to 60 lb ft).
STEP 36
Use a prybar to disengage the center drive shaft from
the yoke of the front drive shaft.
STEP 40
STEP 37
BD01D368
BD01D331
Install the bolts and straps that fasten the center

drive shaft to the yoke of the front drive shaft. Tighten
the bolts to a torque of 61 to 81 Nm (45 to 60 lb ft).

the center drive shaft to the transmission.
STEP 38
Hold the center drive shaft and remove from the
machine.
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-9
REAR DRIVE SHAFT

Removal
Installation
STEP 41
STEP 45
BD01D323
BD01D362

the rear drive shaft to the transmission.
STEP 42
Hold the rear drive shaft into position and install the
bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 61 to 81 Nm
(45 to 60 lb ft).
Use a prybar to disengage the rear drive shaft from

the transmission.
STEP 46
STEP 43
BD01D323
BD01D362

the rear drive shaft to the rear axle.
Install the bolts and straps that fasten the rear drive
shaft to the transmission. Tighten the bolts to a
torque of 61 to 81 Nm (45 to 60 lb ft).
STEP 44
Hold the rear drive shaft and remove from the
machine.
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-10
ENGINE DRIVE SHAFT

STEP 50
Removal
NOTE: It may be necessary to remove the fuel tank
to gain access to the bolts and straps that fasten the
engine drive shaft to the transmission. Step 47 to
Step 54 show how to remove the fuel tank.
STEP 47
2
BD01D330
Tag and disconnect the two wires from the fuel level
indicator.
STEP 51
BD01D325
1. DRAIN VALVE
2. HOSE
Connect a drain hose to the drain valve (1) on the

fuel tank and drain the tank.
STEP 48
Loosen the hose clamp and disconnect the return
hose (2) from the fuel tank. Plug the hose and cap
the fitting. Put an identification tag on the hose for
reference during installation. Refer to the above
photo.
BD01D328
Loosen and remove the bolt and nut that fasten the
breather to the machine.
STEP 49
STEP 52
BD01D326
Loosen the hose clamp and disconnect the fuel

supply hose from the fuel tank. Plug the hose and
cap the fitting. Put an identification tag on the hose
for reference during installation.
Bur 6-42480
BD01D332
Place a jack under the center of the fuel tank plate.
Issued 8-01
Printed in U.S.A.
Copyright
6005-11
STEP 53
STEP 56
BD01D327
BD01D199
Loosen and remove the six bolts that fasten the fuel
tank guard to the machine.
Loosen and remove the six bolts that fasten the

engine drive shaft to the engine.
STEP 54
STEP 57
Lower the fuel tank slowly making sure all hoses and
wires are free and clear.
Remove the engine drive shaft from the machine.
STEP 55
BD01D342
Remove and discard the bolts and straps that fasten

the engine drive shaft to the transmission.
IMPORTANT: The bolts and straps that fasten the
engine drive shaft to the transmission must be
replaced when removed.
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-12
ENGINE DRIVE SHAFT

STEP 60
Installation
STEP 58
BD01D332
BD01D342
Place the engine drive shaft into position on the

transmission and install new straps and bolts.
Tighten the bolts to a torque of 34 to 41 Nm (25 to 30
lb ft).
Place the fuel tank onto a jack and raise into position
making sure all hoses are in place.
STEP 61
STEP 59
BD01D327
Install the six bolts that fasten the fuel tank and guard
on the machine.
BD01D199
STEP 62
Install the six bolts that fasten the engine drive shaft
to the engine. Tighten the bolts to a torque of 53 to
62 Nm (39 to 46 lb ft)
BD01D328
Install the bolt and nut that fastens the breather to the
machine.
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-13
STEP 63
STEP 65
BD01D325
Install the return hose on the fitting and tighten the

hose clamp. Make sure that the drain valve is in the
closed position.
BD01D330
Install the two wires to the fuel level indicator.
STEP 64
BD01D326
Install the fuel supply hose on the fitting and tighten

the hose clamp.
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
6005-14
UNIVERSAL JOINTS
Installation
Removal
NOTE: The bearing race and journal that make up

the universal joint are not serviced separately. If the
bearing race or journal is worn or damaged, a new
universal joint must be used.
STEP 66
Remove the drive shaft.
STEP 67
STEP 69
Clean the slots in the yoke of the drive shaft.
STEP 70
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 67.
STEP 71
Install the drive shaft.
BD01D331
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 68
Remove the universal joint from the drive shaft.
Bur 6-42480
Issued 8-01
Printed in U.S.A.
Copyright
Section
6006
6006
WHEELS AND TIRES
CASE CORPORATION
700 State Street
Bur 6-42490

Printed in U.S.A.
August, 2001
Copyright
6006-2
TABLE OF CONTENTS
WHEELS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE PRESSURE 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42490
Issued 8-01
3
3
3
3
4
4
Printed in U.S.A.
Copyright
6006-3
WHEELS AND NUTS

General Information
Torque Specification
The wheel nuts must be tightened after every 20

hours of operation until the wheel nuts stay tight:
Tighten the wheel nuts to 298 Nm (220 pound-feet) in

the sequence shown in Figure 1. Then a final torque
of 640 to 720 Nm (475 to 530 pound-feet) in the
same sequence.
A. If the machine is new.

B. If a wheel has been removed and installed.
TIRE PRESSURE 521D

17.5 x 25 L2 ...................................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
17.5 x R25 L3 ................................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
17.5 x R25 XTLA TL ......................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
17.5 x R25 XHA TL........................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
15.5 x R25 XTLA TL ......................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
15.5 x R25 XHA TL........................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
Bur 6-42490
Issued 8-01
Printed in U.S.A.
Copyright
6006-4
CHANGING TIRES
1. Have a qualified tire mechanic service the split
rim wheels used on this machine.
The split rim wheels used on this machine

can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and
stand at the front or rear of the tire.
2. The correct tire equipment, especially a tire

inflation cage, is required. Using the wrong
procedure for a split rim wheel can result in
death.
When inflating a tire off the machine, put

th e w he el in a tire inflatio n c ag e. Th e
retaining ring and rim can come off with
enough force to result in death to a person
in front of the rim.
IMPORTANT: When installing a Michelin tire,

lubricate the tire with a tire mounting lubricant and
inflate the tire to 551 kPa, 5.5 bar (80 psi) to make
sure that the tire is seated on the rim. Then decrease
the pressure to the specified pressure.
48-44
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and
axle flange are clean and free of dirt and grease.
4. Tighten the wheel nuts to 298 Nm (220

pound-feet) in the sequence shown in Figure 1.
Th e n ti g h t e n th e w h e e l n u ts in t h e s a m e
s e q u e n c e t o 6 4 0 to 7 2 0 N m ( 4 7 5 t o 5 3 0
pound-feet).
2. Install the wheel, hardened washers and wheel

nuts.
3. Use a hand wrench (not an impact) to tighten the
w h e e l n u t s t o p u l l t h e w h e e l a g a in s t t h e
planetary housing. DO NOT use an impact
wrench to tighten the wheel nuts.
1
8
10
9
2
BS00J104
FIGURE 1. WHEEL NUT TORQUE SEQUENCE
Bur 6-42490
Issued 8-01
Printed in U.S.A.
Copyright
Section
6007
6007
TRANSMISSION CONTROL VALVE
CASE CORPORATION
700 State Street
Bur 6-42500

Printed in U.S.A.
June, 2002
Copyright
6007-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
3
7
9
SPECIAL TOOLS
CAS2885 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
INPUT/OUTPUT SHAFT SEAL
INSTALLATION TOOL
TORQUE CONVERTER SEAL
INSTALLATION TOOL
CAS2869
TRANSMISSION
OUTPUT SHAFT SEAL
INSTALLATION TOOL
(621 MODEL ONLY)
BS02C093 THRU 096
CAS40075 TRANSMISSION TOOL KIT
SPECIAL TORQUES
Screws Securing End Housings to Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Screws Securing Pressure Regulator Locating Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Screws Securing Covers to End Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Nm (48 lb-in)
Valve Housing Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in)
Screws Securing Distribution Plate to Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm (84 lb-in)
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-3
DISASSEMBLY
STEP 1
STEP 3
To a i d in a s s e m b ly, p u t a l ig n m e n t m a r k s o n
transmission control valve (7, figure 1), distribution
plate (2), and valve plate (4).
Remove distribution plate (2), housing gasket (3),

valve plate (4), and housing gasket (5). Discard
housing gaskets (3 and 5).
STEP 2
STEP 4
Remove 18 screws (1) securing distribution plate (2)

to transmission control valve (7).
Remove six filter screens (6) from valve plate (4).
7
5
4
3
2
BS98J157
1. SCREW
2. DISTRIBUTION PLATE
3. HOUSING GASKET
4. VALVE PLATE
5. HOUSING GASKET
6. FILTER SCREEN
7. TRANSMISSION CONTROL VALVE
FIGURE 1. TRANSMISSION CONTROL VALVE PLATES AND GASKETS
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-4
STEP 5
STEP 13
To aid in assembly, put alignment marks on covers

(3 and 6, figure 2), end housings (14), and valve
housing (27). Put alignment marks on wiring harness
(8) connector and cover (3).
Remove two screws (13) from opposite corners of

end housing (14).
STEP 14
STEP 6
Remove clamp (1) securing wiring harness (8)
connector to cover (3).
STEP 7
Remove 14 screws (2) securing cover (3) to end
housing (14).
STEP 8
Remove cover (3) and gasket (4). Discard gasket (4).
BS02C114
STEP 9
Remove 14 screws (5) securing cover (6) to end
housing (14).
STEP 10
Remove cover (6) and gasket (7). Discard gasket (7).
STEP 11
Install CAS2885 transmission valve adjustment tool

set in holes where screws (13) were removed.
Tighten hex rods of CAS2885 down against end
housing. Remove remaining 16 screws from end
housing (14). Loosen CAS2885 hex rods uniformly to
release spring tension. Remove end housing and
gasket (15). Discard gasket. Remove CAS2885
studs.
STEP 15
BS02C113
Disconnect wiring harness (8) connectors from six

pressure regulators (11). Remove wiring harness
from housings (14 and 27) by carefully routing
h ar ne s s a n d co n n ec to rs th ro u g h op e n ing s in
housings.
Remove three pistons (16 and 18), springs (17 and

19), spring (20), and piston (21) from valve housing
(27).
STEP 12
STEP 16
Remove three screws (9) and locating plates (10)

securing three pressure regulators (11) to end
housing (14). Remove pressure regulators (11).
Remove and discard O-ring (12) from pressure
regulators.
Repeat Steps 12 through 14 for other side of valve

housing (27).
BS02C115
NOTE: End housings (14) are under spring pressure.

Use CAS2885 transmission valve adjustment tool set to
hold springs down.
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-5
1
3
2
21
20
18
19
26
11
12
23
25
22
10
18
19
15
14
13
14
10
15
5
16
17
27
13
11
12
24
17
16
6
BS01B099
1.
2.
3.
4.
5.
6.
CLAMP
SCREW
COVER
GASKET
SCREW
COVER
7.
8.
9.
10.
11.
12.
GASKET
WIRING HARNESS
SCREW
LOCATING PLATE
PRESSURE REGULATOR
O-RING
13.
14.
15.
16.
17.
18.
SCREW
END HOUSING
GASKET
PISTON
SPRING
PISTON
19.
20.
21.
22.
23.
24.
SPRING
SPRING
PISTON
PISTON
SPRING
ORIFICE
25. PLUG
26. O-RING
27. VALVE HOUSING
FIGURE 2. TRANSMISSION CONTROL VALVE

Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-6
STEP 17
STEP 18
BS02C1163
Remove three pistons (16 and 18), springs (17 and

19), piston (22), and spring (23) from valve housing
(27).
BS02C117
Remove six orifices (24) from valve housing (27).
STEP 19
Remove eight plugs (25). Remove and discard Oring (26) from plugs.
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-7
INSPECTION
STEP 20
STEP 25
Clean all metal parts in cleaning solvent.
Check pressure regulators (11) for cracks, breaks, or

o th er d a ma g e . C h e ck c on n e ct or c o nt ac ts fo r
looseness or signs of corrosion. Replace a pressure
regulator if any of these conditions are seen. Check
resistance of pressure regulators using a multimeter.
Replace a pressure regulator if resistance is not 17
to 21 ohms.
STEP 21
Immerse end housings (14,figure 2), valve housing
(27), valve plate (4, Figure 1), and distribution plate
(2) in cleaning solvent and agitate cleaning solvent.
COMPRESSED AIR. Use compressed air to remove
foreign matter from interior of housings and plates
and to ensure that all bores are clear of foreign
matter.
STEP 22
COMPRESSED AIR. Use compressed air to ensure
that orifices (24, figure 2) are clear of foreign matter.
STEP 23
STEP 26
Check wiring harness (8) connectors for signs of
breaks, cracks, or other damage. Check contacts for
foreign matter or corrosion. Check harness wiring for
signs of broken or cracked insulation and broken or
frayed wiring at connection to connectors. Replace
wiring harness if any of these conditions are seen.
STEP 27
Check filter screens (6, figure 1) for blockage, rips, or

tears. Replace if any of these conditions are seen.
Check springs (17, 19, 20, and 23, figure 2) for

cracks, breaks, distortion, or signs of permanent set.
Replace a spring if any of these conditions are seen.
STEP 24
STEP 28
Inspect the plates (2 and 4, figure 1), housings (14

and 27, figure 2) and covers (3 and 6) for corrosion,
cracks, breaks, chipping or other damage. Check
bores in housings for deep scratches, gouges, and
other damage. Replace a housing or cover if any of
the above conditions are seen.
Inspect pistons (16, 18, 21 and 22, figure 2) for

cracks, breaks, chipping, grooves, or other damage.
Replace if any of these conditions are seen.
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-8
1
3
2
21
20
18
19
26
11
12
23
25
22
10
18
19
15
14
13
14
10
15
5
16
17
27
13
11
12
24
17
16
6
BS01B099
1.
2.
3.
4.
5.
6.
CLAMP
SCREW
COVER
GASKET
SCREW
COVER
7.
8.
9.
10.
11.
12.
GASKET
WIRING HARNESS
SCREW
LOCATING PLATE
PRESSURE REGULATOR
O-RING
13.
14.
15.
16.
17.
18.
SCREW
END HOUSING
GASKET
PISTON
SPRING
PISTON
19.
20.
21.
22.
23.
24.
SPRING
SPRING
PISTON
PISTON
SPRING
ORIFICE
25. PLUG
26. O-RING
27. VALVE HOUSING
FIGURE 3. TRANSMISSION CONTROL VALVE

Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-9
ASSEMBLY
NOTE: Apply clean Case No. 1 engine oil (15W-40)
to pistons (16, 18, 21, and 22, figure 3) and springs
(17, 19, 20, and 23), orifices (24), new O-rings (12
and 26), and filter screens (6, figure 4) before
assembly.
STEP 31
STEP 29
BS02C118
Push down on pistons (16) to compress springs (17)

and use 5.0 mm (0.197 inch) diameter pins to hold
pistons in position. Install pins in locations shown
above.
BS02C117
STEP 32
Install six orifices (24, figure 3) with concave side

facing up. Install orifices until contact with shoulder in
valve housing (27) is made.
STEP 30
15
A
BS02C119
BS02C115
Install springs (17 and 19) and piston (21) in valve

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

housing (27). Make sure 15 mm (0.6 inch) diameter
recess (A) in end housing is facing spring (20). Install
CAS2885 transmission valve adjustment tool set to
secure end housing. Remove three pins installed in
Step 31 above. Install 16 screws (13) then remove
adjustment tool set and install remaining two screws
(13). Tighten screws (13) to a torque of 5.5 Nm (48
lb-in).
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-10
STEP 33
STEP 36
BS02C121
BS02C123
Install a new O-ring (12) lubricated with clean Case

No. 1 engine oil (15W-40) on pressure regulators
(11). Install pressure regulators and locating plates
(10). Make sure pressure regulators are positioned
as shown above. Locating plates (10) are installed
with the nose (bump) down. Install screws (9) and
tighten to a torque of 5.5 Nm (48 lb-in).
Do Step 33 to install remaining pressure regulators

(11) except make sure pressure regulators are
positioned as shown above.
STEP 37
4
STEP 34
BS02C125
At opposite side of valve housing (27), install springs

(17, 19, and 23) and pistons (16, 18, and 22) in valve
housing (27) bores.
Install wiring harness (8) by routing harness and

connectors through openings in housings (14 and
27 ). C on nect h arne ss con ne cto rs to p ressu re
regulators (11). Install gasket (4). Insert wiring
harness multi-pin circular connector in its hole in
cover (3) making sure marks made in Step 5 are
aligned. Secure connector to cover using clamp (1).
STEP 35
STEP 38
BS02C116
Install 14 screws (2) to secure cover (3) to end

housing (14). Tighten screws to a torque of 5.5 Nm
(48 lb-in).
STEP 39
Install gasket (7) and cover (6).
STEP 40
Install 14 screws (5) to secure cover (6). Tighten
screws to a torque of 5.5 Nm (48 lb-in).
BS02C122
Repeat Steps 31 and 32 except when installing end

housing (14), make sure 19 mm (0.75 inch) diameter
recess (A) faces large piston as shown above.
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-11
STEP 41
STEP 42
BS02C127
BS02C128
Install a new O-ring (26) on eight plugs (25). Install

eight plugs and tighten to a torque of 6 Nm (53 lb-in).
Install two studs in transmission control valve (7,

Figure 4) then install housing gasket (5).
7
5
4
3
2
6
BS98J157
1. SCREW
2. DISTRIBUTION PLATE
3. HOUSING GASKET
4. VALVE PLATE
5. HOUSING GASKET
6. FILTER SCREEN
7. TRANSMISSION CONTROL VALVE
FIGURE 4. TRANSMISSION CONTROL VALVE PLATES AND GASKETS
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
6007-12
STEP 43
STEP 44
BS02C129
BS02C130
Install six filter screens (6) flush in bores of valve

plate (4). Screens must be facing upward toward
distribution plate (2). Make sure marks made in Step
1 are aligned.
Install housing gasket (3) then distribution plate (2).

Make sure marks made in Step 1 are aligned. Install
18 screws (1) and tighten evenly to a torque of 9.5
Nm (84 lb-in).
STEP 45
Refer to Section 6003 and install transmission
control valve.
Bur 6-42500
Issued 6-02
Printed in U.S.A.
Copyright
SECTION INDEX
BRAKES
Section Title
Section Number
Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001

Hydraulic Brake Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008
CASE CORPORATION
700 State Street
Bur 6-42510

Printed in U.S.A.
August, 2001
Copyright
7001
Copyright
Section
7001
REMOVAL AND INSTALLATION OF BRAKE
COMPONENTS
CASE CORPORATION
700 State Street
Bur 6-42521

Printed in U.S.A.
Copyright
7001-2
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.I.N. JEE0135501 AND ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42521
Revised 2-03
3
3
3
4
4
4
4
6
6
6
6
8
8
8
Printed in U.S.A.
Copyright
7001-3
BRAKE VALVE
Removal
the loader bucket to the floor. Stop the engine.
2. Put blocks on both sides of each tire to prevent
machine movement.
3. Make sure the brake accumulators are
completely discharged. Push down and release
the brake pedals at least 30 times.
4. Turn the master disconnect switch to the OFF
position.
5. Remove the cab skirts located under the cab or
canopy.

reservoir. Start the vacuum pump
11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
12. Stop the vacuum pump and remove.
13. Remove the mounting bolts (2), washers (3),
brake valve plate (4) and the brake valve (1).
Installation
1. Install the brake valve (1), brake valve plate (4),
washers (3) and mounting bolts (2). Refer to the
illustration below.
6. To release the pressure on the parking brake

accumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.

7. Connect a drain hose to the quick disconnect

couplings in each brake circuit to release any
pressure in the brake circuit.
8. Clean the brake accumulator charging valve (1)

and lines, refer to the illustration below.
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake
valve (1).
3. Remove the plugs from the hydraulic lines and

connect the hydraulic lines to the brake valve (1).
5. Connect all of the electrical connections.
Turn the master disconnect switch to the ON
position.
6. Bleed the brake system. See Section 7002.
7. Install the cab skirts.
8. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
3
2
1
BS01C126
1. BRAKE ACCUMULATOR
CHARGING VALVE
2. MOUNTING BOLTS
3. WASHERS
4. BRAKE VALVE PLATE
5. BRAKE PEDAL
BRAKE ACCUMULATOR CHARGING VALVE ILLUSTRATION

Bur 6-42521
Revised 2-03
Printed in U.S.A.
Copyright
7001-4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

Removal
machine movement.
3. Make sure the service brake accumulators (1)
and the parking brake a ccumulator (2) are
the brake pedal at least 30 times, refer to the
4. Remove the left cab skirt located under the cab
or canopy.
6. Turn the master disconnect switch to OFF.
7. Clean the brake accumulators (1), parking brake
accumulator (2) and lines.
8. Put identification tags on all lines that are
connected to the brake accumulators (1) and
parking brake accumulator (2).
10. Disconnect the lines from both brake
accumulators (1) and parking brake accumulator
(2).
Installation
1. Install the brake accumulators (1) to the brake
accumulator mounting bracket (10). Refer to the
2. Install the muffler clamps (8), washers (7) and
nut s(6). Tighten the nuts (6).
3. Install the parking brake accumulator (2) to the
bracket (9).
4. Install the muffler clamps (5), washers (4) and
nuts (3). Tighten the nuts (3).
reservoir and start the pump.
6. Connect the lines for both brake accumulators
(1) and for the parking brake accumulator (2).
8. Install the left cab skirt.
9. Turn the master disconnect switch to the ON
position.
11. Refer to Section 7008 and perform the Parking
Brake Test Procedure.
11. Install plugs or caps on each line.

13. Remove the nut (3), washer (4), and muffler
clamps (5).
14. Remove the parking brake accumulator (2).
15. Remove the nuts (6), washer (7), and muffler
clamps (8).
16. Remove the brake accumulators (1).
Bur 6-42521
Revised 2-03
Printed in U.S.A.
Copyright
7001-5
8
8
1
1
8
10
7
6
5
6
7
10
3
4
9
BS01C127
1.
2.
3.
4.
5.
BRAKE ACCUMULATOR
PARKING BRAKE ACCUMULATOR
NUT
WASHER
MUFFLER CLAMP
6.
7.
8.
9.
10.
NUT
WASHER
MUFFLER CLAMP
PARKING BRAKE ACCUMULATOR BRACKET
BRAKE ACCUMULATOR MOUNTING
BRACKET
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION - P.I.N. JEE0135500 AND BELOW
Bur 6-42521
Revised 2-03
Printed in U.S.A.
Copyright
7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

Removal
machine movement.
3. Make sure the service brake accumulators (1)
and the parking brake a ccumulator (2) are
the brake pedal at least 30 times, refer to the
4. Remove the left cab skirt located under the cab
or canopy.
Installation
1. Position and support the brake accumulators (1)
on the rear mounting bracket (10). Loosely install
washers (6 and 5) and bolts (4) to secure the
accumulators to the rear mounting bracket (10).
Refer to the illustration on page 7.
2. Move the front mounting bracket (9) in front of
the brake accumulators (1) and loosely install
washers (6 and 5) and bolts (4).
3. Install washers (8) and bolts (7) to secure front
mounting bracket (9) to chassis. Tighten bolts
securely.
4. Tighten eight bolts (4) securely.
5. Install the parking brake accumulator (2) on front
6. Turn the master disconnect switch to OFF.
6. Install and tighten nut (3).
7. Clean the brake accumulators (1), parking brake

accumulator (2), and lines.

reservoir and start the pump.

connected to the brake accumulators (1) and
parking brake accumulator (2).
8. Connect the lines for both brake accumulators

(1) and the parking brake accumulator (2).

10. Disconnect the lines from both brake
accumulators (1) and parking brake accumulator
(2).
11. Install plugs or caps on each line.
13. Remove the nut (3) holding the parking brake
accumulator (2).

10. Install the left cab skirt.
position.
13. Refer to Section 7008 and perform the Parking
Brake Test Procedure.
14. Remove the parking brake accumulator (2).

15. Remove the bolts (4) and washers (5 and 6)
securing the brake accumulators to the front
16. Remove bolts (7) and washers (8) holding the
front mounting bracket (9) to the chassis.
17. Move the front mounting bracket (9) towards the
fr o n t o f th e lo a d er a n d r e mo v e t h e b r a k e
accumulators (1).
Bur 6-42521
Revised 2-03
Printed in U.S.A.
Copyright
7001-7
2
6
1
7
4
10
6
5
BS02K144
1.
2.
3.
4.
5.
BRAKE ACCUMULATOR
NUT
BOLT
WASHER
6.
7.
8.
9.
10.
WASHER
BOLT
WASHER
FRONT MOUNTING BRACKET
REAR MOUNTING BRACKET
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION - P.I.N. JEE0135501 AND ABOVE
Bur 6-42521
Revised 2-03
Printed in U.S.A.
Copyright
7001-8
BRAKE PUMP
Installation
Removal
1. Install the brake pump (1), mounting bolts (2)

and lock washers (3). Refer to the illustration
below for units P.I.N. JEE0135500 and below or
illu stra tion on p age 9 fo r un its P.I.N.
JEE0135501 and above.

machine movement.
3. Raise the engine hood and turn the master
disconnect switch to the OFF position.
2. Tighten the mounting bolts (2).

4. Clean the brake pump (1) and lines, refer to the

illustration below.
4. Remove the plugs or caps and connect the lines

to the brake pump (1).

connected to the brake pump (1).

position.

7. Disconnect the lines from the brake pump (1)

and put plugs or caps on each line.


9. Remove the mounting bolts (2) and lock washers
(3) from the brake pump (1) and remove the
brake pump (1).
8
4
1
3
2
6
5
9
8
7
9
BS01C125
1. BRAKE PUMP
2. MOUNTING BOLT
3. LOCK WASHER
4. GASKET
5. SPACER
6. GEAR
7. O-RING
8. ELBOW
9. HOSE
BRAKE PUMP ILLUSTRATION - P.I.N. JEE0135500 AND BELOW

Bur 6-42521
Revised 2-03
Printed in U.S.A.
Copyright
7001-9
1
4
5
4
8
12
11
9
7
11
12
10
BS02K143
1.
2.
3.
4.
5.
6.
BRAKE PUMP
BOLT
WASHER
GASKET
SPACER
COTTER PIN
7.
8.
9.
10.
11.
12.
NUT
GEAR
PRESSURE HOSE
SUCTION HOSE
ELBOW
O-RING
BRAKE PUMP ILLUSTRATION - P.I.N. JEE0135501 AND ABOVE
Bur 6-42521
Revised 2-03
Printed in U.S.A.
Copyright
7001-10
NOTES
Bur 6-42521
Revised 2-03
Printed in U.S.A.
7002
Copyright
Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING
CASE CORPORATION
700 State Street
Bur 6-40811

Printed in U.S.A.
March, 2001 (Revised February, 2003)
Copyright
7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-40811
Revised 2-03
3
3
5
6
6
7
8
8
8
9
11
Printed in U.S.A.
Copyright
7002-3
SPECIFICATIONS
Brake pump output ....................................................................................................................30.8 L/min at 172 bar
(8.14 gpm at 2500 psi at 2200 rpm)
Accumulator nitrogen charge pressure...........................................................................53 to 57 bar (775 to 825 psi)
Accumulator valve cut in pressure......................................................................... 147 to 167 bar (2130 to 2422 psi)
Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2756 to 2843 psi)
Brake warning pressure switch............................................................................................ 117 bar (1697 psi) falling
141 bar (2045 psi) rising
Brake redundant pressure switch .......................................................................................................62 bar (900 psi)
Brake light pressure switch..................................................................................................................4.1 bar (60 psi)
Modulation pressure front brake cylinders.........................................................................60 + 6 bar (870 to 987 psi)
Modulation pressure rear brake cylinders .........................................................................57 + 6 bar (825 to 943 psi)
SPECIAL TOOL
94L95
CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND

CHARGE THE ACCUMULATOR WITH NITROGEN.
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-4
20
25
18
14
15
17
24
6
3
1
4
2
21
5
15
19
14
20
16
10
13
23
11
12
7
8
9
22
BC00N001
1.
2.
3.
4.
5.
6.
7.
8.
9.
FRONT BRAKES
REAR BRAKES
PARKING BRAKE
FRONT AXLE TEST PORT
REAR AXLE TEST PORT
BRAKE PUMP
BREATHER
RESERVOIR
10.
11.
12.
13.
14.
15.
16.
17.
18.
OIL COOLER (OPTIONAL)

19. BRAKE LIGHT PRESSURE SWITCH
HYDRAULIC FILTER
20. REDUNDANT BRAKE PRESSURE SWITCH
BY-PASS WARNING SWITCH
21. FROM COUPLER LOCKING VALVE (OPTIONAL)
FILTER BY-PASS
22. NOT USED WITH OPTIONAL FAN REVERSER
BRAKE ACCUMULATOR
23. REVERSE FLOW CHECK VALVE (USED WITH RIDE
CONTROL ONLY)
BRAKE ACCUMULATOR TEST PORT
FAN REVERSER (OPTIONAL)
24. BRAKE AND ACCUMULATOR CHARGING VALVE
25. PARKING BRAKE ACCUMULATOR
PARKING BRAKE ACCUMULATOR DIAGNOSTIC FITTING (NOT USED IN UNITS P.I.N. JEE0135501 AND
ABOVE)
521D BRAKE ILLUSTRATION

Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-5
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM

NOTE: The hydraulic brake schematic is included in
the hydraulic schematic. Refer to the rear pocket of
this manual.
1. Make sure the oil level in the hydraulic reservoir
is correct. Remove all pressure from the brake
system by pushing and releasing the brake pedal
many times with the engine stopped, until there
is no pressure on the pedal.
2. Install two 207 bar (3000 psi) pressure gauges to
both front and rear hydraulic brake accumulator
lines.The test ports for the accumulators are
located behind the left cab skirt.
NOTE: On units P.I.N. JEE0135500 and below,
there are three accumulators and test ports located
behind the cab skirt. The accumulator and test port
closest to the outside of the machine is for the
parking brake. The accumulator and test port located
in the middle is for the rear brakes. The accumulator
and test port farthest to the inside is for the front
brakes. Refer to the illustration on page 9. On units
P.I.N. JEE0135501 and above, there are three
accumulators and two test ports located behind the
cab skirt. The accumulator and test port located to
the outside of the loader is for the rear brakes. The
accumulator and test port to the inside of the loader
is for the front brakes. The small bottle type
accumulator is for the parking brake. Refer to the
3. Make sure that the hoses on the pressure
gauges are long enough so the gauges can be
read while sitting in the operators seat.
NOTE: The gauges can not be connected if
hydraulic pressure remains in the system.
4. Start the engine. Run the engine at low idle while
re ad ing th e p re ssu re g au g es . Th e a lar ms
(buzzer, master warning light and brake pressure
warning light) should shut off when the
accumulator with the lowest pressure reaches
126 to 140 bar (1825 to 2025 psi).
6. With the engine running at high idle, push and

release the brake pedal rapidly while reading the
drop in pressure on the gauges. The pressure
drops ma y not be equal, but as the lowest
pressure reaches 147 to 167 bar (2130 to 2422
psi), the system pressure must start to increase.
This is the valve cut in pressure.
NOTE: The brake cut-in and cut-out pressures of the
brake system charge valve are factory preset and are
not adjustable.
NOTE: If the pressure on one of the pressure
gauges is lower than specified, the problem can be a
bad accumulator valve.
7. Stop the engine. Push and release the brake
several times while reading the pressure on the
gauges. Each push and release of the pedal will
resu lt in a sligh t drop in p ressu re, bu t not
necessarily equal on the two gauges. As the
lowest pressure reaches 110 to 124 bar (1600 to
1800 psi) the brake warning lamp and alarm
buzzer must actuate. If the warning lamp and
alarm buzzer fail to work, test the low brake
pressure warning switches and electrical circuit.
If the warning lamp and alarm buzzer actuate at
a higher or lower pressure than specified, test
the low brake pressure warning switches and
replace as needed.
8. Continue to slowly push and release the brake
pedal several times until the gauge pressure
sudd enly drop s to zero. The last pressu re
reading before the drop to zero is the nitrogen
charge pressure in the accumulator. Test the
pressure in both accumulators. If the pressure is
below 53 to 59 bar (775 to 825 psi), charge or
replace the accumulator(s) (see page 6).
NOTE: Cold temperature can cause a drop in
pressure.
5. After the alarms stop, run the machine at high

idle to finish charging the accumulators. The
pressure must increase on both gauges until 190
to 196 bar (2755 to 2842 psi) is reached. This is
the accumulator valve cut-out pressure. It is
normal for the pressure to drop slightly once the
cut-out pressure is reached.
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-6
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is
completely discharged by doing the following:
A. Stop the engine.
B. Push down and release the brake pedal many

times to release the pressure.
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.
4. Turn the stem out of valve F until the stem stops.

94L95
5. Remove the cap screws and guard from the

accumulator.
6. Remove the cap from the accumulator valve
stem.
7. Connect valve F to the accumulator valve stem.
NITROGEN CHARGING KIT
8. Make sure that valve D is open.

9. Turn the stem into valve F and read the pressure
gauge E.
10. The pressure must be 53 to 57 bar (775 to 825
psi). If the p ressure is to o low, cha rge th e
accumulator with dry nitrogen.
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator
according to the instructions in Checking the
Nitrogen Charge in the Accumulator. Keep the
nitrogen charging kit connected to the accumulator.
1. Close (turn counterclockwise) valve A and open
valve B. Close valves C and D.
2. Turn the stem out of valve F until the stem stops
moving. Disco nn ect va lve F fr om th e
accumulator valve stem.
3. Connect the nitrogen charging kit to a dry
nitrogen tank.
4. Slowly turn valve A clockwise and read gauge E
until the pressure is 53 to 57 bar (775 to 825 psi).
Stop turning valve A.
5. If the pressure increases above 57 bar (825 psi),

quickly open and close valve D and read gauge
E. If the pressure is still too high, close valve A
(turn counterclockwise) a small amount and
quickly open and close valve D. The pressure
shown on gauge E is the charge pressure.
6. Connect valve F to the accumulator valve stem.
Turn the stem into valve F until the stem stops
moving and open valve D to c harge the
accumulator.
7. After the accumulator stops charging, turn the
stem out of valve F until the stem stops moving.
8. Close valve B and disconnect the nitrogen
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
Ins tall the guard and cap screws on the
accumulator.
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-7
BLEEDING THE BRAKE SYSTEM

1. Check the level of hydraulic fluid in the reservoir.
Add fluid to the reservoir if necessary.
5. Locate connector at end of engine harness wire

(1) and disconnect connector from fuel injector
pump fuel solenoid connector.
NOTE: The fuel solenoid is located behind the fuel
injection pump near the fuel lines.
6. Loosen pressure side hose fitting (4, page 11 or
12) on brake pump. Pressure side hose is the
smaller of the two hoses connected to the brake
pump. Refer to illustration on page 11 or 12.
7. Turn the engine over until a few drops of oil leak
past the pressure side hose fitting.
BD00M048
8. Tighten the hose fitting and connect the fuel

solenoid connector to the engine harness wire
(1) connector.
1. SAFETY LINK
2. Raise loader arms and install the safety link (1)

for safe access to the front axle bleed screws.
10. Keep the engine speed at low idle until both

brake accumulators are fully charged.
NOTE: This will be approximately 30 seconds after

the low brake pressure light goes out.
4. Stop the engine.

12. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).
13. 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.
14. Start the engine and run at low idle.
15. Push the brake pedal all the way down and
slowly release for one cycle.
BD01D216
16. Close all four wheel end bleed screws.
17. Fully depress the brake pedal three times in 5

second cycles.
18. 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.
19. Open the bleed screw on the right front axle.

Repeat step 18.
20. Open the bleed screw on the left rear axle.
Repeat step 18.
BS02J060

1. FUEL SOLENOID WIRE
21. Open the bleed screw on the right rear axle.

Repeat step 18.
22. Tighten all bleed screws, caps and plugs.
23. Check the hydraulic fluid and add as necessary.
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-8
BRAKE MODULATION PRESSURE CHECK

Adjusting the Brake Modulation
Pressure
Testing the Brake Modulation

Pressure
1. Make sure the hydraulic accumulator cut-in and
cut-out pressures are correct. Refer to page 5 of
this section.
NOTE: The adjusting bolt to adjust the modulation

pressure is located in the cab, under the brake pedal.
2. Stop the engine. Pump the brake pedal until

there is no pressure in the brake system.
2
1
1
BD00N012
1. FRONT AXLE TEST PORT

2. REAR AXLE TEST PORT
3. Connect two 207 bar (3000 psi) pressure gauges

to the front axle test port (1) and the rear axle
test port (2).
NOTE: These test ports are located behind the left
cab skirt near the brake valve. The test port closest
to the front of the machine is for the front brakes and
the test port for the rear brakes is towards the rear.
4. Install two 207 bar (3000 psi) pressure gauges to
the accumulator test ports (3 and 4). Refer to the
illustration on page 9 or 10.
6. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
the gauges rise above 170 bar (2645 psi).
7. Apply and hold the brakes for 10 to 15 seconds.
BD00N121
1. TAMPER RESISTANT COVER

2. ADJUSTING BOLT
1. Remove the tamper resistant cover (1).

NOTE: This is a tamper resistant cover and it will be
necessary to install a new cover after the modulation
pressure is adjusted.
2. Turn the adjusting bolt (2) to adjust the
modulation pressure.
NOTE: The rear brake modulation pressure cannot
be adjusted separately from the front brake
modulation pressure.
3. Repeat steps 5 through 10 in the Testing the
Brake Modulation Pressure procedure.
4. Repeat these steps until the brake modulation
pressure is within the specified range.
8. Make a note of the pressure on the gauges for

the front and rear axles.
9. The front axle brake pressure should read 60 to
68 bar (870 to 986 psi). This is the modulation
pressure for the front axle.
10. The rear axle brake pressure should read 57 to
65 bar (825 to 943 psi).
11. If the pressures are not within the specified
r a n g e , i t w i ll b e n e c e s s a r y t o a d ju s t t h e
modulation pressures.
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-9
CHECKING THE BRAKE SYSTEM

1. Check the level of the hydraulic fluid in the
reservoir, add as needed.
6. Start the engine and let idle until both the front
a nd r ea r ac cu mu lato r s ( 5 an d 6 ) a r e fully
charged. The accumulators are fully charged at
190 to 196 bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal (8) 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 (8) down. The
low brake pressure light should activate when
the pressure reaches 110 to 124 bar (1600 to
1800 psi). After the low brake pressure light
activates, press the brake pedal eight more
times.
BD00M030
2. Install the articulation lock (1) before doing this

test.
10. Record the readings on the pressure gauges.

The pressure gauges should read at or above 52
to 58 bar (750 to 850 psi).
3. Remove the left side cab skirt to gain access to

the brake accumulators (5 and 6). Refer to the
illustration below or on page 10.
11. If the pressures are at or above 52 to 58 bar (750

to 850 psi), the test is complete.
4. Pump the brake pedal (8) until there is no

hydraul ic pressu re in the brake system
(approximately 20 pumps).
12. If the pressures are not within the required

specifications, then the brake system must be
bled.
5. Connect two 207 bar (3000 psi) pressure gauges

to the test ports (3 and 4).
13. After bleeding the brake system, perform the

brake system check again.
4
7
BC01B050
1.
2.
3.
4.

PARKING BRAKE ACCUMULATOR TEST PORT
FRONT BRAKE ACCUMULATOR TEST PORT
REAR BRAKE ACCUMULATOR TEST PORT
5.
6.
7.
8.
FRONT BRAKE ACCUMULATOR

REAR BRAKE ACCUMULATOR
BRAKE AND ACCUMULATOR CHARGING VALVE
BRAKE PEDAL
BRAKE SYSTEM COMPONENTS - P.I.N. JEE0135500 AND BELOW
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-10
1
5
BS02M025
1.
2.
3.
4.

NOT USED
FRONT BRAKE ACCUMULATOR TEST PORT
REAR BRAKE ACCUMULATOR TEST PORT
5.
6.
7.
8.
FRONT BRAKE ACCUMULATOR

REAR BRAKE ACCUMULATOR
BRAKE PEDAL
BRAKE SYSTEM COMPONENTS - P.I.N. JEE0135501 AND ABOVE
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-11
BRAKE PUMP OUTPUT TEST

1. Connect the flowmeter to the brake pump as
shown below for units P.I.N. JEE0135500 and
below or as shown on page 12 for units P.I.N.
JEE0135501 and above.
3. Measure the flow at 0 bar (0 psi). Record the flow

reading. Slowly close the load valve on the
flowmeter and read the flow at 170 bar (2500
psi). Record the flow reading.
2. Make sure the load control of the flowmeter is

open. Start the engine. Run the engine at full
th ro ttle . M ak e su r e th e oil is a t o p e ra tin g
temperature.
4. Divide the flow reading at 170 bar (2500 psi) by

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.
11
9
NOTE
10
6
2
12
5
4
3
12
2
1
BS02M027
1.
2.
3.
4.
FROM HYDRAULIC RESERVOIR

5. BRAKE PUMP
9. FILTER INLET MANIFOLD
ELBOW
6. FLOWMETER INLET HOSE
10. FILTER
PLUG
7. CAS-10280 FLOWMETER
11. FILTER TO RESERVOIR HOSE
TO ACCUMULATOR VALVE
8. FLOWMETER OUTLET HOSE
12. O-RING
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
BRAKE PUMP OUTPUT TEST - P.I.N. JEE0135500 AND BELOW
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
7002-12
11
9
NOTE
10
6
2
1
2
12
3
BS02M026
1.
2.
3.
4.
FROM HYDRAULIC RESERVOIR

5. BRAKE PUMP
ELBOW
10. FILTER
PLUG
TO ACCUMULATOR VALVE
12. O-RING
BRAKE PUMP OUTPUT TEST - P.I.N. JEE0135501 AND ABOVE
Bur 6-40811
Revised 2-03
Printed in U.S.A.
Copyright
BRAKE ACCUMULATORS
CASE CORPORATION
700 State Street
Bur 6-42531

Printed in U.S.A.
7004
Section
7004
Copyright
7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE ACCUMULATOR P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42531
Revised 2-03
......
......
......
......
......
......
......
......
......
......
3
3
4
4
4
4
6
6
6
6
Printed in U.S.A.
Copyright
7004-3
SPECIAL TOOL
94L95
CAS-10899 NITROGEN CHARGING KIT
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

E
C
F
A
94L95
NITROGEN CHARGING KIT
NOTE: The parking brake accumulator used on

P.I.N. JEE0135501 and above is not rechargeable
nor repairable.
1. Use the CAS-10899 nitrogen charging kit to
discharge the accumulator, refer to illustration
above. The tool must be disconnected from the
nitrogen tank.
2. Close valves B, C and D.
3. Adjust the regulator A to the minimum pressure
setting by turning the knob counterclockwise.
4. Turn the T-handle on valve F fully out.
5. Remove the guard (2) and valve assembly cap
(9) from the accumulator, refer to Figure 2.
Bur 6-42531
6. Connect valve F to the valve stem on the

accumulator.
7. Turn the T-handle inward on valve F to engage
the pin in the valve stem.
8. Open valve D and check the charge pressure on
gauge E.
9. To discharge the accumulator, partially open
valve B. The accumulator charge will bleed down
through the regulator.
10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
11. The accumulator can now be disassembled.
Revised 2-03
Printed in U.S.A.
Copyright
7004-4
BRAKE ACCUMULATORS
Assembly
Disassembly
NOTE: See Section 7001 for the proper procedure
to remove the accumulator.
WA R N I N G : D O N O T a t t e m p t t o
disassemble any accumulator until the
nitrogen charge is properly discharged.
SM386
1. Fasten the body (1) in a vise. Be careful not to

damage the body (1), refer to the illustration on
page 5.
2. Remove the screws (3) and guard (2) from the
body (1).
3. Remove the pressure valve (4) and the elbow (8)
from the body (1).
4. Remove and discard the O-ring (7) from the
elbow (8).
5. Loosen and remove the gland (6) from the body
(1).
6. Remove the piston (5) from the body (1).
7. Remove and discard the wear ring (9), O-ring
(11) and the backup ring (10) from the piston (5).
8. Remove the seals (12) from the gland (6).
Inspection
1. Clean body (1), gland (6) and piston (5) in
cleaning solvent, refer to the illustration on page
5.
2. Inspect the piston (5) for cracks, burrs or other
damage.

damage the body (1). Refer to the illustration on
page 5.
2. Install a new wear ring (9), O-ring (11) and
backup ring (10) on the piston (5).
3. Lubricate the bore of the body (1) and the piston
(5) with clean oil.
4. Start the piston (5) into the body (1), round
surface first. Then push the piston (5) farther into
the body (1).
NOTE: The piston (5) must be installed squarely and
slowly into the body (1). Once the piston (5) is started
straight into the bore of the body (1), use a hammer
and wood block to gently tap the piston into the
polished area of the bore. Keep force on the piston
(5) while tapping into the bore or damage may occur
to the O-ring.
5. Install new seals (12) on the gland (6).
6. Lubricate the seals (12) with clean oil and start
the gland (6) into the body (1).
7. Tighten the gland (6).
8. Install a new O-ring (7) on the elbow(8).
9. Install the elbow (8) on the body (1).
10. Install the pressure valve (4) in the elbow (8).
11. Install the guard (2), screws (3) in the body (1).
12. Charge the accumulator with dry nitrogen
according to instructions in Section 7002.
3. Inspect the bore of the body (1) for scratches or

scoring using a light.
NOTE: Minor scratches or scoring in the bore of the
body (1) can be removed using crocus cloth.
4. Inspect the pressure valve (4) and replace as
needed.
Bur 6-42531
Revised 2-03
Printed in U.S.A.
Copyright
7004-5
12
10
11
4
2
3
7
BS01B223
1. BODY
2. GUARD
3. SCREW
4. PRESSURE VALVE
5. PISTON
6. GLAND
7. O-RING
8. ELBOW
9. WEAR RING
10. BACKUP RING

11. O-RING
12. SEALS (2)
BRAKE ACCUMULATOR
Bur 6-42531
Revised 2-03
Printed in U.S.A.
Copyright
7004-6

NOTE: The parking brake accumulator used on
P.I.N. JEE0135501 and above is not rechargeable
nor repairable.
Disassembly
SM386

page 7.
body (1).
3. Remove the pressure valve (4) from the
body (1).
pressure valve (4).
(1).
Assembly
page 7.
(5) with clean oil.
the body (1).
to the O-ring.
8. Install a new O-ring (7) on the pressure valve (4).

9. Install the pressure valve (4) on the body (1).
Inspection
1. Clean body (1), gland (6) and piston (5) in
cleaning solvent, refer to the illustration on page
7.
according to instructions in Section 7002.
WA R N I N G : U s e o n l y n i t r o g e n w h e n
charging the accumulator. DO NOT use air
or oxygen that will cause an explosion.
SM115A

damage.
needed.
Bur 6-42531
Revised 2-03
Printed in U.S.A.
Copyright
7004-7
11
10
1
BS01B224
1. BODY
2. GUARD
3. SCREW
4. PRESSURE VALVE
5. PISTON
6. GLAND
7. O-RING
8. WEAR RING
9. BACKUP RING
10. O-RING
11. SEALS (2)
PARKING BRAKE ACCUMULATOR - P.I.N. JEE0135500 AND BELOW
Bur 6-42531
Revised 2-03
Printed in U.S.A.
Copyright
7004-8
NOTES
Bur 6-42531
Revised 2-03
Printed in U.S.A.
Copyright
Section
7008
7008
PARKING BRAKE
CASE CORPORATION
700 State Street
Bur 6-42540

Printed in U.S.A.
August, 2001
Copyright
7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42540
Issued 8-01
3
3
4
4
7
Printed in U.S.A.
Copyright
7008-3
PARKING BRAKE
STEP 6
Removal and Disassembly

STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wh eel ch ocks on each wheel to prevent
machine movement.
STEP 3
BD01D296
Loosen and remove the parking brake hose. Cap and

plug the hose and fitting.
STEP 7
BDOOM030
Install the articulation lock.
STEP 4
BD01D346
Loosen and remove the cover from the parking

brake.
STEP 8
BD01D136
Place the master disconnect switch in the OFF

position.
STEP 5
With the engine in the OFF position, pump the brake
pedal at least 20 times to discharge the
accumulators.
BD01D347
Loosen the jam nut that secures the center post.
Bur 6-42540
Issued 8-01
Printed in U.S.A.
Copyright
7008-4
STEP 9
Inspection
STEP 12
Clean and inspect all parts for wear and damage.
Inspect the brake disc for wear and damage.
Replace all parts that are worn or damaged.
Assembly and Installation

STEP 13
BD01D347
Turn the center post counterclockwise until the brake

pads are loose.
STEP 10
BD01D350
Install the two brake pads in the parking brake

assembly.
STEP 14
Install the parking brake assembly on the brake disc.
BD01D348
Loosen and remove the two bolts holding the parking

brake to the transmission. Remove the parking
brake.
STEP 15
STEP 11
BD01D348
Install the two bolts holding the parking brake to the

transmission. Tighten the two bolts.
BD01D351
Remove the two brake pads from the parking brake

assembly.
Bur 6-42540
Issued 8-01
Printed in U.S.A.
Copyright
7008-5
STEP 16
STEP 20
BD01D296
BD01D346
Remove the plugs and caps and install the hose onto
the parking brake.
Remove the cover from the front of the parking

brake.
STEP 17
STEP 21
Park the machine on a clear level surface with wheel

chocks and the articulation lock in place.
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.
STEP 18
Start the machine and run the engine at low idle with
the bucket resting on the ground.
STEP 19
BD01D347
1. JAM NUT
2. CENTER POST
Disengage the parking brake.

NOTE: Hydraulic pressure will not be applied to the
parking brake until the parking brake rocker switch is
turned off, the service brakes applied and the
transmission is put into gear.
Loosen the jam nut (1) that secures the center post
(2).
STEP 22
A. Place the parking brake rocker switch in the

OFF position.
B. Apply the service brake and put the machine
into gear.
C. The parking brake light on the cluster will turn
off at this time.
D. Place the transmission back into neutral
before proceeding.
BD01D347
Turn the center post clockwise until both brake pads

contact the brake disc, then turn the center post
counterclockwise one turn.
Bur 6-42540
Issued 8-01
Printed in U.S.A.
Copyright
7008-6
STEP 23
STEP 27
BD01D347
BD00M030
Tighten the jam nut to secure the center post.
Remove the articulation lock.
STEP 24
STEP 28
BD01D346
Install the cover on the parking brake.
BD01D140
Place the ma ster d isconn ect switch to the O N

position.
STEP 25
Perform the Pa rking Brake Test Procedu re as
described in this section.
STEP 26
Re fe r to Se ctio n 70 02 fo r Bleed in g th e Bra ke
System.
Bur 6-42540
Issued 8-01
Printed in U.S.A.
Copyright
7008-7
PARKING BRAKE TEST PROCEDURE

STEP 29
STEP 37
While testing, the machine must be on a clear level

surface with the bucket in the travel position.
Shift the gear selector into third gear forward and

slowly increase the engine speed to wide open
throttle.
STEP 30
Start the machine and run the engine at low idle in
third gear neutral.
STEP 38
STEP 31
STEP 39
Place the Transmission-Auto switch to the manual

position,
Reduce the engine speed to low idle and return the

transmission neutral.
STEP 32
STEP 40
Place the Parking Brake switch in the ON position.
Shift the gear selector to third gear reverse and

slowly increase the engine speed to wide open
throttle.
STEP 33
Press the Program switch on the instrument cluster.
Verify that the machine does not move.
STEP 41
STEP 34
Verify that the machine does not move.
Press the Up Count switch until the display reads

011.
STEP 42
STEP 35
Reduce the engine speed to low idle and return the

transmission to neutral.
Return the Program switch to the OFF position.
STEP 36
Press the UP Count switch until the display reads 01.
This mode will allow the transmission to engage
while the parking brake is applied.
STEP 43
Press the Reset switch on the instrument cluster to
exit the test mode.
STEP 44
If any machine movement was detected, the parking
brake must be adjusted.
Bur 6-42540
Issued 8-01
Printed in U.S.A.
Copyright
7008-8
NOTES
Bur 6-42540
Issued 8-01
Printed in U.S.A.
Copyright
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
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Pilot Pressure Accumulator and Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
CASE CORPORATION
700 State Street
Bur 6-42550

Printed in U.S.A.
August, 2001
Copyright
8001
Copyright
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC
COMPONENTS
CASE CORPORATION
700 State Street
Bur 6-42560

Printed in U.S.A.
August, 2001
Copyright
8001-2
TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42560
Issued 8-01
3
3
6
9
9
10
15
15
17
19
19
20
22
22
24
26
26
28
29
29
30
32
32
33
34
34
36
38
38
39
Printed in U.S.A.
Copyright
8001-3
REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE

Removal
STEP 6
STEP 1
Loosen the filler cap on the reservoir to release the

air pressure in the reservoir.
Park the machine on a level surface.
STEP 7
STEP 2
Drain the hydraulic reservoir.
STEP 8
BD00M048
Raise the lift arms and install the safety link on the lift
arm cylinder.
BD00M041
Loosen and remove the bolts and washers that

fasten the access cover plate for the loader control
valve. Remove the cover plate.
STEP 3
Stop the engine and apply the parking brake.
IMPORTANT: Pump the brake repeatedly to be sure
the brake accumulators have no hydraulic pressure,
then move the loader control valve back and forth
several times to release any hydraulic pressure in the
pilot control circuit.
STEP 4
BD01D138

position.
STEP 5
Release the pressure in the ride control accumulator
with the manual bleeder valve at the rear of the front
chassis.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-4
6
5
REAR OF MACHINE
3
4
BS01D179

2. PILOT ACCUMULATOR HOSE
3. PILOT PRESSURE HOSE
4. CHECK VALVE
5. PRESSURE SWITCH FITTING
6. FLOAT SWITCH
4 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION
STEP 9
STEP 10
Disconnect the hoses from the remo te contro l

valve(s) at the loader control valve one at a time and
fasten an identification tag to each hose. Refer to the
illustration above.
Install a plug in each hose and a cap on each fitting.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-5
STEP 11
STEP 12
1
2
4
3
4
5
BD01D376
1.
2.
3.
4.
5.
6.
7.
VALVE RETURN HOSE

RIDE CONTROL TANK HOSE
ACCUMULATOR DRAIN HOSE
PUMP LOAD SENSING HOSE
STEERING LOAD SENSING HOSE
STEERING PRESSURE HOSE
PUMP PRESSURE HOSE (NOT SHOWN)
A. Tag and disconnect the valve return hose (1)

at the loader control valve and install a plug in
the hose and a cap on the fitting.
B. Tag and disconnect the pump pressure hose
(7) and install a plug in the hose and a cap on
the fitting.
NOTE: The pump pressure hose (7) will be
connected to a elbow at the bottom of the loader
control valve.
C. Tag and disconnect the ride control tank hose
(2) and install a plug in the hose and a cap on
the fitting.
D. Tag and disconnect the accumulator drain
hose (3) and install a plug in the hose and a
cap on the fitting.
BD01D381
1.
2.
3.
4.
ROD END TILT TUBE

HEAD END TILT TUBE
HEAD END LIFT TUBE
ROD END LIFT TUBE
A. Tag and disconnect the rod end tilt tube (1)

from the loader control valve and install a plug
in the tube and a cap on the fitting.
B. Tag and disconnect the head end tilt tube (2)
C. Tag and disconnect the head end lift tube (3)
D. Tag and disconnect the rod end lift tube (4)
E. Tag and disconnect any auxiliary spool tubes
if equipped.
STEP 13
E. Tag and disconnect the pump load sensing

cap on the fitting.
F. Tag and disconnect the steering load sensing
cap on the fitting.
G. Tag and disconnect the steering pressure
cap on the fitting.
BS01D190
Loosen and remove the three bolts and washers that

hold the loader control valve to the valve mounting
plate.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-6
STEP 14
Use proper lifting device to lift and remove the loader
control valve.
Installation
B. Connect the head end lift tube (3) to the

C. Connect the head end tilt tube (2) to the
D. Connect the rod end tilt tube (1) to the loader
control valve.
STEP 15
STEP 17
2
4
5
BD01D376
BS01D190
A. Install and align the loader control valve with

the valve mounting plate.
B. Install the bolts and washers that fasten the
loader control valve to the valve mounting
plate. Tighten the bolts.
1.
2.
3.
4.
5.
6.
7.
VALVE RETURN HOSE

ACCUMULATOR DRAIN HOSE
PUMP LOAD SENSING HOSE
STEERING LOAD SENSING HOSE
STEERING PRESSURE HOSE
PUMP PRESSURE HOSE (NOT SHOWN)
A. Connect the steering pressure hose (6) to the

IMPORTANT: Before installing the fittings or

connecting the tubes to the fittings, install new
O-rings on the fittings.
B. Connect the steering load sensing hose (5) to

STEP 16
C. Connect the pump load sensing hose (4) to

D. Connect the accumulator drain hose (3) to the
1
2
E. Connect the ride control tank hose (2) to the

loader control valve/
F. Connect the pump pressure hose (7) to the
bottom of the loader control valve.
G. Connect the valve return hose (1) to the

BD01D381
1.
2.
3.
4.
ROD END TILT TUBE

HEAD END TILT TUBE
HEAD END LIFT TUBE
ROD END LIFT TUBE
A. Connect the rod end lift tube (4) to the loader

control valve.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-7
7
6
5
REAR OF MACHINE
3
4
BS01D179
1.
2.
3.
4.
LOADER CONTROL VALVE

PILOT ACCUMULATOR HOSE
PILOT PRESSURE HOSE
CHECK VALVE
5.
6.
7.
8.
PRESSURE SWITCH FITTING

FLOAT SWITCH
OPTIONAL
OPTIONAL
4 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION
STEP 18
STEP 19
Connect the lines from the remote control valve to

th e lo a d e r co n tr o l v a lv e . R e f e r to t h e a b o v e
illustration.
Fill the hydraulic reservoir with oil. Refer to Section

1002 for the correct oil.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-8
STEP 20
STEP 22
Start the engine and run at half throttle.
STEP 23
Slo w ly a n d co mp le te ly e x te nd an d r et ra ct a ll
cylinders at least 10 times to remove any air from the
circuits.
STEP 24
Stop the engine and check for leaks.
STEP 25
Install the access cover on the front of the machine.
BD01D138
Place the master disco nnect switch in the ON

position.
STEP 21
STEP 26
Check the level of the hydraulic oil and add hydraulic
oil as required.
BD00M048
Raise the loader arms and remove the safety link.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-9
REMOVAL AND INSTALLATION OF THE REMOTE CONTROL VALVE

STEP 34
Removal
Unlatch and open the window on the right hand side.
STEP 27
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 35
IMPORTANT: Pump the brake repeatedly to be sure

the brake accumulators have no hydraulic pressure,
then move the loader control lever back and forth
several times to release any hydraulic pressure in the
pilot control circuit.
STEP 28
BD01D271
Loosen and remove the ten screws holding the

access panel to the cab.
STEP 36
Remove the access panel.
STEP 37
BD01D138

position.
STEP 29
fasten the right skirt panel under the right side of the
ROPS cab or ROPS canopy. Remove the right skirt
panel.
STEP 30
Loosen the filler cap on the reservoir to release any
air in the reservoir.
STEP 31
STEP 32
Unlatch and open the right hand side access door.
STEP 33
Lift the access door up and remove the access door
from the pins.
Bur 6-42560
BD01D390
Disconnect the wire from the solenoid and loosen

and remove the lock-out solenoid to gain access to
the hydraulic hoses.
STEP 38
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.
STEP 39
Tag and disconnect the electrical connectors for the
remote control valve.
Issued 8-01
Printed in U.S.A.
Copyright
8001-10
STEP 40
Installation
STEP 43
Install new O-rings on the adapters for the remote
control valve.
STEP 44
BD01D720
Loosen and remove the two screws and washers

holding the hydraulic control tower cover. Remove
the cover.
STEP 41
BD01D722
Install the remote control valve and screws in the

hydraulic control tower and tighten the screws.
STEP 45
Connect the electrical connectors for the remote
control valve.
STEP 46
BD01D722
Loosen and remove the four screws that fasten the

remote control valve to the hydraulic control tower.
STEP 42
Remove the remote control valve from the hydraulic
control tower.
BD01D720
Install the cover over the remote control valve and

install the two screws and washers.
STEP 47
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 12 through 14 as necessary._
STEP 48
Fill the hydraulic reservoir. See Section 1002 for the
correct hydraulic oil.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-11
STEP 49
STEP 54
BD01D136
BD01D271

position.
Install the access panel on the ROPS cab or the

ROPS canopy
STEP 50
STEP 55
Start the engine and run the engine at low idle.
Close the right hand window.
STEP 51
STEP 56
Check to see that the remote control valve works

correctly.
Install the access door on the pins and close the

access door.
STEP 52
STEP 57
Check for hydraulic oil leakage at the remote control

valve.
Install the right skirt panel under the ROPS cab or the
ROPS canopy and tighten the bolts.
STEP 53
Check the level of hydraulic oil in the reservoir and
add as required.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-12
BS01D180
1. PILOT TANK HOSE
JOYSTICK AND 2 LEVER HOSE ILLUSTRATION
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-13
2
2
1
1
BS01D178
1. PILOT TANK HOSE

3 LEVER HOSE ILLUSTRATION
Bur 6-42560
1. PILOT TANK HOSE

JOYSTICK AND 1 LEVER HOSE ILLUSTRATION
Issued 8-01
Printed in U.S.A.
Copyright
8001-14
1
1
BS01D177
1. PILOT TANK HOSE

2 LEVER HOSE ILLUSTRATION
Bur 6-42560
1. PILOT TANK HOSE

JOYSTICK HOSE ILLUSTRATION
Issued 8-01
Printed in U.S.A.
Copyright
8001-15
REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP

STEP 61
Removal
STEP 58
parking brake.
STEP 59
3
1
2
4
BD01D303
1. BOLTS (4)
2. CASE DRAIN HOSE
3. SUCTION HOSE
4. HYDRAULIC PUMP
A. Loosen and remove the four bolts (1)

c o n n e c t in g t h e s u c ti o n h o s e ( 3 ) t o t h e
hydraulic pump (4).
BD01D138

position.
STEP 60
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.
STEP 62
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

the hydraulic hoses. Slide the bracket up to gain
enough clearance for the hydraulic pump to be
removed.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-16
STEP 63
STEP 65
2
4
1
3
BD01D308
1. BOLTS (4)
2. LOAD SENSING HOSE
3. PRESSURE HOSE
4. HYDRAULIC PUMP
BD01D307
Loosen and remove the two bolts that fasten the

hydraulic pump to the transmission.
A. Loosen and remove the four bolts (1)

conn ecting the p ressure ho se (3) to th e
hydraulic pump (4).
STEP 66
B. Tag and disconnect the load sensing hose (2)

from the hydraulic pump (4).
STEP 67
Remove the hydraulic pump from the machine.
C. Plug all lines and cap all fittings.
STEP 64
BD01D335
Remove and discard the O-ring from the hydraulic

pump.
BD01D333
Use proper lifting device to strap and support the

hydraulic pump.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-17
STEP 71
Installation
STEP 68
3
2
1
BD01D308
1. PRESSURE HOSE
2. HYDRAULIC PUMP
3. LOAD SENSING HOSE
BD01D335
Use proper lifting device to lift and support the

hydraulic pump. Install a new O-ring on the hydraulic
pump.
A. Install the pressure hose (1) to the hydraulic

pump (2).
STEP 69
B. Install the load sensing hose (3) to the

hydraulic pump (2).
STEP 72
1
2
BD01D334
Install the hydraulic pump on the transmission.

BD01D303
STEP 70
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).
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-18
STEP 73
STEP 76
BD01D329
BD01D136
Install the bracket holding the hydraulic hoses.

Tighten the bolts.
Place the master d isco nnect switch in the O N

position.
STEP 74
STEP 77
See Section 9007 for installing the ROPS cab or

ROPS canopy.
Start the engine and run the engine at low idle for two
minutes.
STEP 75
Fill the hydraulic reservoir with hydraulic oil. See
Section 1002 for correct oil type.
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 78
Stop the engine and check for hydraulic oil leakage
at the hydraulic pump.
STEP 79
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-19
REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS

STEP 85
Removal
STEP 80
parking brake.
STEP 81
Pump the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, then move
the loader control lever back and forth several times
to release any hydraulic pressure in the pilot control
circuit.
BD01D709
STEP 82
Relieve the pressure in the ride control accumulator
with the manual bleeder valve located at the rear of
the front chassis.
Loosen and remove the bolt, washer and spacer that

hold the pivot pin for the yoke.
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.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-20
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

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.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-21
STEP 94
STEP 97
BD01D710
Align the pivot pin with the front frame and install the
spacer, washer and bolt. Tighten the bolt.
BD01D712
Install the pivot pin for the yoke. Stop the engine.
STEP 98
STEP 95
BD01D709
BD01D708
Remove the caps and plugs and connect the hoses

to the lift cylinder.
Align the pivot pin with the yoke and install the
spacer, washer and bolt. Tighten the bolt.
STEP 99
STEP 96
If the yoke of the lift cylinder is not aligned with the
loader frame, have another person start and run the
engine at low idle and use the loader control lever to
SLOWLY move the yoke into alignment with the
loader frame.
SLOWLY extend and retract the piston rod three

times to remove any air from the lift cylinders.
STEP 100
Lubricate the pivot pins with molydisulfide grease.
STEP 101
Check the level of hydraulic oil in the reservoir and
ad d as r eq uire d. Tig hte n the filler cap o n th e
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-22
REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER - Z-BAR

LOADER
Removal
STEP 106
STEP 102
parking brake.
STEP 103
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 104
BD01D695

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

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.
BD01D696

target bar to the mounting bracket. Remove the
target bar.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-23
STEP 108
STEP 111
BD01D699
BD01D701
Disconnect the hoses from each side of the bucket

cylinder. Install plugs in the hoses and caps on the
fittings.
Remove the pivot pin from the rod end of the bucket
cylinder.
STEP 112
STEP 109
BD01D704
BD01D700
Use a ccep ta ble eq uip ment to ho ld th e bu cket

cylinder.
STEP 110
Remove the pivot pin from the head end of the

bucket cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
replaced.
STEP 113
BD01D698

fasten the pivot pin from both ends of the bucket
cylinder.
Bur 6-42560
BD01D706
Raise the bucket cylinder and remove the cylinder

from the machine.
Issued 8-01
Printed in U.S.A.
Copyright
8001-24
STEP 118
Installation
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
Conn ect the ho ses to ea ch side of th e bucket

cylinder.
STEP 119
Use acceptable lifting equipment to lower the bucket

cylinder into position.
If the rod end of the bucket cylinder is not aligned

with the bellcrank, have another person start the
engine and run the engine at low idle and use the
bucket control lever to SLOWLY move the piston rod
eye into alignment with the bellcrank.
STEP 116
STEP 120
BD01D706
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
pivot pin to the front frame. Tighten the bolt.
Install the spacer, washer and bolt that fasten the

pivot pin to the bellcrank. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect

the grease line to the pivot pin.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-25
STEP 122
STEP 125
BD01D697
BD01D694
Install the two bolts that fasten the mounting bracket

for the switch to the bucket cylinder.
Connect the proximity switch connector to the wiring

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
BD01D695
Install the two bolts for the mounting bracket for the
target bar.
STEP 124
STEP 130
and add as required. Tighten the filler cap on the
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-26
REMOVAL AND INSTALLATION OF THE BUCKET CYLINDERS - XT LOADER

Removal
STEP 134
STEP 131
Disconnect the tubes from the elbows at both ports of

the bucket cylinders. Install a plug in the tube and a
cap on the elbow.
Lower the bu cket to the floor. With the engine

stopped, move the bucket control lever to release
any pressure in the bucket circuit.
NOTE: Steps 132 and 133 apply only to the left
hand bucket cylinder. For the right hand bucket
cylinder go to step 134.
STEP 135
Remove the roll pin (1) from the yoke (2). Remove
the pivot pin (3). Refer to the illustration on page 28.
STEP 136
Loosen and remove the nuts (4) and washers (5) at
the top and bottom of the cylinder bellcrank.
STEP 132
2
STEP 137
3
Remove the inner bellcrank (6) from the pivot pins

(7).
STEP 138
5
Remove the nut (8) and the grease line (9) from the
bucket cylinder (10).
1
4
STEP 139
6
BS01C084
1.
2.
3.
4.
5.
6.
BUCKET CYLINDER (LEFT HAND SIDE)

PROXIMITY SWITCH MOUNTING BRACKET
TARGET MOUNTING BRACKET
PROXIMITY SWITCH GUARD
PROXIMITY SWITCH
TARGET BAR
Fasten acceptable lifting equipment to the bucket

cylinder (10) and remove the bucket cylinder (10)
from the machine.
Disconnect the Return-to-Dig proximity switch (5)

and remove with the mounting bracket (2) as an
assembly.
STEP 133
Remove the Return-to Dig target bar (6) with the
mounting bracket (3) from the yoke of the bucket
cylinder (1).
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-27
10
9
8
1
10
7
BS01C085
1.
2.
3.
4.
5.
ROLL PIN
YOKE
PIVOT PIN
NUT
WASHER
6.
7.
8.
9.
10.
INNER BELLCRANK
PIVOT PIN
NUT
GREASE LINE
BUCKET CYLINDER
XT LOADER BUCKET CYLINDER REMOVAL AND INSTALLATION ILLUSTRATION

Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-28
Installation
STEP 140
Use acceptable lifting equipment to install the bucket
cylinder (10) closed end on the pivot pins (7). Refer
STEP 141
Install the grease line (9) and the nut (8) on the
bucket cylinder (10).
STEP 142
Install the inner bellcrank (6) on the pivot pins (7).
STEP 143
Install the washers (5) and nuts (4) on the retaining
bolts. Tighten the nuts (4).
STEP 144
Align and install the pivot pin (3) in the yoke (2).
STEP 145
Install the roll pin (1) in the yoke (2) and pivot pin (3).
Bur 6-42560
STEP 146
Install the Return-to Dig target bar and proximity
switch assembly. Connect the proximity switch
connector to the wiring harness connector. This step
applies only to the left hand bucket cylinder.
STEP 147
Remove the plugs and caps and connect the tubes to
the elbows at the cylinder ports.
STEP 148
Start the engine and run the engine at low idle.
STEP 149
SLOWLY, extend and retract the piston rod three
times to remove any air from the bucket cylinder (10).
STEP 150
STEP 151
Check the level of the hydraulic oil in the hydraulic
reservoir and add as required. See Section 1002 for
the correct hydraulic oil.
Issued 8-01
Printed in U.S.A.
Copyright
8001-29
REMOVAL AND INSTALLATION OF THE OIL COOLER

STEP 157
Removal
STEP 152
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 153
BD01D234
Disconnect the top hose and install a plug in the hose

and a cap on the fitting.
STEP 158
BD01D138

position.
STEP 154
BD01D231
Disconnect the hose from the bottom of the oil cooler.

Install a plug in the hose and a cap on the fitting.
BD01D230
With the hood raised loosen the two bolts holding the
shield in place and remove the shield.
STEP 155
release the air pressure in the reservoir.
STEP 156
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-30
STEP 159
Installation
STEP 161
Place the oil cooler in position in the cooling frame.
STEP 162
BD01D234
BD01D231
BD01D231

fasten the oil cooler to the cooling frame.
STEP 160
Remove the oil cooler from the machine.
BD01D234
Install the bolts and washers that fasten the oil cooler
to the cooling frame
STEP 163
BD01D231
Connect the hose to the bottom of the oil cooler.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-31
STEP 164
STEP 167
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 168
BD01D234
Connect the hose to the top of the oil cooler.
STEP 165
Fill the hydraulic reservoir with hydraulic oil. See
Section 1002 for the correct hydraulic oil.
BD01D230
Install the shield and tighten the two bolts holding the
shield.
STEP 166
STEP 169
and add hydraulic oil as required.
BD01D136

position.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-32
REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATOR

STEP 175
Removal
STEP 170
parking brake.
STEP 171
With the engine NOT running, pump the brake
repeatedly to be sure the brake accumulators have
no hydraulic pressure, the move the loader control
lever back and forth several times to release any
hydraulic pressure in the pilot control circuit.
BD01D716
STEP 172
the front chassis.
Loosen and remove the nuts and washers from the

U-bolt. Remove the U-bolt.
STEP 176
STEP 173
release any air in the reservoir.
STEP 174
BD01D717

accumulator bracket to the front frame.
STEP 177
BD01D717
Remove the ride control accumulato r from the

machine.
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.
NOTE: The above photo shows the center drive
shaft removed and was done for photographic
reasons only.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-33
STEP 181
Installation
STEP 178
Place the ride control accumulator in position on the
front frame.
STEP 179
BD01D717
Remove the caps and plugs and install the hose on

the elbow at t he bottom of the ride c ontrol
accumulator.
STEP 182
Install the two bolts that fasten the accumulator
bracket to the front frame. Tighten the bolts.
Refer to Section 8002 Testing the Ride Control for

the proper charging of the accumulator to check for
leaks.
STEP 180
STEP 183
BD01D717

BD01D716
Install the U-bolt, washers and nuts. Tighten the nuts.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-34
REMOVAL AND INSTALLATION OF THE RIDE CONTROL VALVE

Removal
STEP 189
STEP 184

Park the machine on a level surface and apply the

parking brake.
STEP 190
STEP 185
BD01D138
BD00M048
Raise the loader arms and install the safety link.

position.
STEP 191
STEP 186
BD01D374
Remove the access cover.
Disconnect the electrical connector on top of the ride

control valve.
STEP 187
STEP 192

no hydraulic pressure, then move the loader control
Tag and disconnect the accumulator bleed hose (4)

from the elbow (5) at the ride control valve (3). Install
a plug in the hose and a cap on the fitting. Refer to
the illustration on page 35.
STEP 188
Tag and disconnect the ride control tank hose (6)

from the adapter (14). Install a plug in the hose and a
cap on the fitting.
BD00M041

the front chassis.
Bur 6-42560
STEP 193
Issued 8-01
Printed in U.S.A.
Copyright
8001-35
STEP 194
STEP 196
Tag and disconnect the ride control accumulator

hose (10) from the elbow (11). Install a plug in the
hose and a cap on the fitting.
Loosen and remove the four bolts (12) and washers

(13) that fasten the ride control valve (3) to the ride
control bracket (2).
STEP 195
STEP 197
Tag and disconnect the ride control head tube (8)

from the fitting (9). Install a plug in the hose and a
cap on the fitting.
Remove the ride control valve from the machine.
STEP 198
Remove and discard all O-rings.
1
4
3
2
5
14
13
12
9
11
7
10
BS01D191
1.
2.
3.
4.
5.
6.
7.
FRONT FRAME (LEFT SIDE)

RIDE CONTROL BRACKET
RIDE CONTROL VALVE
ACCUMULATOR BLEED HOSE
ELBOW
ELBOW
8.
9.
10.
11.
12.
13.
14.
RIDE CONTROL HEAD TUBE

FITTING
RIDE CONTROL ACCUMULATOR HOSE
ELBOW
BOLT (4)
WASHER (4)
ADAPTER
RIDE CONTROL VALVE ILLUSTRATION

Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-36
STEP 207
Installation
STEP 199
Install the ride control valve (3) in position on the
front frame (1). Refer to the illustration on page 35.
STEP 200
Install the washers (13) and bolts (12) through the
ride control bracket (2) and into the ride control valve
(3). Tighten the bolts (12).
STEP 201
Lubricate and install new O-rings to all necessary
fittings.
BD01D136
STEP 202

position.
Connect the ride control head tube (8) to the fitting

(9) at the ride control valve (3).
STEP 208
Start and run the engine at low idle for two minutes.
STEP 203
Connect the ride control accumulator hose (10) to the
elbow (11) at the ride control valve (3).
STEP 204
Connect the ride control tank hose (6) to the adapter
STEP 209
at the ride control valve.
STEP 210
STEP 205
Connect the accumulator bleed hose (4) to the elbow
STEP 206
BD00M041
Install the access cover.
BD01D374
Connect the electrical connector to the ride control

valve.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-37
STEP 211
STEP 212
STEP 213
Refer to Section 8002 and perform the Ride Control
Test Procedure.
BD00M048
Raise the loader arms and remove the safety link.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-38
REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE

STEP 218
Removal
STEP 214

bucket to the ground. Stop the engine and apply the
parking brake.
STEP 215

no hydraulic pressure, then move the loader control
2
1
5
BD01D360
STEP 216
STEP 217
1.
2.
3.
4.
5.
6.
7.
FAN FORWARD HOSE

FAN REVERSE HOSE
FAN VALVE RETURN HOSE
FAN VALVE SUPPLY HOSE
NUTS
WASHERS (NOT SHOWN)
BOLTS (NOT SHOWN)
A. Tag and disconnect the fan forward hose (1)

from the fan reversing valve. Install a plug in
B. Tag and disconnect the fan reverse hose (2)
from the fan reversing valve. Install a plug in
C. Tag and disconnect the fan valve return hose
(3) from the fan reversing valve. Install a plug
in the hose and a cap on the fitting.
BD01D359
Disconnect the electrical connector for the fan

reversing valve.
D. 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.
E. Loosen and remove the nuts (5), washers (6)
and bolts (7).
STEP 219
Remove the fan reversing valve from the machine.
STEP 220
Remove and discard all O-rings from the fittings.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-39
STEP 224
Installation
STEP 221
Place the fan reversing valve into position on the
machine.
STEP 222
Lubricate and install new O-rings in the fittings.
STEP 223
5
BD01D359
Connect the electrical connector for the fan reversing

valve.
STEP 225
Check the level of the hydraulic oil in the reservoir.
2
1
STEP 226
5
BD01D360
1.
2.
3.
4.
5.
6.
7.
FAN FORWARD HOSE

FAN REVERSE HOSE
FAN VALVE RETURN HOSE
FAN VALVE SUPPLY HOSE
NUTS
WASHERS (NOT SHOWN)
BOLTS (NOT SHOWN)
A. Install the bolts (7), washers (6) and nuts (5).

Tighten the nuts (5).
minutes.
STEP 227
at the fan reversing valve.
STEP 228
reservoir.
B. Connect the fan valve supply hose (4) to the

fitting on the fan reversing valve.
C. Connect the fan valve return hose (3) to the
elbow on the fan reversing valve.
D. Connect the fan reverse hose (2) to the fitting
on the fan reversing valve.
E. Connect the fan forward hose (1) to the fitting
on the fan reversing valve.
Bur 6-42560
Issued 8-01
Printed in U.S.A.
Copyright
8001-40
NOTES
Bur 6-42560
Issued 8-01
Printed in U.S.A.
8002
Copyright
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,
AND PRESSURE CHECKS
CASE CORPORATION
700 State Street
Bur 6-40820

Printed in U.S.A.
March, 2001
Copyright
8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING THE HYDRAULIC PUMP PERFORMANCE AND TORQUE LIMITER . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
521D HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
521D HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-40820
Issued 3-01
3
4
5
5
5
5
6
6
6
7
7
8
8
10
10
11
12
12
12
12
13
14
15
Printed in U.S.A.
Copyright
8002-3
SPECIFICATIONS
Pump Output ...............................................................................................135 to 138 L/min at 2000 rpm at 138 bar
(35.5 to 36.5 gpm at 2000 rpm at 2000 psi)
Main relief valve pressure settings
521D (Z-Bar/XT) ................................................................................................248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A and B port (Z-Bar) ......................................................................................................290 bar (4206 psi)
Bucket A port (XT) .....................................................................................................................183 bar (2654 psi)
Bucket B port (XT) .....................................................................................................................290 bar (4206 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Accumulator pressure .................................................................................................................... See Section 7002
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-4
SPECIAL TOOLS
B877168V
633L95
CAS-1808 FLOWMETER FITTING KIT
CAS-1904 PRESSURE FITTING KIT
B877895M
632L95
CAS-10090 HAND PUMP
B877558M
B785789M
CAS-10280 FLOWMETER
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-5
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and
damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is
the oil level correct?.
No
Fill the hydraulic reservoir with the hydraulic oil

specified in Section 1002.
Yes
Heat the oil in the hydraulic system to
operating temperature. Operate the
machine to find which circuits have
problems.
Problems in All Circuits - See the following pages for other circuits
Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for contaminated
oil. Is the oil contaminated?
No
See Page 7. Do the flowmeter tests of the

hydraulic pump.
No
Adjust the main relief valve. See page 8 in

this section.
Yes
See Section 8003 and clean or replace the
oil.
Problem in All Loader Circuits

See Page 8 and check the pressure setting of
the main relief valve in the loader control
valve. Is the pressure setting correct?
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-6
Problem in a Single Loader Circuit

Star t and r un the engine at full throttle.
Operate the control for the bad circuit. Does
the cylinder move in both directions?
No
The loader control valve is damaged. See

Section 8005 and repair the loader control
valve
No
See Section 8006 and repair the cylinder.
No
See Section 8005. Disassemble the loader

contr ol valve and c heck for wo r n o r
damaged parts.
No
Repair the component as necessary.
No
See the Ride Control Test Procedure page

11 in this section.
Yes
Check the cylinder piston packing. Is the

packing good?
Yes
See Page 10. Check and adjust the circuit
relief valves. Then check the operation of
the circuit again. Does the circuit work
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
circuit. Is the steering circuit good?
Yes
See Page 7. Do the Primary Pump Output
Test.
Problem in the Ride Control

Lift ar ms rapidly and continuously sink
towards the ground.
Yes
Check the manual bleed valve for the ride
control accumulator to be sure that it is
closed.
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
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 52C to 60C (125F to 140F). The following
is the procedure for heating the hydraulic oil.
A. Start the engine and run at high idle.
B. Lower the loader bucket to the ground.
C. Hold the lift control lever in the FLOAT
position.
D. Roll the bucket back against the stops and

hold.
BD00N020
E. View the oil temperature by pressing the

program switch, then press the up count
switch to function 008. Return the program
switch to the center (OFF) position.
STEP 2
BD00N017
1. TEST PORT (LOAD SENSE)

2. TEST PORT (PUMP PRESSURE)
1
BD00M041
1. COVER PLATE
Remove the cover plate to gain access to the loader

control valve.
Connect two 69 bar (1000 psi) test gauges to the test

ports (1) and (2) located on the loader control valve.
STEP 4
Start the engine and run at low idle.
STEP 5
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).
STEP 6
The pressure on test por t (1) should read
approximately 29 bar (420 psi). The pressure on test
port (2) 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 two readings.
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-8
STEP 7
Subtract the reading of the test port (1) from the
reading of the test port (2).
STEP 8
Adjusting the Main Hydraulic

Pump
STEP 10
The difference between the two readings should be

22 + 1/-0 bar (320 + 15/-0 psi).
STEP 9
If this reading is more or less than that specified, it
will be necessary to adjust the pump.
BS01B022
Turn the pump adjusting screw closest to the pump

as illustrated. Turn the screw clockwise to increase
t h e d i f fe r e n ti a l p r e s s u r e. Tu r n i n g t h e s c r ew
counterclockwise will decrease the differential
pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).
TESTING THE HYDRAULIC PUMP PERFORMANCE AND TORQUE LIMITER

STEP 1
STEP 3

Make sure that the flowmeter valve is in the closed

position. Raise the lift arms to the stops and secure
the lift control lever in the RAISE position.

position.
hold.
View the oil temperature by pressing the program
switch, then press the up count switch to function
008. Return the program switch to the center (OFF)
position.
STEP 2
Connect the flowmeter (5) by installing a tee fitting (1)
between the pump and the loader control valve (2).
Refer to illustration on page 9.
Bur 6-40820
STEP 4
Operate the engine at 2000 r pm and open the
flowmeter valve until the pump pressure is 500 psi.
The flow at this point should be 36.5 to 37.5 gpm.
STEP 5
Close the flowmeter valve slowly and read the flow at
2000 psi @ 2000 rpm. The flow should read 35.5 to
36.5 gpm.
STEP 6
Continue slowly closing the flowmeter valve,
monitoring the flow with the engine speed at 2000
rpm. At a point between 2200 and 2400 psi, the flow
should noticeably start decreasing. This is the torque
limit setting of the pump. Record this pressure.
Issued 3-01
Printed in U.S.A.
Copyright
8002-9
STEP 7
STEP 8
Continue slowly closing the flowmeter valve until

3300 psi is reached. The flow should read between
23.5 and 26.0 gpm.
If any of the pump flow readings are not within

specifications, the pump may be out of calibration
and Technical Services Group should be contacted.
9
7
NOTE
6
8
4
5
2
1
BS01A308
1. TEE
4. LOADER CONTROL VALVE INLET HOSE
8. FILTER
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
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
BD00M030
Remove the cover plate to gain access to the loader

control valve.
STEP 4
Install the articulation lock (1).
STEP 2
1
2
1
BD00N017

2. TEST PORT
BD00M048
1. SAFETY LINK
Raise the loader arms and install the safety link (1).
Bur 6-40820
Stop the engine and install a 345 bar (5000 psi)

pressure gauge to the test port (2) on the front of the
loader control valve (1).
Issued 3-01
Printed in U.S.A.
Copyright
8002-11
STEP 5
Adjustment

STEP 10

position.
hold.
E. View the oil temperature by pressing the
program switch, then press the up count
switch to function 008. Return the program
switch to the center (OFF) position.
STEP 6
Start the engine and remove the safety link (refer to
step 2) and lower the loader arms to the ground.
STEP 7
Operate the machine at full throttle. Tilt the bucket to
a full rollback position and hold while observing the
pressure gauge.
2
1
STEP 8
The pressure should read between 248 and 252 bar
(3596 to 3654 psi).
STEP 9
If the pressure is not within the specifications, it will
be necessary to adjust the main relief valve.
BS01A046

2. RELIEF VALVE ADJUSTMENT
With the engine running and the loader on the

ground, loosen the jam nut and turn the adjustment
s c r e w ( 2 ) c l o c k w i s e fo r h i g h e r p r e s s u r e o r
counterclockwise for lower pressure.
NOTE: 1/4 turn of the adjusting screw changes the
pressure setting approximately 35 bar (500 psi).
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.
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-12
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Pressure Check
STEP 3
STEP 1
Connect the hand pump to the disconnected line that

goes to the loader control valve.
Circuit relief valves are located as shown below.
6
5
Make sure that the hand pump is full of hydraulic oil

and that the temperature of the oil is approximately
21C (70F).
STEP 4
STEP 5
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
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.
1
1
Adjustment
STEP 1
Loosen the lock nut. Turn the adjustment screw

clockwis e to increase the pressure or
counterclockwise to decrease the pressure.
BS01A046
1.
2.
3.
4.
5.
6.
CIRCUIT RELIEF VALVE

MAIN RELIEF VALVE
BUCKET SPOOL
LIFT SPOOL
AUXILIARY SPOOL
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.
STEP 2
Check the pressure again. Repeat the adjustment as
necessary.
Leak Test
Test for internal leakage by raising the lift arms to the
top and shutting the engine off.
A. Turn the key to the RUN position and
disengage the controller lock-out switch.
B. Wait for the buzzer to stop.
C. Repeatedly put the lift control lever into the
FLOAT position and back to neutral. The
system must allow a minimum of 10
actuations into float and still cause the lift
arms to come down.
D. If 10 full actuations cannot be made, an
internal hydraulic leak exists.
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-13
TESTING THE RIDE CONTROL

STEP 1
STEP 8
Verify that the manual ride control accumulator

bleeder valve is closed.
Accelerate the machine to at least 5 km/hr (3 mph).

At 5km/hr (3 mph) the lift arms should raise a visible
amount, 102mm to 635mm (4 to 12 inches)
depending on bucket and coupler weight. This is an
indication that the ride control is functioning. As the
machine continues to travel there should be visible
c y l i n d e r m ove m e n t i n r e s p o n s e t o t h e r o a d
conditions.
NOTE: The bleeder valve is located on the left wall

of the front chassis immediately behind the ride
control accumulator. If this valve is left open, the lift
arms will rapidly and continuously sink. Ride control
will not function in this state because the ride control
accumulator cannot charge.
STEP 2
Move the machine to a clear level area with sufficient
space to accelerate the machine to 5 km/hr (3 mph)
for 30 seconds and stop.
STEP 3
Start the engine.
STEP 4
Activate the ride control. Press down on the symbol
side of the switch to activate. The indicator light WILL
NOT illuminate at this time.
NOTE: The ride control switch is located in the bank
of rocker switches to the right of the operators seat. It
is in the center row, second switch from the front.
STEP 5
Raise the lift arms to near the top of their travel.
STEP 6
Rapidly dump the bucket until it hits the dump stops.
This will create a down force on the liftarms and they
should drop visibly. Repeat this process 2 or 3 times
if necessary.
NOTE: The oil displaced from the lift cylinders is
used to charge the ride control accumulator.
STEP 7
NOTE: With an empty bucket, cylinder travel will not

exceed 25mm (1 inch).
STEP 9
With the machine traveling over 5 km/hr (3 mph)
check the indicator light on the ride control rocker
switch, it should be illuminated.
STEP 10
Slow the machine down and observe the indicator
light. The indicator light should go out when the
machine slows below 5 km/hr (3 mph).
STEP 11
Stop the machine.
STEP 12
De-activate the ride control with the rocker switch.
Repeat steps 5, 6 and 7.
STEP 13
Accelerate the machine to at least 5 km/hr (3 mph).
This time there should be no visible raising of the
liftarms and the light should remain off. The quality of
the ride should be noticeably worse with the ride
control de-activated.
STEP 14
Stop the machine.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the liftarms or the bucket on
their stops.
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-14
521D HYDRAULIC COMPONENT LOCATIONS

6
20
15
14
13
3
2
1
4
5
16
10
11
12
4
19
18
17
BC00N140
1.
2.
3.
4.
5.
6.
7.
8.
RIDE CONTROL VALVE (OPTIONAL)

RIDE CONTROL ACCUMULATOR
RIDE CONTROL ACCUMULATOR BLEEDER VALVE
LIFT CYLINDERS
BUCKET CYLINDER (TILT CYLINDER)
STEERING CYLINDERS
AUXILIARY STEERING PUMP AND MOTOR (OPTION NORTH AMERICAN MODELS)
9. AUXILIARY STEERING PRIORITY VALVE (OPTION NORTH AMERICAN MODELS)
10. AUXILIARY STEERING PRESSURE SWITCH
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
STEERING PRESSURE DIAGNOSTIC COUPLER

BRAKE ACCUMULATORS
BRAKE LIGHT PRESSURE SWITCH
BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
REAR BRAKE CYLINDERS
FRONT BRAKE CYLINDERS
PARKING BRAKE CYLINDER
FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC
COUPLERS
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-15
521D HYDRAULIC COMPONENT LOCATIONS
41
40 22
38
30
39
34
37
24
25
29
32
28
33
35
36
25
21
31
26
27
23
BC00N140
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
FAN DRIVE MOTOR

FAN REVERSING VALVE
BRAKE HYDRAULIC PUMP
COUPLER LOCKING VALVE
COUPLER LOCKING CYLINDERS
IMPLEMENT HYDRAULIC PUMP
HYDRAULIC FILTER
HYDRAULIC RESERVOIR
HYDRAULIC RESERVOIR BREATHER
HYDRAULIC COOLER
PILOT PRESSURE ACCUMULATOR
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
PILOT PRESSURE DIAGNOSTIC COUPLER

FLOAT SWITCH
CONTROLLER
PUMP PRESSURE DIAGNOSTIC COUPLER
LOAD SENSING DIAGNOSTIC COUPLER
BRAKE PRESSURE SWITCH (2)
AUXILIARY STEERING LOAD SENSE SOLENOID VALVE (OPTIONAL)
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.
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8002-16
NOTES
Bur 6-40820
Issued 3-01
Printed in U.S.A.
Copyright
8003
Section
8003
CLEANING THE HYDRAULIC SYSTEM
CASE CORPORATION
700 STATE STREET
RACINE, WI 53404 U.S.A.

3350 SOUTH SERVICE ROAD
BURLINGTON, ON L7N 3M6 CANADA
Bur 7-49640

Printed in U.S.A.
Issued May 1995
Copyright
8003-2
TABLE OF CONTENTS
PORTABLE FILTER ..................................................................................................................................................... 3
GENERAL INFORMATION ............................................................................................................................................ 4
TYPES OF CONTAMINATION ....................................................................................................................................... 4
CLEANING THE HYDRAULIC SYSTEM .......................................................................................................................... 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM .................................................................................................... 7
NOTE: The Case Corporation reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install them on units
previously sold.
Bur 7-49640
Issued 5-95
Printed in U.S.A


Copyright
Alt+ to display template

information
8003-3
SPECIAL TOOLS
806128
The part number for the Fitting Kit is CAS-10508.
806127
The part number for the Portable Filter is CAS-10162A.
Bur 7-49640
Issued 5-95
Printed in U.S.A.


Copyright
8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major cause of
the malfunction of hydraulic components. Contamination is
any foreign material in the hydraulic oil. Contamination can
enter the hydraulic system in several ways.
1. Cylinder rod seals leak.

2. Control valve spools do not return to neutral.
3. Movement of control valve spools is difficult.
1. When you drain the oil or disconnect any line.

4. Hydraulic oil becomes too hot.
2. When you disassemble a component.
5. Pump gears, housing, and other parts wear 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.
All hydraulic systems operate with some contamination.
The design of the components in this hydraulic system
per mits efficient operation with a small amount of
contamination. An increase in this amount of contamination
can cause problems in the hydraulic system. The following list
includes some of these problems.
8. Cycle times are slow; machine does not have enough

power.
If your machine has any of these problems, check the
hydraulic oil for contamination. See Types of Contamination
below. If you find contamination, use the Portable Filter to
clean the hydraulic system.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic and
visible.
1. Microscopic contamination occurs when very fine
particles of foreign material are in suspension in the
hydraulic oil.
2. These particles are too small to see or feel. Microscopic
contamination can be found by identification of the
following problems or by testing in a laboratory. Examples
of the problems:
3. Visible contamination is foreign material that can be

found by sight, touch, or odor. Visible contamination can
cause a sudden failure of components. Examples of
visible contamination:
a. Particles of metal or dirt in the oil.
b. Air in the oil.
c. The oil is dark and thick.
d. The oil has the odor of burned oil.
a. Cylinder rod seal leak.

e. Water in the oil. See page 7.
b. Control valve spools do not return to NEUTRAL.
c. The hydraulic system has a high operating
temperature.
Bur 7-49640
Issued 5-95
Printed in U.S.A.


Copyright

information
8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the
following steps:
a. Remove all the hydraulic oil from the inlet and outlet
hoses for the portable filter.
b. Remove the filter element from the portable filter.
c. Remove all hydraulic oil from the portable filter.
d. Clean the inside of the housing for the filter
element.
2. You must know whether the contamination is microscopic
or visible. See Types of Contamination on page 4.
8. See the fitting kit shown on page 3. Install the valve in the
hole for the drain plug. Make sure that the valve is closed.
10. Connect the inlet hose for the portable filter to the valve
that is installed in the hole for the drain plug.
11. Disconnect the vacuum pump from the filler cap opening
on the hydraulic reservoir.
12. Install the outlet hose for the portable filter in the
13. Open the valve that is installed in the hole for the drain
plug.
3. If the contamination is microscopic:

a. Check the maintenance schedule for the machine to
lear n if the hydraulic oil must be changed. If
needed, change the hydraulic oil. See Section 1002
for specifications. Change the hydraulic filter.
b. Do steps 6 through 38.
14. Move the switch for the portable filter to the ON position.
Start and run the engine at 1500 rpm (r/min).
15. Run the portable filter for 10 minutes.
16. Continue to run the portable filter. Increase the engine
s p e e d t o f u l l t h r o t t l e. H e a t t h e o i l t o o p e r a t i n g
temperature by doing the following steps:
4. If the contamination is visible:

a. Change the hydraulic oil and hydraulic filter. See
Section 1002 for oil specifications.
b. Do steps 5 through 38.
a. Hold the bucket control lever in the ROLLBACK

position for 15 seconds.
b. Return the bucket control lever to NEUTRAL for 30
seconds.
5. Check the amount of contamination in the hydraulic

system by doing the following steps:
c. Repeat steps 17a through 18b 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 the cylinder
wall, etc. Repair the cylinders as necessary.
17. Continue to run the engine at full throttle. Continue to run

the portable filter.
b. If, in your judgment, the damage to the cylinders

was caused by severe contamination and is not the
result of normal wear, it is necessary to remove,
clean and repair valves, pump, lines, cylinders,
hydraulic reservoir, etc. in the hydraulic system.
18. Operate each hydraulic circuit to completely extend and

retract the cylinders. Continue to operate each hydraulic
circuit two times, one after the other, for 45 minutes.
20. Continue to run the portable filter for 10 minutes.
6. Connect a vacuum pump to the hydraulic reservoir air

breather hose. Start the vacuum pump.
21. Stop the portable filter.
7. Loosen and remove the drain plug from the reservoir.

23. Remove the hose from the hydraulic reservoir.
Bur 7-49640
Issued 5-95
Printed in U.S.A.


Copyright
8003-6
24. Close the valve that is installed in the hole for the drain
plug.
30. Stop the vacuum pump. Disconnect the vacuum pump

from the hydraulic reservoir.
25. Disconnect the inlet hose for the portable filter from the
valve.
31. Remove the hydraulic filter element from the machine.

32. Install a new hydraulic filter element on the machine.
26. Connect a vacuum pump to the breather hose of the

33. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.

28. Remove the valve from the hole for the drain plug.
34. Start the engine. Check for oil leakage around the new
hydraulic filter.
29. Install the drain plug.
Bur 7-49640
Issued 5-95
Printed in U.S.A.


Copyright

information
8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min).
2. Completely retract the cylinders of all attachments on the
machine.
WARNING: If retracting the cylinder rods

causes the attachment to be raised, block
the attachment in place before proceeding to
the next step!
39-4
NOTE: Any attachment or part of an attachment that is

raised must be supported with acceptable equipment to
prevent the attachment from falling.
3. Loosen and remove the filler cap from the reservoir.
9. Move each control lever in both directions to release

pressure in the hydraulic circuits.
10. Disconnect the line from the rod end and closed end of
each cylinder.
11. Be sure all control levers are in the NEUTRAL position.
IMPORTANT: C h e ck t h e o i l l eve l i n t h e hy d r a u l i c
reser voir frequently while doing step 14. Have another
person hold a container under the hydraulic lines while
you do step 14.
13. Slowly move each control lever in both directions until oil
begins to flow from the open line. Hold the control lever in
place until clean oil flows from the open line.
4. Drain the hydraulic oil from the reservoir.

a. The reservoir holds approximately 15 U.S. gallons
(56.8 litres) of hydraulic oil.
b. Have available acceptable equipment to drain the
hydraulic oil.
NOTE: Any attachment or part of an attachment that is

raised must be supported with acceptable equipment to
prevent the attachment from falling.
15. Connect the line to the CLOSED end of each cylinder.
c. Remove the drain plug from the bottom of the

reservoir.
5. Remove the hydraulic oil filter from the machine.
6. Install a new hydraulic oil filter on the machine.
7. Install the drain plug in the bottom of the reservoir.
8. Fill the hydraulic reservoir with 14.4 U.S. gallons (54.5
litres) of Case TCH Fluid.
17. Slowly and completely extend all cylinders. As the piston
rod comes out of the cylinder, oil will be pushed out of the
rod end of the cylinder.
18. Support the loader frame so that the loader frame will
stay in the RAISED position.
20. Connect the lines to the rod end of the cylinders.
21. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
22. Install the filler cap for the reservoir.
Bur 7-49640
Issued 5-95
Printed in U.S.A.
Copyright
Copyright
Section
8006
8006
CYLINDERS
CASE CORPORATION
700 State Street
Bur 6-42590

Printed in U.S.A.
August, 2001
Copyright
8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CYLINDERS Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CYLINDERS FOR XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Z-BAR AND XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42590
Issued 8-01
3
3
3
4
4
4
6
7
7
7
9
10
10
10
12
13
13
13
13
13
13
14
14
14
Printed in U.S.A.
Copyright
8006-3
SPECIFICATIONS
Approximate weight
Lift Cylinder - XT and Z-Bar.......................................................................................................75.7 kg (167 pounds)
Bucket Cylinder - Z-Bar Models.................................................................................................75.6 kg (167 pounds)
Bucket Cylinder - XT Models ........................................................................................................73 kg (160 pounds)
SPECIAL TORQUES
Screw in Gland Z-Bar Bucket Cylinder ..........................................................135 to 542 Nm (100 to 400 pound-feet)
Screw in Gland XT Bucket Cylinder ..............................................................135 to 542 Nm (100 to 400 pound-feet)
Screw in Gland for Lift Cylinders XT and Z-Bar Models ................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders XT and Z-Bar Models ...............................1780 to 2180 Nm (1312 to 1607 pound-feet)
Piston Bolt for Z-Bar Bucket Cylinder ....................................................3310 to 3850 Nm (2440 to 2838 pound-feet)
Piston Bolt for XT Bucket Cylinder ........................................................1780 to 2180 Nm (1312 to 1607 pound-feet)
Lock Screw for all Cylinders .............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier ......................................................................................................................................... CAS-1039
Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
8006-4
LIFT CYLINDER
Disassembly
1. Clean the outside of the cylinder. If the hoses
were removed with the cylinder, remove the
hoses from the cylinder.
2. Fasten the tube (1) in an acceptable repair stand
or other holding equipment, refer to Figure 1. Do
not damage the tube (1).
3. Loosen and remove the self-tapping screw (12).
4. Use a spanner wrench to loosen and remove the
gland (4) out of the tube (1).
5. Pull the piston rod (13) straight out of the tube (1)
to prevent damage to the tube (1).
6. Fasten the piston rod eye or yoke in a vise and
put a support under the piston rod (13) near the
piston (15). Put a shop cloth between the support
piston rod (13).
7. Use a torque multiplier, CAS-1039, to loosen and
remove the bolt (14), washer (19) that fastens
the piston (15) to the piston rod (13).
10. Remove the seal (16), ring (17)and the wear ring
(18) from the piston (15).
Inspection
1. Discard the parts that were removed from the
piston and the gland.
2. Clean all parts in cleaning solvent. Use only lint
free cloths for cleaning and drying.
3. Check to be sure that the piston rod is straight. If
the piston rod is not straight, replace it with a
new piston rod.
4. Illuminate the inside of the tube for deep grooves
and other damage. If there is any damage to the
tube, replace it with a new tube.
5. Remove any small scratches on the piston rod or
inside the tube with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
6. Inspect the bushings in the piston rod eye or
yoke and the tube. Replace as required.
7. Inspect the gland for rust. Clean and remove rust
as necessary.
8. Inspect the gland end of the tube for sharp edges
that will cut the gland O-ring and remove as
necessary.
9. Inspect the piston for damage and wear. If the
piston is damaged or worn, replace it with a new
piston.
11. Remove the O-ring (10), ring (9), O-ring (11),

wiper (5), seal (6), seal (7), and bushing (8) from
the gland (4).
Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
8006-5
BC01A163
1.
2.
3.
4.
5.
TUBE
BUSHING
WIPER
GLAND
WIPER
6.
7.
8.
9.
10.
SEAL
SEAL
BUSHING
RING
O-RING
11.
12.
13.
14.
15.
O-RING
SCREW (NOT SHOWN)
ROD
BOLT
PISTON
16.
17.
18.
19.
SEAL
RING
WEAR RING
WASHER
FIGURE 1. LIFT CYLINDER

Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
8006-6
Assembly
NOTE: If a new gland is being used, put the part
number of the cylinder on the new gland.
1. Install the bushing (8) in the gland (4), refer to
Figure 1.
2. Install the seal (6) in the gland (4). The seal (6) is
to be installed so that the lips of the seal (6) are
toward the bushing (8). The seal (6) can be
difficult to install.
3. Install the seal (7) in the gland (4). The side of
the seal (7) with the groove must be toward the
bushing (8).
4. Install a new wiper (5) in the gland (4). The lips of
the wiper (5) must be toward the outside end of
the gland (4).
5. Install a new O-ring (11) in the groove on the OD
of the gland (4).
6. Install a new ring (9) in the groove on the OD of
the gland (4). If both sides of the ring (9) are not
flat, the side that is not flat must be toward the
small end of the gland (4).
7. Install a new O-ring (10) next to the ring (9) in the
groove on the outside of the gland (4). The
O-ring (10) must be toward the small end of the
gland.
16. Install the bolt (14) into the piston rod (13).
Tighten the bolt (14) to a torque of 1780 to 2180
N m ( 1 3 1 2 t o 1 6 0 7 p o u n d - f e e t) . A t o r q u e
multiplier can be used to help torque the bolt
(14).
17. Install a new wear ring (18) in the wide groove on
the outside of the piston (15), refer to Figure 1.
18. Install a new ring (17) in the other groove on the
outside of the piston (15).
19. Install a new seal (16) on the top of the ring (17).
or other holding equipment. Be careful to prevent
damage to the tube (1).
21. Lubricate the inside of the tube (1) and the piston
(15) with clean oil.
22. Push the piston (15) straight into the tube (1).
24. Lubricate the O-rings (10 and 11) on the gland
(4) with clean oil.
25. Turn the gland (4) into the tube (1). Tighten the
gland (4) to a torque of 135 to 542 Nm (100 to
400 pound-feet).
26. If the original parts are being assembled:
8. Fasten the piston rod eye or yoke in the vise.
A. Tighten the gland to a torque of 135 to 542

Nm (100 to 400 pound-feet).
9. Remove any marks and sharp edges on the

chamfer at the end of the piston rod (13). Make
sure that the piston rod (13) is clean.
B. Install and tighten the lock screw (12) to a

torque of 2.3 Nm (20 inch-pounds).
10. Lubricate the bore of the gland (4) and the piston
rod (13) with clean oil.
C. If, after tightening the gland, the lock screw

(12) holes are not aligned, a new hole for the
lock screw (12) must be drilled. See Step 27.
27. If a new gland (4) or a new tube (1) are being

assembled:
12. Put a support below and near the end of the

piston rod (13). Use a shop cloth between the
suppo rt and the pisto n ro d (13) to prevent
13. Start the piston (15) onto the piston rod (13).
14. Put the washer (19) on the bolt (14).
and the threads of the piston bolt using Loctite
threads.
Bur 6-42590
A. Tighten the gland (4) to 135 to 542 Nm (100 to

400 pound-feet).
B. Use a No. 27 drill bit and drill a hole half in the
gland (4) and half in the tube (1). Drill to a
depth of 11 mm (7/16 inch). Do not drill within
13 mm (1/2 inch) of a ho le for the gland
wrench.
C. Install and tighten the lock screw (12) to a
28. If the hoses were removed with the cylinder,
install new O-rings, if equipped, on the hose
fittings. Lubricate O-rings with clean oil. Install
the hoses.
Issued 8-01
Printed in U.S.A.
Copyright
8006-7
BUCKET CYLINDERS Z-BAR MODELS

Disassembly
or other holding equipment, refer to Figure 2. Do
not damage the tube (1).
3. Loosen and remove the locking screw (12) from
the gland (4) and tube (1).
gland (4) out of the tube (1).
6. Fasten the piston rod eye or yoke in a vise and
put a support under the piston rod (12) near the
piston (17). Put a shop cloth between the support
piston rod (12).
7. Use a torque multiplier, CAS-1039 to loosen and
remove the bolt (15), washer (14) that fastens
the piston (17) to the piston rod (12).
10. Remove the seal (18), backup ring (19) and wear
ring (20) from the piston (17).
Inspection
new piston rod.
7. Inspect the gland for rust and clean and remove
rust as necessary.
necessary.
piston.
11. Remove the O-ring (11), backup ring (10), wiper

(5), seal (6), seal (7) and bushing (8) from the
gland (4).
Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
8006-8
BS01A174
1.
2.
3.
4.
5.
TUBE
BUSHING
SCREW (NOT SHOWN)
GLAND
WIPER
6.
7.
8.
9.
10.
SEAL
SEAL
BUSHING
O-RING
BACKUP RING
11.
12.
13.
14.
15.
O-RING
PISTON ROD
BUSHING
WIPER
BOLT
16.
17.
18.
19.
20.
WASHER
PISTON
SEAL
BACKUP RING
WEAR RING
FIGURE 2. BUCKET CYLINDER FOR Z-BAR MODELS

Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
8006-9
Assembly
NOTE: If a new gland is being used, put the part
number of the cylinder on the new gland.
Figure 2.
2. Install the seal (6) in the gland (4). The seal (6) is
to be installed so that the lips of the seal (6) are
toward the bushing (8). The wide seal (6) can be
difficult to install.
3. Install the seal (7) in the gland (4). The side of
the seal (7) with the groove must be toward the
bushing (8).
the wiper (5) must be toward the outside end of
the gland (4).
5. Install a new O-ring (9) in the groove on the
gland (4).
6. Install a new backup ring (10) in the groove on
the OD of the gland (4). If both sides of the
backup ring (10) are not flat, the side that is not
flat must be toward the small end of the gland
(4).
7. Install a new O-ring (11) next to the backup ring
(10) in the groove on the outside of the gland (4).
The O-ring (11) must be toward the small end of
the gland.
16. Install the bolt (15) into the piston rod (12).
Tighten the bolt (15) to a torque of 3310 to 3850
N m ( 2 4 4 0 t o 2 8 3 8 p o u n d - f e e t) . A t o r q u e
multiplier can be used to help torque the bolt
(15).
17. Install a new wear ring (20) in the wide groove on
the outside of the piston (17), refer to Figure 2.
18. Install a new backup ring (19) in the other groove
on the outside of the piston (17).
19. Install a new seal (18) on the top of the backup
ring (19).
or other holding equipment. Be careful to prevent
damage to the tube (1).
24. Lubricate the O-rings (9 and 11) on the gland (4)
with clean oil.
25. Turn the gland (4) into the tube (1). Tighten the
gland (4) to a torque of 407 +/- 68 Nm (300 +/- 50
pound-feet).
8. Fasten the piston rod eye or yoke in the vise.

9. Remove any marks and sharp edges on the

chamfer at the end of the piston rod (12). Make
sure that the piston rod (12) is clean.

C. If, after tightening the gland, the lock screw (3)

holes are not aligned, a new hole for the lock
screw (3) must be drilled. See Step 27.

assembled:

suppo rt and the pisto n rod (12) to prevent
13. Start the piston (17) onto the piston rod (12).
14. Put the washer (16) on the bolt (15).
threads.
Bur 6-42590
A. Tighten the gland (4) to a torque of 135 to 542

wrench.
fittings. Lubricate O-rings with clean oil. Install
the hoses.
Issued 8-01
Printed in U.S.A.
Copyright
8006-10
BUCKET CYLINDERS FOR XT MODELS

Disassembly
2. Fasten the cylinder in a vise or other holding
equipment. Be careful to prevent damage to the
tube (1), refer to Figure 3.
3. Loosen and remove the lock screw (3) from the
gland (4) and tube (1).
gland (4) from the tube (1).
6. Fasten the rod yoke in a vise and put a support
below the piston rod (12) near the piston (13).
Use a shop cloth between the support and the
piston rod (12) to prevent damage to the piston
rod (12).
7. Use a torque multiplier, CAS-1039, to loosen and
remo ve th e p is to n b olt (1 7) a nd ha rde ne d
washer (18) that secure the piston (13).
10. Remove the backup ring (14), piston seal (15)
and wear ring (16) from the piston (13).
Inspection
new piston rod.
7. Inspect the gland for rust and clean and remove
rust as necessary.
necessary.
piston.
11. Remove the wiper (5), seal (7), seal (8) and the
bushing (6) from the gland (4).
NOTE: Use care not to scratch the ID of gland when
removing seals.
12. Remove the O-ring (10) and backup ring (11)
from the OD of gland (4).
Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
8006-11
BS01A175
1.
2.
3.
4.
5.
TUBE
BUSHING
SCREW
GLAND
WIPER
6.
7.
8.
9.
10.
BUSHING
SEAL
SEAL
O-RING
O-RING
11.
12.
13.
14.
15.
BACKUP RING
PISTON ROD
PISTON
BACKUP RING
SEAL
16.
17.
18.
19.
20.
WEAR RING
BOLT
WASHER
GREASE FITTING
WIPER
FIGURE 3. BUCKET CYLINDER FOR XT MODELS

Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
8006-12
Assembly
NOTE: If a new gland (4) is being installed, put the
part number of the cylinder on the new gland (4).
16. Install the piston bolt (17). Tighten the piston bolt
(17) to a torque of 1780 ti 2180 Nm (1312 to
1607 pound-feet). A torque multiplier can be
used to help tighten the piston bolt (17).

Figure 3.
17. Install a new wear ring (16) in the groove on the

outer end of the piston (13).
2. Install the seal (8). The seal (8) must be installed

with the seal lips toward the small end of the
gland (4). The seal (8) can be difficult to install.
18. Install the piston backup ring (14) into the

remaining groove in the piston (13).
3. Install the seal (7). The seal (7) must be installed

with the lips toward the small end of the gland (4)
also.
the wiper (5) must be toward the large end of the
gland (4).
5. Install a new O-ring (9) in the groove of the gland
(4).
6. Install a new backup ring (11) in the groove on
the outside of the gland (4). If both sides of the
backup ring (11) are not flat, the side that is not
flat must be toward the small end of the gland
(4).
7. Install the O-ring (10) on the gland (4). The
O-ring (10) must be toward the small end of the
gland (4).
8. Fasten the piston rod yoke in the vise.
9. Remove any marks and sharpen edges on the
chamfer at the end of the piston rod (12).
suppo rt and the pisto n ro d (12) to prevent
damage to the rod.
13. Put the piston (13) on the end of the piston rod
(12).
14. Put the hardened washer (18) on the piston bolt
(17).
threads.
Bur 6-42590
19. Install a new piston seal (15) on top of the

backup ring (14).
20. Fasten the tube (1) in a vise or other holding
equipment. Be careful to prevent damage to the
tube (1).
24. Lubricate the O-ring (9 and 10) on the gland (4)
with clean oil.
25. Tighten the gland (4) into the tube (1). Tighten
the gland to a torque of 135 to 542 Nm (100 to
400 pound-feet).
C. If, after tightening the gland, the lock screw (3)
holes are not aligned, a new hole for the lock
screw (3) must be drilled. See Step 27.
assembled:
A. Tighten the gland (4) to 135 to 542 Nm (100 to
400 pound-feet).
wrench.
fittings. Lubricate the O-rings with clean oil.
Install the hoses.
Issued 8-01
Printed in U.S.A.
Copyright
8006-13
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS

Z-BAR AND XT MODELS
Disassembly
1. Put the piston tube (4) in a press, refer to Figure
4.
2. Use an acceptable driver to press the wipers (1)

and bushings (2) out of the piston tube (4).
3. Clean the bore for the bushings (2) in the tube

(4).
Assembly
1. Use an acceptable driver to press a new bushing
(2) into the tube (4) until the bushing (2) is
centered in the tube (4).
2. Use an acceptable driver to install the wipers (1)
in the tube (4). The lips of the wipers (1) must be
toward the outside of the bore.
2
1
2
BS01C003
1. WIPER
2. BUSHING
3. PISTON ROD YOKE

4. TUBE
FIGURE 4. BUSHING AND WIPER REMOVAL AND

REPLACEMENT LIFT CYLINDERS
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS

Disassembly
1. Put the piston tube (4) in a press, refer to Figure
5.

and bushing (2) out of the piston tube (4).
3. Clean the bore for the bushings (2) in the tube
(4).
Assembly
4
2
1. Use an acceptable driver to press new bushings

(2) into the tube (4). Refer to Figure 5.
in the tube (4). The lips of the wipers (1) must be
toward the outside of the bore.
BS01C002
1. WIPER
2. BUSHING
3. PISTON ROD YOKE

4. TUBE

REPLACEMENT XT BUCKET CYLINDERS
Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
8006-14
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS

Disassembly
1. Put the piston rod eye (3) in a press, refer to
Figure 6.
1
2

and bushing (2) out of the piston rod eye (3).
3. Put the tube (4) in a press.
4. Use an acceptable driver to press the bushings

(2) out of the tube (4).
5. Clean the bore for the bushings (2) in the piston
rod eye (3) and the tube (4).
Assembly
(2) into the piston rod eye (3). Refer to Figure 6.

in the piston rod eye (3). The lips of the wipers
(1) must be towards the outside of the bore.

(2) into the tube (4).
BS01C004
1. WIPER
2. BUSHING
3. PISTON ROD EYE

4. TUBE

REPLACEMENT Z-BAR BUCKET CYLINDER
Bur 6-42590
Issued 8-01
Printed in U.S.A.
Copyright
Section
8007
8007
COUPLER SOLENOID LOCKING VALVE
CASE CORPORATION
700 State Street
Bur 6-42600

Printed in U.S.A.
August, 2001
Copyright
8007-2
TABLE OF CONTENTS
COUPLER SOLENOID LOCKING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42600
Issued 8-01
......
......
......
......
......
......
......
......
3
3
3
3
Printed in U.S.A.
Copyright
8007-3
COUPLER SOLENOID LOCKING VALVE

Disassembly
STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve.
STEP 12
Install nut (1) to secure solenoid (2).
STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3).
STEP 3
Remove valve cartridge (3) from valve housing (7).
STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).

STEP 5
Immerse valve cartridge (3) and valve housing (7) in

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
ensure that all passage ways and bores are clear.
4
6
STEP 6
Check valve cartridge for (3) for cracks, breaks,

chipping, or other damage. Replace if any of these
conditions are seen.
6
6
5
STEP 7
Check bores in valve housing (7) for deep scratches,

gouges, and other damage. Replace valve if any of
these conditions are seen.
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
STEP 9
Install new O-rings (4 and 5) and back-up rings (6) as
shown.
GS98J818
1.
2.
3.
4.
NUT
SOLENOID
VALVE CARTRIDGE
O-RING
5. O-RING
6. BACKUP RING
7. VALVE HOUSING
STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
Bur 6-42600
Issued 8-01
Printed in U.S.A.
Copyright
8007-4
NOTES
Bur 6-42600
Issued 8-01
Printed in U.S.A.
Copyright
8013
Section
8013
PILOT PRESSURE ACCUMULATOR AND RIDE
CONTROL ACCUMULATOR
CASE CORPORATION
700 State Street
Bur 6-42621

Printed in U.S.A.
Copyright
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PILOT PRESSURE ACCUMULATOR P.I.N. JEE0135500 AND BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42621
Revised 2-03
3
3
3
4
6
6
6
6
8
8
8
8
10
Printed in U.S.A.
Copyright
8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ............................ 17.2 +/- 1.7 bar (250 +/- 25 psi) at 21 C (70F)
Ride Control Accumulator Fluid Capacity............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure
P.I.N. JEE0135500 and Below ...................................................................................................207 bar (3000 psi)
P.I.N. JEE0135501 and Above ................................................................................................. 248 bar (3600 psi)
Pilot Pressure Accumulator Dry Nitrogen Pressure......................... 13.8 +/- 1.7 bar (200 +/- 25 psi) at 21 C (70 F)
Pilot Pressure Accumulator Fluid Capacity ............................................................................ 95 liters (59.5 cu. inch)
Pilot Pressure Accumulator Maximum Operating Pressure ...........................................................207 bar (3000 psi)
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
CAS-10899 NITROGEN ACCUMULATOR CHARGING KIT
Bur 6-42621
B786441M
CAS-1456 GLAND WRENCH
Revised 2-03
Printed in U.S.A.
Copyright
8013-4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
94L95
CAS-10899 NITROGEN CHARGING KIT
NOTE: The pilot pressure accumulator used on

P.I.N. JEE0135501 and above is not repairable nor
rechargeable.
1. Use the CAS-10899 Nitrogen Charging Kit to
d i s c h a r g e t h e a c c u m u l a t o r, r e f e r t o t h e
illustration above. The tool must be disconnected
from the nitrogen tank.
2. Close valves B, C and D.
3. Adjust the regulator A to the minimum pressure
setting by turning the knob counterclockwise.
7. Turn the T-handle inward on valve F to engage

the pin in the valve stem.
8. Open valve D and check the charge pressure on
gauge E.
9. To discharge the accumulator, partially open
valve B. The accumulator charge will bleed down
through the regulator.
10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
11. The accumulator can now be disassembled.
4. Turn the T-handle on valve F fully out.

5. Remove the guard and valve assembly cap from
the accumulator.
6. Connect valve F to the valve stem on the
accumulator.
Bur 6-42621
Revised 2-03
Printed in U.S.A.
Copyright
8013-5
NOTES
Bur 6-42621
Revised 2-03
Printed in U.S.A.
Copyright
8013-6
RIDE CONTROL ACCUMULATOR

Assembly
Disassembly
NOTE: Refer to Section 8001 for the proper
procedure for the removal of the ride control
accumulator.
SM386

page 7.
body (1).
body (1).
pressure valve (4).
5. Loosen and remove the cap (12) from the body
(1).
(1).

page 7.
(5) with clean oil.
the body (1).
to the O-ring.
5. Install and tighten the cap (12) into the body (1).



10. Install the pressure valve (4) in the body (1).
Inspection
1. Clean body (1), gland (6), cap (12) and piston (5)
in cleaning solvent, refer to the illustration on
page 7.
according to instructions on page 10.

damage.
needed.
Bur 6-42621
Revised 2-03
Printed in U.S.A.
Copyright
8013-7
11
6
10
12
BS01B224
1.
2.
3.
4.
BODY
GUARD
SCREW
PRESSURE VALVE
5.
6.
7.
8.
PISTON
GLAND
O-RING
WEAR RING
9.
10.
11.
12.
BACKUP RING
O-RING
SEALS (2)
CAP
RIDE CONTROL ACCUMULATOR ILLUSTRATION
Bur 6-42621
Revised 2-03
Printed in U.S.A.
Copyright
8013-8
PILOT PRESSURE ACCUMULATOR

NOTE: The pilot pressure accumulator used on
P.I.N. JEE0135501 and above is not repairable nor
rechargeable.
Disassembly
SM386

page 9.
body (1).
body (1).
pressure valve (4).
Assembly
page 9.
(5) with clean oil.
the body (1).
to the O-ring.
5. Install the cap (12) in the body (1).
5. Loosen and remove the cap (12) from the body

(1).


(1).


10. Install the pressure valve (4) in the body (1).
according to instructions on page 10.
Inspection
1. Clean body (1), gland (6), cap (12) and piston (5)
in cleaning solvent, refer to the illustration on
page 9.
WA R N I N G : U s e o n l y n i t r o g e n w h e n
charging the accumulator. DO NOT use air
or oxygen that will cause an explosion.
SM115A

damage.
needed.
Bur 6-42621
Revised 2-03
Printed in U.S.A.
Copyright
8013-9
11
10
3
12
2
7
4
3
1
BS01B224
1.
2.
3.
4.
BODY
GUARD
SCREW
PRESSURE VALVE
5.
6.
7.
8.
PISTON
GLAND
O-RING
WEAR RING
9.
10.
11.
12.
BACKUP RING
O-RING
SEALS (2)
CAP
PILOT PRESSURE ACCUMULATOR ILLUSTRATION - P.I.N. JEE0135500 AND BELOW
Bur 6-42621
Revised 2-03
Printed in U.S.A.
Copyright
8013-10
CHARGING THE ACCUMULATOR WITH NITROGEN
GS98N801
1. TO NITROGEN TANK
2. VALVE A
3. VALVE B
4. VALVE D
5. TO ACCUMULATOR
6. VALVE C
NITROGEN CHARGING KIT CAS-10899
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.
Bur 6-42621
Revised 2-03
Printed in U.S.A.
Copyright
8013-11
1. Close the shutoff valve A by turning it all the way
to the le ft ( cou nterc loc kwise), re fe r to th e
10. Install the charging hose fitting onto the

accumulator pressure valve (4), refer to the
illustrations on pages 7 and 9.
2. Open valve B by turning it out all the way to the

left (counterclockwise).
11. Tighten the needle valve by turning it clockwise.

Slowly open the gauge valve D and observe the
re ad in g o n the ga ug e. Th is rea d in g is th e
nitrogen pressure level inside the accumulator,
refer to illustration on page 10.
3. Close valve C by turning it all the way to the right

(clockwise).
4. Close the gauge valve D by turning it all the way
to the right (clockwise).
5. Connect the charging hose to the nitrogen supply
tank.
6. SLOWLY turn valve A clockwise while watching
the high pressure gauge. Stop turning valve A
when the needle on the gauge reaches 31 bar
(450 psi).
NOTE: If the needle goes over the needed pressure,
quickly open and close valve D and check the
pressure setting again.
12. Open the shutoff valve A on the nitrogen supply

tank. While observing the pressure on the gauge,
slightly op en the nee dle valve on th e
accumulator charge hose. By regulating the
needle valve, fill the accumulator to 31 bar (450
psi). Close the needle valve. Close the shutoff
valve A on the nitrogen supply tank.
13. Close valve B by turning to the right (clockwise).
After a few minutes, check the accumulator for
leakage.
7. Remove the two cap screws (3) and the

protection bracket (2) from the body (1) on the
accumulator, refer to the illustrations on pages 7
and 9.
14. Back off the needle valve on the accumulator

end of the charging hose by turning it
counterclockwise the maximum amount. This will
p r e v e n t n it r o g e n f r o m e s c a p in g f r o m th e
accumulator as the hose is removed. Remove
t h e c h a r g in g h o s e f r o m t h e a c c u m u l a to r
pressure valve (4), refer to the illustrations on
pages 7 and 9.
8. Remove the valve cap from the pressure valve

(4) on the accumulator.
15. Install the valve cap onto the pressure valve (4)
on the accumulator.
9. Back off the needle valve on the accumulator

end of the charging hose by turning it
counterclockwise to the maximum amount. This
pr ev en ts n itro ge n fro m e sca p in g fro m th e
accumulator when the charging hose is attached
to the accumulator gas charging valve, refer to
the illustration on page 10.
16. Install the protection bracket (2) over the

pressure valve (4) and secure it with cap screws
(3).
The charging kit is now ready to be installed on the

accumulator.
Bur 6-42621
17. Remove the charging hose from the nitrogen

supply tank, refer to the illustration on page 10.
Revised 2-03
Printed in U.S.A.
Copyright
8013-12
NOTES
Bur 6-42621
Revised 2-03
Printed in U.S.A.
Copyright
SECTION INDEX
MOUNTED EQUIPMENT
Section Title
Section Number
Pedals and Levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001

Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant . . . . . . . . . . . . .9002
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Removal and Installation of Air Conditioning Components for Systems with HFC134a Refrigerant . . . . . . . . . .9004
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
ROPS Cab and ROPS Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010
CASE CORPORATION
700 State Street
Bur 6-42640

Printed in U.S.A.
August, 2001
Copyright
9001
Copyright
Section
9001
PEDALS AND LEVERS
CASE CORPORATION
700 State Street
Bur 6-40830

Printed in U.S.A.
March, 2001
Copyright
9001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCELERATOR PEDAL AND CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-40830
Issued 3-01
3
4
6
6
6
7
Printed in U.S.A.
Copyright
9001-3
SPECIFICATIONS
Engine speeds
Low idle - 521D Z-Bar and XT......................................................................................... 1020 to 1080 r/min (rpm)
High idle - 521D Z-Bar and XT ........................................................................................ 2220 to 2280 r/min (rpm)
Stop bolt for accelerator pedal
(Top of floor plate to top of stop bolt)........................................................................................ 68 mm (2.7 inches)
Brake light pressure switch..................................................................................................................4.1 bar (60 psi)
Brake warning pressure switch............................................................................................. 141 bar (2045 psi) rising
117 bar (1697 psi) falling
Parking brake adjustment
Adjusting screw - M16 ................................................................................................................0.5 mm to 1.5 mm
Adjusting screw - M20 ................................................................................................................1.0 mm to 3.0 mm
Bur 6-40830
Issued 3-01
Printed in U.S.A.
Copyright
9001-4
ACCELERATOR PEDAL AND CABLE ADJUSTMENT

1. Disconnect the ball joint (8) from the cable (4) at
the throttle lever (10) on the fuel injection pump,
refer to the illustration on the next page.
(OFF) position. If the engine speeds are not
equal to the specifications in this section, adjust
the stop bolts on the fuel injection pump as
required.
NOTE: Adjustment of the high idle must be done by
an authorized Case service person.
3. Adjust the stop bolt (1) for the accelerator pedal
(2) so that the dimension from the top of the floor
plate to the top of the stop bolt (1) is 68 mm (2.7
inches).
Bur 6-40830
4. Make sure that the ball joint (3) at the end of

cable (4) is turned all the way onto cable (4).
5. Have another person push the accelerator pedal
(2) all the way against the stop bolt (1).
6. Move the rear cable clamp (6) and cable (4) so
that the throttle lever (10) on the fuel injection
pump contacts the high idle stop, and make a
mark for the position of the rear cable clamp (6).
7. Have the other person release the accelerator
pedal (2).
8. Move the rear cable clamp (6) and cable (4)
forward 2 mm (0.07 inches) and tighten the rear
cable clamp (6).
9. Check to see that the high and low idle engine
speeds are as specified in this section.
Issued 3-01
Printed in U.S.A.
Copyright
9001-5
1
2
3
5
4
4
10
BS01B023
1.
2.
3.
4.
5.
STOP BOLT
ACCELERATOR PEDAL
BALL JOINT
CABLE
CABLE CLAMP
6.
7.
8.
9.
10.
REAR CABLE CLAMP

SPRING
BALL JOINT AT THROTTLE ARM
THROTTLE BRACKET
THROTTLE ARM
ACCELERATOR PEDAL AND CABLE ADJUSTMENT
Bur 6-40830
Issued 3-01
Printed in U.S.A.
Copyright
9001-6
PARKING BRAKE
Checking the Parking Brake
2. The transmission must be in manual shift mode
and the gear select must be in 3rd gear.
NOTE: The Transmission Control Module will
disconnect the transmission if any other gear is used.
5. Release the lock nut (2) and turn the adjusting

screw (3) clockwise until the two brake pads (4)
make contact with the brake disc (5).
6. Turn the adjusting screw (3) counter clockwise
and set the clearance, this should be 1/2 of one
turn, refer to the table below.
Type
Adjusting
Screw
4. Press the up count switch until the display reads

011.
Small
M16 (size 8)
5. Press the program switch back to the center

position.
Large
M20 (size 10)
3. Press the program switch.
6. Press the up count switch once.

7. Make sure the transmission selector is in 3rd
neutral and the parking brake switch is on and in
manual mode.
8. Shift the transmission selector into 3rd gear
FORWARD and slowly increase engine rpm.
9. The parking brake should hold the machine at
full throttle.
Clearance (mm)
Revolutions
Min.
Rated Clearance
Max
Min.
Rated Clearance
Max
0.5
1.0
1.5
1.0
2.0
3.0
1/4
1/2
3/4
2/5
4/5
1 1/5
7. Hold the adjusting screw (3) in position with a

allen head wrench and lock with the lock nut (2).
8. Install the end cap (1).
9. Perform the Checking
procedure again.
the
Parking
Brake
10. If the parking brake is still out of adjustment, see

section 7008 and replace the brake shoes on the
parking brake.
10. If the machine begins to move, decrease the

engine speed and stop the engine. See Adjusting
the Parking Brake in this section.
11. Press the reset switch to exit the test mode.
Adjusting the Parking Brake

3

2. Start the engine and run at low idle with the
service brakes engaged and the bucket resting
on the ground throughout this procedure.
NOTE: Hydraulic pressure will not be applied to the

parking brake until the parking brake rocker switch is
turned off, the service brakes are applied, and the
transmission is put into gear.
A. Set the parking brake rocker switch to the off

position.
B. With the service brakes applied, put the
machine into gear.
C. The parking brake light on the cluster will turn
off at this time.
BS00N110
1. END CAP
2. LOCK NUT
3. ADJUSTING SCREW
4. BRAKE PADS
5. BRAKE DISC
6. PARKING BRAKE
PARKING BRAKE
D. Put the transmission back into neutral before

proceeding.
4. Remove the end cap (1), refer to the illustration
on this page.
Bur 6-40830
Issued 3-01
Printed in U.S.A.
Copyright
9001-7
BRAKE PEDAL
11
3
4
8
1
10
9
11
4
11
3
5
7
6
4
BS00N109
1.
2.
3.
4.
BRAKE PEDAL
BRAKE MODULATION PRESSURE ADJUSTING BOLT
TAMPER RESISTANT COVER
5.
6.
7.
8.
FRONT BRAKE TEST PORT

REAR BRAKE TEST PORT
BRAKE LIGHT PRESSURE SWITCH
9. PIN
10. E-RING
11. BASE
BRAKE PEDAL
Bur 6-40830
Issued 3-01
Printed in U.S.A.
Copyright
9001-8
NOTES
Bur 6-40830
Issued 3-01
Printed in U.S.A.
9002
Copyright
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM
CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
CASE CORPORATION
700 State Street
Bur 6-42650

Printed in U.S.A.
August, 2001
Copyright
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42650
Issued 8-01
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Printed in U.S.A.
Copyright
9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH.
M171B
ATTENTION: Only authorized technicians certified

by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems. It is mandatory that all
refrigerant must be RECOVERED and RECYCLED
when removed from a system during servicing.
Refrigerant HFC-134a is the most stable, and easiest
to work with of the refrigerants now used in air
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFCs) which are
harmful to the earths ozone layer.
Safety procedures must be followed when working
with Refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
Liquid refrigerant getting into the eyes can cause
se rio u s in jur y. D o th e fo llow ing if yo u g et
refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.
3. Keep refrigerant containers in the correct upright

position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat.
4. Always reclaim refrigerant from the system, if
you are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
the air conditioner system before reclaiming
refrigerant and when you test the system.
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never permit
fumes to be inhaled.
7. Never leak test with compressed air or flame
testers. Tests have indicated that compressed
mixt ur e s o f HFC - 13 4 a a n d a ir c an fo rm a
combustible gas.
8. Always reclaim refrigerant from the system
before removing any air conditioning component.
B. See a physician immediately.

2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-4
299L7C
BELT TENSION TOOL CAS-10808
A22094
REFRIGERANT RECOVERY, RECYCLING AND CHARGING

STATION, OEM-1415
A22090
109L7
ELECTRONIC LEAK DETECTOR OEM-1437

SAFETY GOGGLES CAS-10073-3
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-5
OPERATION
The refrigerant, still in a high pressure liquid form,
then flows from the receiver-drier to the expansion
valve. The expansion valve then causes a restriction
in flow of refrigerant to the evaporator core. The
e va p o r a t o r me t e r s r e fr ig e ra n t f lo w b a s e d o n
evaporator heat load.
The refrigerant circuit of the air conditioning system

con ta in s five major co mp on ents: comp ressor,
condenser, receiver-drier, expansion valve and
evaporator. These components are connected by
tubes and hoses and operate as a closed system.
The air conditioner system is charged with HFC-134a
refrigerant.
As the refrigerant flows through the evaporator core,

the refrigerant is heated by the air around and
flowing through the evaporator fins. The combination
of increased heat and decreased pressure causes
the air flow through the evaporator fins to become
very cool and the liquid refrigerant to become a low
pressure gas. The cooled air then passes from the
evaporator to the cab for the operators comfort.
The compressor receives the refrigerant as a low

pressure gas. The compressor then compresses the
refrigerant and sends it in the form of a high pressure
gas to the condenser. The air flow through the
condenser then removes t he heat from the
refrigerant. As the heat is removed the refrigerant
changes to a high pressure liquid.
The electrical circuit of the air conditioning system

consists of a fan speed control, temperature control,
one (1) relay, a blower motor, blower resistor, A.C.
compressor clutch, A.C. low pressure switch, A.C.
high pressure switch, and A.C. warning light.
The high pressure refrigerant liquid then flows from

t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e
receiver-drier is a container filled with moisture
removing material, which removes any moisture that
may have entered the air conditioner system in order
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
1. EXPANSION VALVE
2. EVAPORATOR
Bur 6-42650
3. COMPRESSOR
4. CONDENSER
5. RECEIVER-DRIER
Issued 8-01
Printed in U.S.A.
Copyright
9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check
the following and correct as necessary:
1. - Obtain service history if possible.
5. - Are there heavy accumulations of oil, or oily

dust around the fittings, indicating refrigerant
leakage?
6. - Are air ducts undamaged, sealed properly and
in position?
2. - Is compressor drive belt in place and tensioned?

3. - Are grille screens, fan blades, condenser, air filter, and
evaporator unobstructed?
7. - Condensate drain hoses and check valves

present and unobstructed?
4. - Are there any sharp bends or kinks in the

hoses?
Problem: No Cooling
Compressor Runs
No
Mechanical - See Mechanical Compressor

Check Page 8
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem
See Pressure Testing, Page 13
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-7
Problem:
Not Enough Cooling
Problem:
Erratic Cooling
MECHANICAL
HEATER
See Mechanical Compressor Check Page 8.
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
INTERNAL SYSTEM PROBLEM

Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-8
SYSTEM CHECKS
Mechanical Compressor Check
Compressor and Fan Belts
1. Too much belt wear - replace a worn belt,

because a worn belt will cause too much
slippage.
Compressor Mounting Brackets
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
2. Bracket has cracks or breaks - replace the
bracket.
Compressor Clutch
1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Re mo ve the compresso r for
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
b e t w e e n t h e f r o n t p la t e a n d p u l le y
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
co m p re s so r c loc k wis e . Co m p re s so r
rotation should be smooth and not require
much effort.
Pulley and Belt Alignment
1. The
compressor
pulley
and
the
compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Us e a str aig ht ed g e to ch ec k p u lle y
alignment. Adjust the compressor
mounting bracket if needed.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
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.
Low and High Pressure Switches
1. See Section 4002 and check the high and

low pressure switches.
Blower Fuse (10 amp)
1. Check for damaged blower fuse.
Blower Fan Switch
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
Blower Motor
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
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.
Temperature Control Switch
Bur 6-42650
NOTE: Blower must be operating, since

electrical power to temperature control switch
is received from blower switch.
2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
sw itc h t erm in a ls . If co n tin u ity is n ot
present when switch is on maximum cold,
replace switch.
Issued 8-01
Printed in U.S.A.
Copyright
9002-10
Cab Temperature Check

Air Louvers
1. Make sure louvers and recirculation vents are fully open

for most efficient air conditioning operation. Defrost
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 compre ssor fo r 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
Temperature Sensing Probe Check
Bur 6-42650
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
re fr ig e ra n t, th e r e is a r e st ric tio n in th e s ys te m,
compressor is not working correctly, or air ducts are not
sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control
s w i t c h s h o u l d in t e r r u p t t h e c u r r e n t f l o w t o t h e
compressor. Check for current at the control switch
te rm in a ls a s on pr e vio u s pa g e . If c u rr e nt is n ot
interrupted then replace the control switch.
Issued 8-01
Printed in U.S.A.
Copyright
9002-11
Visual and Leak Check

Compressor Hoses
1. Make sure that all hose connections are

tight.
2. Check hoses for bends or cracks.
Replace all hoses that have damage.
1. Shut off the engine.
Leak Finding Check
WARNING: When refrigerant comes in

contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. U se
instructions from manufacturer of leak
finding tool.
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion
valve for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.
Condenser
Bur 6-42650
1. Make sure the condenser is clean and the

seals are in place. Make sure condenser
fans run when temperature control switch
is ON.
Issued 8-01
Printed in U.S.A.
Copyright
9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
Evaporator/Heater Core
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 fin s th at have b end s or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r i c t i o n s . I f t h e c o r e i s d r y, u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
mud, flush the core with water using a
hose without pressure. Make sure the
wate r dra in s freely from th e
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.
Evaporator/Heater Core Sealing
1. See Section 9004 for access to the

2. Make sure seals are in place so blower
will pull a ir o nly throu gh th e
evaporator/heater core and not around
the evaporator/heater core.
Filters
1. Make sure the filters are clean.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-13
PRESSURE TESTING
Manifold Gauge Set
NOTE: The gauge set is not accurate enough to
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether
undercharge or overcharge exists, and then
evacuate, reclaim and recharge system with the
recommended quantity (charge) of HFC-134a.
The manifold gauge set is the most important tool
used to service the air conditioning system. The
manifold gauge set is used to measure the high and
low pressures of the system, as a tool to troubleshoot
for correct refrigeran t charge quantity, system
diagnosis, and operating efficiency. The manifold
gauge set can read both the high (discharge) and low
(suction) sides at the same time, since pressure must
be compared in order to make a diagnosis of system
operation.
During normal operation the low pressure gauge

must always indicate from 10 to 35 psi (0.7 to 2.4
bar) after the system has run 10 to 15 minutes.
HIGH PRESSURE GAUGE - The high pressure
gauge is used to indicate pressures in the high side
of the system. The gauge must indicate from 0 to 400
psi (0 to 27.6 bar) minimum.
During normal operation, the high pressure gauge
will normally indicate from 120 to 310 psi (8.3 to 21.4
bar). See pressure-temperature chart on page 14.
Pressure Test Connection

C o n n e c t th e ma n if o l d g a u g e s e t in t o t h e a ir
conditioning system as shown. Make sure that both
valves in the manifold gauge set are closed.
LOW PRESSURE GAUGE - The low pressure gauge

is a compound gauge. It is best used to judge
e va c u a tio n e ff e ct iv e ne s s . A va c u u m r e a d in g
indicates a system malfunction. For this reason, it is
nece ssary to use a compo und gau ge tha t w ill
indicate both pressure and vacuum.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-14
PRESSURE-TEMPERATURE CHART
AMBIENT
NORMAL LOW
NORMAL HIGH
AIR LOUVER (BEHIND

SEAT)
MAXIMUM TEMP.
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION
F (C)
F (C)
psi (bar)
psi (bar)
80 (27)
9 to 12
145 to 165
(0.62 to 0.83)
(10 to 11.53)
11 to 15
190 to 210
(0.76 to 1.04)
(13.10 to 14.48)
16 to 18
210 to 230
(1.10 to 1.24)
(14.48 to 15.86)
17 to 19
235 to 255
(1.17 to 1.31)
(16.2 to 17.58)
20 to 21
260 to 280
(1.38 to 1.45)
(17.93 to 19.31)
22 to 24
290 to 310
(1.93 to 2.14)
(20 to 21.37)
90 (32)
95 (35)
100 (38)
105 (41)
110 (43)
The pressure-temperature chart is based on the

following conditions:
NOTE: High humidity will cause higher air louver
temperatures and dramatic increase in suction
pressure. The table shown represents readings
taken in low relative humidity. Adjust the chart
according to local conditions.
55 (14)
61 (18)
63 (20)
66 (22)
68 (23)
72 (25)
2. All panels and access doors installed and closed.

3. Cab filters clean and installed.
4. Heater valve at engine closed.
5. Measurements taken 15 minutes after startup.
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
GAUGE
HIGH PRESSURE
GAUGE
SEE
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
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1
WARNING: Always wear safety goggles

when working with liquid refrigerant. Liquid
r e f r ig e r a n t i n y o u r e y e s c o u l d c a u s e
blindness.
SM105A
Make sure the charging station manifold gauge

valves are in the closed position.
STEP 3
BD01D251
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
WARNING: Do not steam clean any air

conditioning system parts while the system is
charged. The heat will cause the refrigerant
to rise to a pressure that could cause the
system to explode.
SM104A
BD00N030
6. A/C TEMPERATURE CONTROL

7. BLOWER FAN SWITCH
Start the engine and run at 1500 RPM maximum

sp ee d . O pe ra te the a ir co nd itio n er sys tem at
maximum cooling setting and blower speed for 15
minutes with the cab door open. Observe the test
gauges and check the chart on page 13 against the
gauge readings.
STEP 2
BD01D273
Connect the hoses from the test gauges to the

service ports by turning the knurled knobs on the
depressors.
Connect the hose from the low pressure gauge to the
port on the suction hose.
Connect the hose from the high pressure gauge to
the port on the discharge hose.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-16
PROBLEM: NO COOLING
VERY LOW
VERY LOW
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
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
rapidly after start-up. (A/C warning light
in cab should illuminate).
Yes
4. Check level of oil in compressor - possible

for compressor to have an oil loss.
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
possible problems.
Bur 6-42650
Issued 8-01
test for
other
Printed in U.S.A.
Copyright
9002-17
HIGH
HIGH
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm
Yes
3. Remove air and moisture

from the

Section 9003.
Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and
unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
recla im a nd recharge refrigera nt un til gauge
pressure is normal. See Section 9003.
A. Liquid line (between evaporator and
condenser) is very hot.
B. Discharge air from evaporator warm.
4. Remove and check condenser for restrictions

caused by oil or reduced heat transfer.
A. Remove refrigerant from the system. See
Section 9003.
B. Use compressed
condenser.
air
to
remove
oil
from
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible
problems.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-18
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at
compressor.
C. Much condensation
outlet.
on
See Section 9004 and replace the expansion

valve.
evaporator
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
table represent the boiling point for HFC-134a.
Refrigerant Contamination
C. Pressure readings below range given in chart indicate

contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart

Temperature F ( C)
Pressure PSIG (Bar)
50 (10)
55 (13)
60 (16)
65 (18)
70 (21)
75 (24)
80 (27)
85 (29)
90 (32)
95 (35)
100 (38)
102 (39)
104 (40)
106 (41)
108 (42)
110 (43)
112 (44)
114 (46)
116 (47)
118 (48)
120 (49)
45 (3.1)
51 (3.5)
57 (3.9)
64 (4.4)
71 (4.9)
78 (5.4)
88 (6.1)
95 (6.6)
104 (7.2)
114 (7.9)
124 (8.6)
129 (8.9)
133 (9.2)
138 (9.5)
142 (9.8)
147 (10.1)
152 (10.5)
157 (10.8)
162 (11.2)
167 (11.5)
172 (11.9)
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO
SLIGHTLY HIGH
NORMAL
476L7
Air in the System - Indications:

1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand.
3. Repair system leak as necessary.
B. Discharge air from heater/evaporator

only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-20
LOW
LO W
476L7
Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator
cool or warm - not cold.
3. Repair system leaks as needed.

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
only a little cool.
B. Condensation
receiver-drier.
or
frost
on
C. Liquid line to receiver-drier cool, with

frost or condensation.
NOTE: The frost will form downstream
from or at the point of the restriction
Bur 6-42650
1. Discharge refrigerant from system-restriction in

receiver-drier or liquid line must be removed.
2. Remove and replace part with restriction.
3. Remove air and moisture from the system. See
Section 9003.
4. Charge system with new refrigerant. See Section
9003.
Issued 8-01
Printed in U.S.A.
Copyright
9002-21
Expansion Valve Not Operating - Indications:

A. Discharge air from evaporator warm
or cool - not cold.
B. Condensation or frost on expansion
valve outlet.
C. Inlet end of expansion valve is
warm.
Bur 6-42650
1. Expansion valve outlet with condensation or frost is

an indication of a restriction in the expansion valve.
Replace expansion valve. See Section 9004.
2. Inlet end of expansion valve is warm (not hot),
indicating expansion valve is not completely open.
If the valve is stuck closed, there will be little or no
flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.
Issued 8-01
Printed in U.S.A.
Copyright
9002-22
HIGH
LOW
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
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
Bur 6-42650
1. Replace expansion valve. See Section 9004.
Issued 8-01
Printed in U.S.A.
Copyright
9002-23
HIGH
HIGH
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
A. Liquid line very hot.
B. Discharge air from evaporator warm.
B. Add refrigerant until gauge pressures are

normal. See Section 9003.
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.
Warm discharge air from evaporator.

from the

Section 9003.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL
NORMAL
476L7
Moisture in the System - Indications:

1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the fre ezing 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.

from the
NOTE: The time needed to remove a large

amount of moisture will be two to three hours
minimum.
Section 9003.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
TO HIGH
HIGH
476L7
Too Much Refrigerant in System - Indications:

A. Cool discharge air from heater/evaporator.
B. Compressor makes noise.
Bur 6-42650
1. Remove refrigerant from system until gauge

readings are below normal. See Section
9003.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.
Issued 8-01
Printed in U.S.A.
Copyright
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
OR
3/4-16
7/8-18
OR
7/8-14
1-14
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.
Bur 6-42650
Issued 8-01
Printed in U.S.A.
Copyright
9003
Section
9003
AIR CONDITIONER SYSTEM SERVICE
CASE CORPORATION
700 State Street
Bur 6-42660

Printed in U.S.A.
August, 2001
Copyright
9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42660
Issued 8-01
3
3
4
5
7
10
Printed in U.S.A.
Copyright
9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ........................................................................................ 1.6 kg (3.5 lbs)
SPECIAL TOOLS
A22094
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING

STATION OEM-1415
Bur 6-42660
109L7
Issued 8-01
Printed in U.S.A.
Copyright
9003-4
SAFETY PROCEDURES

M171B

Refrigerant HFC-134a is the most stable and easiest
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFCs) which are
harmful to the Earths ozone layer.
with refrigerant HFC-134a to prevent possible
personal injury.
se rio u s in jur y. D o th e fo llo w ing if yo u ge t

4. Always reclaim refrigerant from the system, if
you are going to weld or steam clean near the air
conditioner system.
combustible gas.

Bur 6-42660
Issued 8-01
Printed in U.S.A.
Copyright
9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

R e co v e re d re f rig e r a n t p a ss e s th r o u g h a n o il
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
STEP 3
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
BD01D251
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.
BD01D273
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the p ort o n the discha rge h ose . Turn in valve
depressor.
Bur 6-42660
Issued 8-01
Printed in U.S.A.
Copyright
9003-6
STEP 5
STEP 7
A22112
A22110
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position and
depress the recovery start switch.
Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
The compressor will shut OFF automatically when

recovery is complete. Wait for 5 minutes and observe
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 8
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
comp ress or d isch ar ge p re ssure ba ck into th e
separator.
BD01D273
Remove the hoses from the service ports and install

the caps.
Bur 6-42660
Issued 8-01
Printed in U.S.A.
Copyright
9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or
more of the following conditions occurs before you
remove the air and moisture from the system.
A. The system has been opened for service
before.
B. Receiver-drier has operated two or more
years.
C. Disassembly of compressor shows small
particles of moisture removing material (gold
or brown particles).
Air and moisture are removed from the system by a

vacuu m pump. A vacuum pump is the only
equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
from the system.
NOTE: Refer to the vacuum pump manufacturers
user manual for additional information.
STEP 11
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
BD01D273
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.
Removal of air and moisture from the system is
necessary after the refrigerant has been removed
after the system has been opened for maintenance.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.
A22115
Press the Charge key. Program and Charge will

appear on the display.
NOTE: The pump on the reclamation unit will not

pull a sufficient vacuum to remove air and moisture.
Bur 6-42660
Issued 8-01
Printed in U.S.A.
Copyright
9003-8
STEP 13
STEP 16
A22113
A22123
Program 3.5 lbs and press the enter key. The display
will flash once indicating the programmed data has
been accepted.
Press the Vacuum key. Automatic will appear on

the display. Vacuum will appear on the display and
after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
and begin a countdown to zero.
STEP 14
W h e n th e p ro g r a mme d tim e h a s e la p se d , a n
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
le a k - f r e e s y s te m w il l l e a c h r e fr ig e r a n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
STEP 17
A22107
Press the charge key to begin refrigerant charging.

Automatic and Charge will appear on the display.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, the display shows CPL.
Fully open the low and high pressure valves.
STEP 15
A22113
Open the red (vapor) and blue (liquid) valves on the

tank.
Bur 6-42660
Issued 8-01
Printed in U.S.A.
Copyright
9003-9
STEP 18
STEP 20
A22114
A22117
Completely close the high and low pressure manifold

valves.
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.
ATTENTION: Check the OEM equipment manual

before performing Step 19 to avoid damaging the
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP 21
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure
indicator lamp will illuminate when the relay is
actuated by a low or high pressure and the
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.
BD01D273
Stop the engine, close any open valves and carefully

remove the manifold gauge hoses.
STEP 22
BD01D251
Install the caps on the service ports on the suction

and discharge hoses.
Bur 6-42660
Issued 8-01
Printed in U.S.A.
Copyright
9003-10
PRESSURE - TEMPERATURE CHART

AMBIENT
NORMAL LOW
NORMAL HIGH
AIR LOUVER (BEHIND
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
F (C)
psi (bar)
psi (bar)
F (C)
80 (27)
9 to 12
(0.62 to 0.83)
145 to 165
(10 to 11.5)
55 (14)
90 (32)
11 to 15
(0.76 to 1.04)
190 to 210
(13.1 to 14.5)
61 (18)
95 (35)
16 to 18
(1.10 to 1.24)
210 to 230
(14.5 to 15.8)
63 (20)
100 (38)
17 to 19
(1.17 to 1.31)
235 to 255
(16.2 to 17.6)
66 (22)
105 (41)
20 to 21
(1.38 to 1.45)
260 to 280
(17.9 to 19.3)
68 (23)
110 (43)
22 to 24
(1.93 to 2.14)
290 to 310
(20 to 21.4)
72 (25)
The pressure-temperature chart is based on the

following conditions:
1. Engine operating at 1500 RPM
2. No engine load
3. Fan speed control in maximum position (full
clockwise) and all louvers open.
5. Both cab doors open

6. All panels and access doors installed and closed.
7. Cab filters clean and installed.
8. Heater valve at engine closed.
9. Measurements taken 15 minutes after start-up.
4. Cab temperature control set to maximum cooling

(full counterclockwise).
Bur 6-42660
Issued 8-01
Printed in U.S.A.
Copyright
REMOVAL AND INSTALLATION OF AIR CONDITIONING

COMPONENTS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
CASE CORPORATION
700 State Street
Bur 6-42671

Printed in U.S.A.
9004
Section
9004
Copyright
9004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.I.N. JEE0135500 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.I.N. JEE0135500 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.I.N. JEE0135501 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPANSION VALVE AND EVAPORATOR/HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42671
Revised 2-03
3
4
5
5
6
7
7
8
10
10
12
15
15
15
16
16
17
17
Printed in U.S.A.
Copyright
9004-3
SAFETY PROCEDURES

M171B

Refrigerant HFC-134a is the most stable, and easiest
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFCs) which are
harmful to the earths ozone layer.
with Refrigerant HFC-134a to prevent possible
personal injury.
se rio u s in jur y. D o th e fo llow ing if yo u g et

4. Always reclaim refrigerant from the system if you
are going to weld or steam clean near the air
conditioner system.
combustible gas.

Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-4
SPECIAL TOOLS
A22094
REFRIGERANT RECOVERY, RECYCLING AND CHARGING

STATION OEM-1415
Bur 6-42671
109L7
Revised 2-03
Printed in U.S.A.
Copyright
9004-5
COMPRESSOR REMOVAL
STEP 4
P.I.N. JEE0135500 and Below

STEP 1
BD01D189
Remove the fan belt.

BD01D138

position.
STEP 5
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD01D184
Disconnect the low pressure line from the suction

port and the high pressure line from the discharge
p o r t o n t h e c o m p r e s s o r. I m m e d i a t e ly in s t a l l
protective caps on the open ports and lines.
STEP 6
BD01D165
Remove the four bolts and washers holding the drive

belt guard. Remove the guard.
BD01D191
Disconnect the compressor clutch wire from the

engine harness assembly.
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-6
STEP 7
STEP 11
BD01D193
BD01D165
Loosen and remove the four compressor mounting

bolts.
Remove the four bolts and washers holding the drive

belt guard. Remove the guard.
STEP 8
STEP 12
Remove the compressor from the machine.
Identify, tag, and disconnect the low pressure hose

from the compressor suction port and the high
pressure hose from the discharge port. Immediately
install plugs and caps in the hoses and on the ports.
P.I.N. JEE0135501 and Above

STEP 9
STEP 13
Identify, tag, and disconnect the engine harness
connector from the compressor clutch connector.
STEP 14
2
1
BD01D138

position.
STEP 10
3
BS02J067
1. BOLT
2. DRIVE BELT
3. BOLT
4. AC COMPRESSOR
Loosen bolts (1 and 3). Move compressor (4) to put

slack in drive belt (102) then remove drive belt.
STEP 15
Remove bolt (1), two washers, spacer, and nut.
Support compressor (4) and remove bolt (3), three
washers, and nut securing compressor. Remove
compressor from engine.
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-7
COMPRESSOR INSTALLATION
STEP 19
P.I.N. JEE0135500 and Below

STEP 16
Position and support the compressor on the engine.
STEP 17
BD01D184
Slowly remove the protective cap, install a new

O-ring, and connect the high pressure line to the
discharge port on the compressor.
Install the four bolts to secure the compressor.
IMPORTANT: Use caution when removing cap as

new compressors have internal pressure when
shipped.
STEP 18
STEP 20
BD01D193
BD01D191
Connect the compressor clutch wire to the engine

harness assembly.
Bur 6-42671
BD01D184
Carefully remove the protective cap, install a new

O-ring, and connect the low pressure line to the
suction port on the compressor.
Revised 2-03
Printed in U.S.A.
Copyright
9004-8
STEP 21
P.I.N. JEE0135501 and Above

STEP 25
2
1
BD01D189
Install the belt.
STEP 22
BS02J067
1. BOLT
2. DRIVE BELT
3. BOLT
4. AC COMPRESSOR
Position and support compressor (4) on mounting

bracket. Secure using bolt (3), three washers, and
nut. Install bolt (1), two washers, spacer, and nut.
STEP 26
Install drive belt (2). Move compressor (4) to take up
slack in drive belt then tighten bolts (1 and 3).
BD01D165
Install d rive b elt g ua rd a nd secu re u sin g fou r

washers and bolts.
STEP 27
Co nne ct the e ng in e ha rne ss con ne ctor to th e
compressor clutch connector following tags installed
STEP 23
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 24
STEP 28
IMPORTANT: In this step, use caution when
removing cap as new compressors have internal
pressure when shipped.
Slowly remove protective cap from compressor
discharge port. Following tags installed during
removal, install a new O-ring and connect high
pressure hose to compressor discharge port. Repeat
this step to connect low pressure hose to compressor
suction port. Remove and discard tags.
BD01D136

position.
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-9
STEP 29
STEP 31
BD01D165
BD01D136
Install drive b elt g ua rd a nd secu re u sin g fou r

washers and bolts.
Place the master d isco nnect switch in the ON

position.
STEP 30
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-10
EXPANSION VALVE AND EVAPORATOR/HEATER CORE

STEP 36
Removal
STEP 32
bucket to the floor.
STEP 33
STEP 34
BD01D396
Remove the four bolts that fasten the operators seat.
STEP 37
BD01D138
Place the master disconnect in the OFF position.
STEP 35
BD01D397
Remove the two bolts that fasten the strap to the

plate.
STEP 38
BD01D395
Disconnect the wiring harness from the operators

seat (if equipped with air seat option).
BD01D398
Remove the three screws and plate.
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-11
STEP 39
STEP 42
BD01D399
BD01D402
Fold the rubber mat over to gain access to the cover

plate and remove the screws holding the cover plate.
Remove the screws holding the valve cover plate

and remove the plate.
STEP 40
STEP 43
BD01D400
Remove the six screws and remove the back panel.
BD01D403
Remove and discard the insulation tape from the

fittings and the expansion valve.
STEP 41
STEP 44
3
1
BD01D401
Remove the back screw holding the cover plate and

remove the cover plate.
4
DS01D183
5. LIQUID TUBE
6. SUCTION TUBE
7. FITTINGS
8. EXPANSION VALVE
Disconnect the liquid tube (1), suction tube (2) and

the fittings (3) from the expansion valve (3). Cap and
plug all fittings and tubes.
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-12
STEP 45
Remo ve th e expa nsion
Installation
valve
from
the
STEP 49
STEP 46
Install the evaporator/heater core in position in the

machine.
Remove and discard the O-rings from the openings

in the expansion valve.
STEP 50
STEP 47
BD01D265
BD01D265
C o n n e c t t h e h o s e s a n d h o s e c la m p s t o t h e
Remove the hose clamps and the hoses from the

STEP 51
STEP 48
Lubricate new O-rings for the expansion valve with

clean refrigerant oil.
Re mo v e th e ev a po r at or /h ea te r co r e fro m th e
machine.
STEP 52
Install th e new O-rin gs in the ope nin gs of th e
expansion valve.
STEP 53
3
1
4
BS01D183
1. LIQUID TUBE
2. SUCTION TUBE
3. FITTINGS
4. EXPANSION VALVE
Connect the fittings (3) of the evaporator/heater core

to the expansion valve (4).
Connect the liquid (1) and the suction tube (2) to the
expansion valve (4).
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-13
STEP 54
STEP 58
BD01D403
BD01D398
Install new insulation tape around the fittings and the

expansion valve.
Fold the rubber mat back into place and install the
metal plate and screws.
STEP 55
STEP 59
BD01D402
BD01D397
Install the valve cover plate.
Install the strap.
STEP 56
STEP 60
Install the cover for the evaporator/heater core.
STEP 57
BD01D396
Place the operators seat in position and install and

tighten the four bolts.
BD01D400
Position the back panel in place and install the

screws.
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-14
STEP 61
STEP 63
BD01D395
BD01D136
Connect the wiring connector to the operators seat

(if equipped with air seat option).

position.
STEP 62
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-15
CONTROL VALVE
Removal
Installation
STEP 64
STEP 68

bucket to the ground.
Make sure the control knob is in the OFF position.
STEP 69
STEP 65
1
2
BD01D266
BD01D138

position.
STEP 66
Open the access panel on the right side of the
machine.
STEP 67
1. CONTROL VALVE
2. HEATER CABLE
3. FRONT H0SE AND CLAMP

4. REAR HOSE AND CLAMP
A. Install a new control valve (1).

B. Install the rear hose and clamp (4) on the
control valve (1).
C. Install the front hose and clamp (3) on the
control valve (1).
D. Install the heater cable (2) on the heater cable
clip.
STEP 70
2
Close the access panel door.
STEP 71
4
BD01D266
1. CONTROL VALVE
2. HEATER CABLE
3. FRONT HOSE AND CLAMP

4. REAR HOSE AND CLAMP
A. Remove the heater cable (2) from the heater

cable clip.
B. Remove the front clamp and hose (3) from the
control valve (1).
C. Remove the rear clamp and hose (4) from the
control valve (1).
BD01D136

position.
D. Remove the control valve (1).

Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-16
CONDENSER
STEP 77
Removal
STEP 72
bucket to the ground.
STEP 73
BS01D181
Fa s t e n i d e n t if ic a ti o n t a g s o n th e h o s e s a n d
disconnect the hoses from the condenser.
STEP 78
Install plugs in the hoses and caps on the fittings.
BD01D136

position.
STEP 79
STEP 74
STEP 75
1
2
BD01D142
1. COVER
2. CONDENSER
Open the cover (1) to gain access to the condenser

(2).
STEP 76
The condenser is connected to brackets which pivot
on the cooling frame. Pivot the condenser to gain
access to the mounting bolts and the hoses.
Bur 6-42671
BS01D182
L oo s e n a n d re mo v e th e b o lts th a t fa st en th e
condenser to the brackets.
STEP 80
Remove the condenser.
Revised 2-03
Printed in U.S.A.
Copyright
9004-17
CONDENSER
STEP 84
Installation
STEP 81
Inspect the condition of the seals on the condenser.
If the seals are bad, replace the seals.
STEP 82
Put the condenser in position on the brackets.
STEP 83
BS01D181
A. Remove the plugs from the hoses and the

caps from the fittings.
B. Install new O-rings and connect the hoses to
the fittings
STEP 85
Pivot the condenser down and close the cover.
STEP 86
STEP 87
BS01D182
Install the bolts that fasten the condenser to the

brackets.
BD01D136

position.
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
9004-18
NOTES
Bur 6-42671
Revised 2-03
Printed in U.S.A.
Copyright
Section
9006
9006
LOADER
CASE CORPORATION
700 State Street
Bur 6-42690

Printed in U.S.A.
August, 2001
Copyright
9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETURN TO DIG ADJUSTMENT (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
(Z-BAR AND XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETURN TO DIG ADJUSTMENT (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOADER FRAME (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE LOADER FRAME (Z-BAR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOADER FRAME (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE LOADER FRAME ( XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42690
Issued 8-01
3
3
3
3
3
4
5
7
8
10
11
13
Printed in U.S.A.
Copyright
9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth..............................................................................515 to 618 Nm (380 to 456 pound-feet)
BUCKET TEETH
Replacement of the Tooth Points
3
1. Use a hammer and punch to drive the retaining

pin (1) for the tooth point (2) out of the tooth
shank (3), refer to the illustration on this page..
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)
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
a hammer to hit the retaining pin (1) until the
retaining pin (1) is even with the outside of the
tooth shank (3).
7
3
2
10
Replacement of the Bucket Teeth

1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth.
9
7
NOTE: If wear of the bolt or nut makes removal

difficult, the bolt or nut can be cut off.
2. Remove the tooth.
B0740A88J
3. Install the new tooth on the bucket cutting edge

(7).
4. Use new nuts (4), hardened washers (5), and
bolts (6) for the tooth being installed.
5. Tighten the nuts (4) to 515 to 618 Nm (380 to
456 lb ft).
1.
2.
3.
4.
5.
RETAINING RING
TOOTH POINT
TOOTH SHANK
NUT
HARDENED WASHER
6.
7.
8.
9.
10.
BOLT
CUTTING EDGE
PLOW BOLT
NUT
CORNER TOOTH
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 515 to 618 Nm (380 to
456 lb ft).
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-4
RETURN TO DIG ADJUSTMENT (Z-BAR MODELS)
2
6
1
3
4
BS01C083
1. TARGET MOUNTING BRACKET

2. BUCKET CYLINDER
3. TARGET BAR
4. PROXIMITY SWITCH MOUNTING BRACKET
5. PROXIMITY SWITCH
6. PROXIMITY SWITCH GUARD
RETURN TO DIG ADJUSTMENT ILLUSTRATION Z-BAR MODELS
IMPORTANT: Before adjusting the return-to-dig,

make sure that the target bar on the bucket linkage is
not damaged. Slowly roll back and dump the bucket
and make sure that the target bar stays the same
distance from the switch. The switch mounting
bracket protects the switch. Make sure the target bar
cannot touch the switch when the bucket is dumped.
1. Park the machine on a level surface. Raise the
lift arms until they are approximately horizontal
and dump the bucket. Lower the bucket until the
bucket edge is on the ground.
3. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target
mounting bracket (1) parallel to the tilt cylinder
(2). Tighten the bolts, refer to the illustration on
this page.
4. Loosen the bolts holding the proximity switch
mounting bracket (4) to the tilt cylinder (2).
Position the proximity switch (5) parallel to the
target bar (3) and tighten the bolts.
5. Adjust the proximity switch (5) out towards the
target bar (3), until an air gap of 3.5 to 5.0 mm
(1/8 to 3/16 inch) is obtained. Torque the jam nut
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet).
NOTE: The proximity switch (5) must not protrude
past the proximity switch guard (6).
6. Start the engine, position the bucket to the
correct digging angle and stop the engine.
7. Loosen the bolts holding the target bar (3) to the

target mounting bracket (1). Slide the target bar
(3) towards the proximity switch (5) until the face
of the proximity switch (5) is completely covered.
8. Align the target bar (3) parallel to the tilt cylinder
(2) and tighten the bolts.
9. Turn the ignition switch to the ON position. Do
NOT start the engine.
10. Place the bucket control lever in the ROLLBACK
position.
target mounting bracket (1).
12. Slide the target bar (3) slowly away from the
proximity switch (5), until the control lever returns
to the center position. Tighten the bolts holding
the target bar (3).
13. Check to make sure that the 3.5 to 5.0 mm (1/8
to 3/16 inch) gap is still maintained.
15. Place the detent switch in the ON position and
place the return to travel/float detent switch to
the TRAVEL position.
16. Raise the lift arms approximately horizontal, and
put the bucket in the fully dumped position.
17. Place the loader control lever in the ROLLBACK
position, and verify that the electromagnet holds
it in that position until the end of the target bar (3)
passes in front of the proximity switch (5).
18. Lower the lift arms and verify that the bucket is at
the correct digging angle.
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-5
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

(Z-BAR AND XT MODELS)
5
6
3
2
1
BS01C081
1. TARGET MOUNTING PLATE

2. HEIGHT CONTROL TARGET
3. PROXIMITY SWITCH
4. LIFT ARM
5. RETURN TO TRAVEL TARGET

6. FRONT CHASSIS (TOP LEFT HAND SIDE)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION Z-BAR AND XT MODELS

2. Start the engine and apply the parking brake.
3. Lower the lift arms and place the bucket flat on
the ground.
4. Stop the engine.
NOTE: To avoid damge 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.
5. Position the return to travel target (5) opposite

the proximity switch (3) and tighten it to the target
mounting plate (1).
return to travel target (5) until an air gap of 3.5 to
5.0 mm (1/8 to 3/16 inch) is obtained.
7. Lock the proximity switch (3) in this position with
the jam nut. Torque the jam nut to 6 to 7.5 Nm
(4.5 to 5.5 pound-feet).
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
(b ac kh o e, b lad e , bo om, b uc k et, e tc .) to th e
ground and stop the engine.
CSM105
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-6
2
A
3
B
BS01C082
1. HEIGHT CONTROL TARGET
2. RETURN TO TRAVEL TARGET
3. TARGET MOUNTING PLATE
APPROXIMATE
RESULTING HEIGHT
CONTROL HINGE PIN
HEIGHT
MACHINE
APPROXIMATE
RESULTING RETURN TO
TRAVEL HINGE PIN
HEIGHT
521D Z-BAR
57 mm (2.3 inches)
358 mm (14.1 inches)
54 mm (2.1 inches)
3302 mm (130 inches)
521D XT
47 mm (1.9 inches)
438 mm (17.3 inches)
48 mm (1.9 inches)
3302 mm (130 inches)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION Z-BAR AND XT MODELS
8. Refer to the table and the illustration on this

page. Position the height control target (1) on the
target mounting plate (3) using the table above.
13. Place the detent switch in the ON position, and

set the return to travel/float detent switch to the
return to travel position.
NOTE: The higher the height control target (1) is

positioned in its slot in the target mounting plate (3),
the lower the lift arms will stop as they are raised.
14. Place the loader control lever in the raise

position and verify that the electromagnet holds it
in that position until the height control target (2)
passes in front of the proximity switch (3). Refer
9. Tighten the height control target (1).

10. Position the return to travel target (2) using the
table above.
NOTE: The higher the return to travel target (2) is
positioned in its slot in the target mounting plate (3),
the lower the lift arms will stop as they are lowered.
11. Check to make sure the proximity switch (3) and
all of the mounting bolts are tight. Refer to the
Bur 6-42690
15. With the lift arms still raised, place the loader
control lever in the lower position and verify that
the electromagnet holds it in that position until
the return to travel target (5) passes in front of
the proximity switch (3). Refer to the illustration
on page 5.
16. Repeat steps 8 through 15 until the desired
heights are reached.
17. Lower the bucket to the ground and stop the
engine.
Issued 8-01
Printed in U.S.A.
Copyright
9006-7
RETURN TO DIG ADJUSTMENT (XT MODELS)

2
3
5
4
6
BS01C084
1. BUCKET CYLINDER (LEFT HAND SIDE)

2. PROXIMITY SWITCH MOUNTING BRACKET
3. TARGET MOUNTING BRACKET

4. PROXIMITY SWITCH GUARD
5. PROXIMITY SWITCH
6. TARGET BAR
RETURN TO DIG ADJUSTMENT ILLUSTRATION XT MODELS
IMPORTANT: Before adjusting the return-to-dig,

make sure that the target bar on the bucket linkage is
not damaged. Slowly roll back and dump the bucket
and make sure that the target bar stays the same
distance from the switch. The switch mounting
bracket protects the switch. Make sure the target bar
cannot touch the switch when the bucket is dumped.

target mounting bracket (3). Slide the target bar
(6) away from the proximity switch (5) until the
face of the proximity switch (5) is completely
uncovered.
1. Park the machine on a level surface. Raise the

lift arms until they are approximately horizontal
and dump the bucket. Lower the bucket until the
bucket edge is on the ground.
10. Turn the ignition switch to the ON position. Do

NOT start the engine.

3. Loosen the bolts holding the target mounting
bracket (3) to the bucket cylinder clevis. Align the
target mounting bracket (3) parallel to the bucket
cylinder (1) and tighten the bolts. Refer to the
illustration on this page.
target mounting bracket (3). Align the target bar
(6) parallel to the bucket cylinder (1) and tighten
the bolts.
5. Loosen the bolts holding the proximity switch
mounting bracket (2) to the bucket cylinder (1).
Position the proximity switch (5) face parallel to
the target bar (6) and tighten the bolts.
target bar (6) until an air gap of 3.5 to 5.0 mm
(1/8 to 3/16 inch) is obtained. Torque the jam nut
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet).
9. Align the target bar (6) parallel to the bucket

cylinder (1) and tighten the bolts.
11. Place the bucket control lever in the ROLLBACK

position.
target mounting bracket (3).
13. Slide the target bar (6) slowly towards the
proximity switch (5), until the bucket control lever
returns to the center position. Tighten the bolts
holding the targe bar (6).
14. Check to make sure that the 3.5 to 5.0 mm (1/8
to 3/16 inch) gap is still maintained.
16. Place the detent switch in the ON position and
set the return to travel/float detent switch to the
return to travel position.
17. Raise the lift arms to approximately the
horizontal position and put the bucket in the fully
dumped position.
NOTE: The proximity switch (5) must not protrude

past the proximity switch guard (4).
18. Place the loader control lever in the ROLLBACK

position and verify that the electromagnet holds it
in that position until the end of the target bar (6)
passes in front of the proximity switch (5).
7. Start the engine, position the bucket to the

correct digging angle and stop the engine.
19. Lower the lift arms to the ground and verify that
the bucket is at the correct digging angle.
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-8
REMOVING THE LOADER FRAME (Z-BAR MODELS)

1. Park the machine on a level surface and apply
the parking brake. Roll the bucket all the way
forward and lower the bucket to the floor. Stop
the engine.
2. Loosen the filler plug in the reservoir to release
the air in the reservoir.
3. Fasten a chain hoist to the crossmember (1) of
the loader frame (2), refer to the illustration on
page 9.
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).
(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).

(7) out of th e piston rod eye of th e bucket
cylinder (8).
13. Raise the bucket cylinder (8) and use a chain or
other acceptable holding equipment to hold the
bucket cylinder (8) in place.
14. If the machine is equipped with auxiliary
hydraulics, disconnect the two hoses from the
tubes at the bracket on the right side of the
loader frame (2). Install caps on the hoses and
plugs in the tube fittings.
15. If the machine is equipped with front lamps,
loosen and remove the cap screws and lock
washers that fasten the lamp brackets to the
fro nt fr ame . Pu t th e la mp br ack ets on th e
fenders.
16. Connect the chain hoist to the loader frame (2).
(20) and spacer (21) that fasten the pivot pin (9
or 10) to the front frame.
9. Repeat steps 7 and 8 for the other lift cylinder (4

or 6).
18. Raise the loader frame slightly. Use an

acceptable driver and drive the pivot pin (9 or 10)
out of the front frame. Do not lose the washers
(18) and wipers (22) between the front frame and
the loader frame (2).
10. Connect the chain hoist to the bucket cylinder

(8).
19. Repeat Steps 17 and 18 for the other pivot pin (9

or 10).

(16), and spacer (17) that fasten the pivot pin (7)
for the piston rod eye of the bucket cylinder (8) to
the bellcrank (11).
20. Raise the loader frame (2) out of the front frame.
Carefully move the machine out of the loader
frame (2).
8. Raise the lift cylinder (4 or 6) slightly and remove

the driver.
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-9
10
8
18
22
18
20
17
16 15
19
2
6
5
21
11
1
4
14
23
12
13
BS01C087
1.
2.
3.
4.
5.
6.
CROSSMEMBER
LOADER FRAME
PIVOT PIN
LIFT CYLINDER
PIVOT PIN
LIFT CYLINDER
7.
8.
9.
10.
11.
12.
PIVOT PIN
BUCKET CYLINDER
PIVOT PIN
PIVOT PIN
BELLCRANK
BOLT
13.
14.
15.
16.
17.
18.
WASHER
SPACER
BOLT
WASHER
SPACER
WASHER
19.
20.
21.
22.
23.
BOLT
WASHER
SPACER
WIPER
DUMP LINK
LOADER FRAME - Z-BAR MODEL ILLUSTRATION
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-10
INSTALLING THE LOADER FRAME (Z-BAR MODELS)

1. Apply antiseize compound to the inner bores and
outer bores for the pivot pins of the front frame ,
refer to the illustration on page 9.
17. Fasten the chain hoist to one of the lift cylinders

(4 or 6).
2. Move the machine into alignment with the loader

frame (2).
18. Raise the piston rod yoke of the lift cylinder (4 or

6) so the piston rod yoke is aligned with the
loader frame (2).
3. Lower the loader frame (2) into alignment with

the front frame.
19. Install a driver in the piston rod yoke and the

loader frame (2).
4. Apply antiseize compound to the pivot pins (9

and 10) that fasten the loader frame (2) to the
front frame.
20. Repeat Steps 17, 18, and 19 for the other lift
cylinder (4 or 6).
5. Start the pivot pins (9 and 10) into the front

frame. Install the washers (18) and new wipers
(22) between the loader frame (2) and the front
frame.
6. Install the pivot pins (9 and 10) all the way.
7. Install the bolt (19), washer (20) and spacer (21)
that fasten the pivot pins (9 and 10). Tighten the
bolt.
8. Disconnect the chain hoist from the loader frame
(2).
9. If the machine is equipped with front lamps, hold
the front lamps in place and install the cap
screws and lock washers that fasten the front
lamps to the front frame. Tighten the cap screws.
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses. Connect the
hoses to the tubes.
11. Connect the chain hoist to the bucket cylinder (8)
and lower the bucket cylinder (8).
13. Have another person help you at this time. Move
the bucket control lever as required to align the
piston rod eye of the bucket cylinder (8) with the
bellcrank (11). Stop the engine.
IMPORTANT: D o n o t u s e y o u r f i n g e r s t o
check the alignment of the cylinder rod.
Personal injury can be the result.
48-88
14. Install the pivot pin (7) in the bellcrank (11) and
the piston rod eye of the bucket cylinder (8).
15. Install the bolt (15), washer (16), and spacer (17)
that fasten the pivot pin (7). Tighten the bolt.
16. Disconnect the chain hoist from the bucket
cylinder (8).
Bur 6-42690
21. Disconnect the chain hoist from the lift cylinder (4

or 6).
22. Start the engine. Raise the loader frame and roll
the bucket all the way forward. Lower the bucket
to the floor. Stop the engine.
23. Fasten the chain hoist to the crossmember (1) of
the lift control lever as required to align the piston
rod yoke of one of the lift cylinders (4 or 6) with
48-88
26. Remove the driver and install the pivot pin (3).
27. Install the bolt (12), washer (13), and spacer(14)
that fasten the pivot pin (3). Tighten the bolt.
cylinder (4 or 6). Stop the engine.
29. Lubricate the pivot pins with molydisulfide
grease.
30. Disconnect
the
chain
hoist
from
crossmember (1) of the loader frame (2).
the
31. Tighten the filler plug in the reservoir.

hydraulics, start the engine and run the engine at
low idle.
33. Slowly extend and retract the clam cylinders four
times to remove air from the auxiliary circuit.
34. Stop the engine, check the level of the oil in the
reservoir, and check for leaks. Add oil to the
reservoir as required.
Issued 8-01
Printed in U.S.A.
Copyright
9006-11
REMOVING THE LOADER FRAME (XT MODELS)

1. Remove all dirt and grease from the hose and
tube connections for the bucket cylinders and
clam cylinder, if equipped.
13. Disconnect the hoses to the bucket cylinders.

Disconnect the hoses from the tubes at the
bucket cylinders.
2. With the engine running at low idle, roll the

bucket all the way forward and lower the loader
frame until the bucket is on the floor.
14. Install a cap on each hose and a plug in each

tube.

4. Loosen the filler plug in the reservoir to release
the air in the reservoir.
5. Loosen and remove the bolt (7), washer (8), and
spacer (9)that fasten the pivot pin (1) to the
piston rod yoke of the lift cylinder (2 or 10), refer
(1) out of the piston rod yoke of the lift cylinder (2
or 10). Do not remove the driver.
7. Repeat Steps 5 and 6 for the other lift cylinder (2
or 10).
8. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor.
Fasten the chain hoist to a lift cylinder (2 or 10).
9. Raise the lift cylinder (2 or 10) slightly and
remove the driver.
10. Repeat Steps 8 and 9 for the other lift cylinder (2
or 10).
12. Move the bucket control lever to the ROLLBACK
position and the lift control lever to the LOWER
position to relieve any pressure in the circuits.
15. Disconnect the clam hydraulic connections, the

auxiliary hydraulic connections, and the coupler
connections as necessary. Plug and cap lines as
needed.
16. Disconnect the wiring harnesses.
17. If the machine is equipped with front lamps,
loosen and remove the cap screws and lock
washers that fasten the lamp brackets to the
fro nt fr ame . Pu t th e la mp br ack ets on th e
fenders.
18. Connect the chain hoist to the loader frame (3).
19. Loosen and remove the bolt (11), washer (12),
and spacer (13) that fasten the loader frame (3),
pivot pin (4) and anchor link pivot pin (5) to the
machine frame.
20. Raise the loader frame (3) slightly. Use an
acceptable driver and drive both the pivot pins (4
and 5) from the loader frame (3) and anchor link
(6).
21. Do not lose the washers (14) between the front
frame and the loader frame (3).
22. Repeat Steps 19 and 20 on the opposite side of
the machine.
23. Raise the loader frame from the machine. Be
sure all the necessary hydraulic lines, wiring etc.
are properly disconnected.
24. Carefully move the machine out of the loader
frame.
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-12
14
14
12
13
15
11
13
12
11
5
10
3
2
9
8
7
1
BS01C085
1.
2.
3.
4.
5.
PIVOT PIN
LIFT CYLINDER
LOADER FRAME
PIVOT PIN
PIVOT PIN
6.
7.
8.
9.
10.
ANCHOR LINK
BOLT
WASHER
SPACER
LIFT CYLINDER
11.
12.
13.
14.
15.
BOLT
WASHER
SPACER
WASHER
WIPER
LOADER FRAME - XT MODELS ILLUSTRATION
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-13
INSTALLING THE LOADER FRAME ( XT MODELS)

1. Apply antiseize compound to the inner bores and
outer bores of the front frame.
17. Disconnect the chain hoist from the lift cylinder (2

or 10).
2. Move the machine into alignment with the loader

frame (3), refer to the illustration on page 12.
18. Start the engine. Raise the loader frame (3) and
roll the bucket all the way forward. Lower the
bucket to the floor. Stop the engine.
3. Lower the loader frame (3) into alignment with

the machine frame.
4. Apply antiseize compound to the pivot pins (4)
and (5) that fasten the loader frame (3) to the
machine frame.
5. Start the loader frame pivot pin (4), washer (14)
and wiper (15).
6. Install the loader frame pivot pin (4) and anchor
link pivot pin (5) on one side of the machine.
7. Repeat Steps 5 and 6 for the opposite side of the
machine.
19. Fasten the chain hoist to the crossmember of the

loader frame (3).
the lift control lever as required to align the piston
rod yoke of one of the lift cylinders (2 or 10) with
48-88
8. Install the bolt (11), washer (12) and spacer (13)

that secure th e pivot p ins (4 and 5 ) to th e
machine on each side of the machine. Tighten
the bolt.
22. Remove the driver and install the pivot pin (1).
23. Install the bolt (7), washer (8), and spacer (9)
that fasten the pivot pin (1). Tighten the cap bolt.
9. Disconnect the chain hoist from the loader frame

(3).
cylinder (2 or 10). Stop the engine.
10. If the machine is equipped with front lamps, hold

the front lamps in place and install the cap
screws and lock washers that fasten the front
lamps to the front frame. Tighten the cap screws.
25. Lubricate the pivot pins with molydisulfide

grease.

hydraulics, cla m hydrauli cs, or coup ler
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses and make
the necessary connections.
12. Connect the hoses and tubing to the bucket
cylinders.
13. Fasten the chain hoist to one of the lift cylinders
(2 or 10).
26. Disconnect
the
chain
hoist
from
crossmember of the loader frame (3).
the

hydraulics, start the engine and run the engine at
low idle.
28. Slowly extend and retract the clam cylinders four
times to remove air from the auxiliary circuit.
29. Stop the engine, check the level of the oil in the
reservoir, and check for oil leaks. Add oil to the
reservoir as required.
14. Raise the piston rod yoke of the lift cylinder (2 or

10) so the piston rod yoke is aligned with the
loader frame (3).
15. Install a driver in the piston rod yoke and the
loader frame (3).
cylinder (2 or 10).
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-14
BS01C089
1. BUCKET CYLINDER
2. CONTROL VALVE
BUCKET CYLINDER HYDRAULIC CIRCUIT - Z-BAR MODEL
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-15
BS01C086
1. BUCKET CYLINDER
2. CONTROL VALVE
BUCKET CYLINDER HYDRAULIC CIRCUIT - XT MODELS
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
9006-16
B1445A88J
1. LEFT LIFT CYLINDER
2. RIGHT LIFT CYLINDER
3. CONTROL VALVE
LIFT CYLINDER HYDRAULIC CIRCUIT - Z-BAR AND XT MODELS
Bur 6-42690
Issued 8-01
Printed in U.S.A.
Copyright
Section
9007
9007
ROPS CAB AND ROPS CANOPY
CASE CORPORATION
700 State Street
Bur 6-42700

Printed in U.S.A.
August, 2001
Copyright
9007-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY . . . . . . . . . . . .
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY
ROPS CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.......................... 2
......................... 3
......................... 3
......................... 4
......................... 4
. . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TORQUES
ROPS Cab and ROPS Canopy Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773 to 854 Nm (570 to 630 lb-ft)
Operators Seat Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 to 87 Nm (54 to 64 lb-ft)
Top Step Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 to 61 Nm (40 to 45 lb-ft)
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-3
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY

If the machine has rolled over or the ROPS cab or
ROPS canopy has been in some type of accident
(such as hitting an overhead object during transport),
you must replace the ROPS cab or ROPS canopy to
get as much protection as you had originally.
After an accident, check for damage to the ROPS

cab or ROPS canopy, the operators seat, the seat
belt, and all accessories, wiring, etc., in the ROPS
cab or ROPS canopy. Before operating the machine
again, all damaged parts must be replaced.
Do not weld or try to straighten a ROPS cab or
ROPS canopy.
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following:
1. Check the torque on the ROPS cab or ROPS
canopy mounting bolts; torque should be 773 to
854 Nm (570 to 630 lb-ft). If necessary, tighten
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight
and seat belt is not cut or frayed. Check the
torque on operators seat mounting bolts; torque
sh o u ld b e 7 3 to 8 7 N m ( 54 to 6 4 lb- ft ). If
necessary, tighten the bolts to the correct torque.
Replace parts that are worn or damaged.
WARNING: Grade 8 hardware is used to
mount and anchor the ROPS. Parts used for
replacement must be those shown in the
parts catalog.
WARNING: Do not install attachments that

will make the total weight of the machine
more than the weight shown in the maximum
gross vehicle weight section of the ROPS
serial number plate.
47-26
WARNING: Do not change the ROPS in any

way. Changes made to the ROPS which are
not authorized, such as welding, drilling or
cutting will make the ROPS weaker and
decrease your protection. Replace the
ROPS if it becomes damaged in any way.
DO NOT TRY TO MAKE REPAIRS TO THE
ROPS.
47-25
47-27A
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-4
ROPS CAB AND ROPS CANOPY

STEP 5
Removal
NOTE: Procedures and photos in following steps
cover in detail removal and installation of ROPS cab.
Removal and installation of ROPS canopy is similar
to removal and installation of ROPS cab.
STEP 1
BD01D139
Put battery disconnect switch in OFF position. Close

hood.
STEP 2
STEP 6
BD00M030

BD00M031
STEP 3
Put an 18 gallon container below hydraulic oil drain.

remove cap and drain hydraulic oil into container.
Install cap after oil has drained.
STEP 4
STEP 7
Open hood.
BD00M031
If machine is equipped with a heater, put a 37.8 liter

(10 gallon) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-5
STEP 8
STEP 11
2
1
BD01D259
Remove skirting under each side and front of cab.
STEP 9
BD01D263
If machine is equipped with windshield washers,

identify, tag, and disconnect front (1) and rear (2)
windshield washer nozzle hoses from supply hoses.
STEP 12
BD01D261
At RH rear, bottom of cab, disconnect ground strap

from rear chassis.
BD01D264
If machine is equipped with a heater, cut, remove,

and discard two tie straps.
STEP 10
STEP 13
4
3
5
6
6
BD01D262
Tag and disconnect transmission wiring harness

connector from bulkhead connector.
7
BD01D265
If machine is equipped with a heater, open side

access door to gain access to heater hoses (4 and
5). Compress two clamps (3) and disconnect hoses.
Remove clamps (3 and 6) from hoses. Pull hoses
down from cab; grommets (7) may dislodge from cab
when hoses are pulled down.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-6
STEP 14
STEP 17
11
8
10
15
14
BD01D267
BD01D390
Pull boot (8) back from B+ power stud. Tag and

disconnect wire from stud. Tag and disconnect two
wires from ground stud (9). Tag and disconnect rear
chassis wiring harness connector (10) and front
wir in g h ar ne ss co n n ec tor (11 ) fr o m b ulk he a d
connectors.
15
STEP 15
14
BC01D272
Remove solenoid valve (14) from remote valve body

(15). Move solenoid valve away from valve body and
hose connections. Identify, tag, and disconnect
hoses from remote valve body. Plug hoses and cap
valve fittings to prevent entry of foreign matter into
hydraulic system.
BD01D271
STEP 18
Remove access panel.
STEP 16
BD01D275
12
Cut, remove, and discard tie strap.
13
BD01D269
Using suitable tool push up on hose mounting

grommet (12) from bottom of cab. Remove both
halves of grommet (12 and 13) from cab and hoses.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-7
STEP 19
STEP 22
23
25
22
17
16
18
24
26
BD01D277
BD01D285
Cut, remove, and discard tie strap (16). Disconnect

throttle cable (17) from pedal assembly (18). Move
throttle cable away from cab.
If machine is equipped with two brake pedals,

remove retaining ring (22) securing pin (23) to brake
pedal (24). Remove pin. Remove two bolts (25),
pedal and shaft (26), pivot assembly, and block.
Remove pedal (24) cover pad.
STEP 20
STEP 23
19
27
BD01D279
Identify, tag, and disconnect hoses from steering

control valve (19). Plug hoses and cap steering
control valve fittings to prevent entry of foreign matter
into hydraulic system.
Remove three screws, washers, and seal channel

cover (27).
STEP 21
STEP 24
BD01D286
21
20
BD01D282
Remove LH fender (20) and top step (21).
Bur 6-42700
BD01D288
Raise floor mat up and away from brake pedal to

gain access to mounting hardware.
Issued 8-01
Printed in U.S.A.
Copyright
9007-8
STEP 25
STEP 27
28
29
28
BD01D287
BD01D291
Remove hardware securing brake valve to cab floor.

Let brake valve hang down from cab.
STEP 26
30
29
28
BD01D282
BD01D284
If machine has a ROPS cab and is equipped with air

conditioning, refer to Section 9002 and discharge air
conditioning system. At left rear bottom of cab,
d i s c o n n e c t t w o h o s e s f r o m a ir c o n d i t i o n i n g
evaporator tubes. Remove and discard O-rings from
evaporator tubes. Plug tubes and cap hoses to
prevent entry of foreign matter.
At top rear of cab, remove hardware securing LH

flood light (28) to pod (29). Disconnect flood light
connector (30) from wiring harness connector and
remove flood light. Repeat this step to remove RH
flood light.
STEP 28
31
29
BD01D293
Remove two bolts (31) and washers. Remove pod

(29) from cab.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-9
STEP 29
STEP 31
33
32
BD01D297
BD01D283
Install two lifting eyes in threaded holes at top front of

cab.
At LH and RH bottom rear of cab, loosen two bolts

(32) and remove cover plate (33) to gain access to
cab rear mounting hardware.
STEP 30
STEP 32
BD01D389
BD01D289
Remove four nuts (34), washers (35), bolts (36), and

washers (37) securing cab to rear chassis.
STEP 33
BD01D298
Connect lifting equipment to cab at lifting eyes

installed in Step 29 and at rear top LH and RH rails.
BD01D300
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 is free
and clear of cab. Remove the ROPS cab or ROPS
canopy from the machine. Lower cab or canopy onto
wooden blocks to prevent damaging cab or canopy.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-10
33
39
34
35
38
32
37
36
BS01D195
32.
33.
34.
35.
Bur 6-42700
BOLT
COVER PLATE
NUT
WASHER
36.
37.
38.
39.
BOLT
WASHER
RUBBER MOUNT
ROPS CANOPY
Issued 8-01
Printed in U.S.A.
Copyright
9007-11
STEP 36
Installation
STEP 34
Check rubber mounts (38) for deterioration, tears,
deforma tion , or oth er d ama ge; replace rub ber
mounts as necessary.
STEP 35
BD01D290
Install four washers (37), bolts (36), washers (35),

and nuts (34) to secure cab to rear chassis. Tighten
bolts to a torque of 773 to 854 Nm (570 to 630 lb-ft)
STEP 37
BD01D300
40
33
41
32
BD01D283
BD01D388
Position cab over rear chassis then put wood blocks

under brake valve (41). 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. Route
front windshield washer hose (40) towards RH of rear
chassis.
At LH and RH bottom rear of cab, install cover plate

(33) and tighten two bolts (32).
STEP 38
BD01D298
Disconnect lifting equipment from cab.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-12
STEP 39
STEP 42
BD01D297
BD01D284
Remove two lifting eyes installed in Step 29 in

threaded holes at top front of cab.
If machine has a ROPS cab and is equipped with air

conditioning, remove plugs from tubes and caps from
hoses at left rear bottom of cab. Install new O-rings in
air conditioning evaporator tubes. Connect two hoses
to evaporator tubes. Refer to Section 9002 and
charge air conditioning system.
STEP 40
STEP 43
31
29
BD01D293
Position and support pod (21). Secure pod using two

washers and bolts (31).
STEP 41
BD01D287
Align mounting holes in brake valve with associated

holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
STEP 44
30
29
28
BD01D282
At top rear of cab, connect flood light connector (30)

to wiring harness connector. Insert flood light (28)
stud through hole in pod (29) and secure flood light
using nut. Repeat this step to install RH flood light.
BD01D288
Position floor mat.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-13
STEP 45
STEP 48
27
19
BD01D286
BD01D279
Install seal channel cover (27) and secure with three

washers and screws.

Co n n ec t h o se s t o ste e rin g co nt ro l va lve ( 19 )
following tags installed during removal. Remove and
discard tags.
STEP 46
STEP 49
25
22
23
17
24
16
26
18
BD01D285
If machine is equipped with two brake pedals, install

pedal (24) cover pad. Position pedal and shaft (26),
pivot assembly, and block; secure with two bolts (25).
Install pin (23) through brake pedal (24) and pedal
shaft crank. Install retaining ring (22) to secure shaft.
Connect throttle cable (17) to pedal assembly (18).

Install new tie strap (16) to secure front windshield
washer hose to throttle cable.
STEP 47
STEP 50
BD01D277
21
20
BD01D282
Install LH fender (20) and top step (21). Tighten step

(21) mounting bolts to a torque of 54 to 61 Nm (40 to
45 lb-ft).
Bur 6-42700
BD01D275
Position hoses as shown and install new tie strap.
Issued 8-01
Printed in U.S.A.
Copyright
9007-14
NOTE: If machine has a joystick controller, go to
Step 51; if machine has a two-lever controller, go to
Step 52; if a joystick and one-lever controller go to
Step 53; if a three-lever controller go to Step 54; If a
joystick and two-lever controller go to Step 55.
NOTE: Except for pilot pressure and pilot tank
hoses, hose ends are color coded.
STEP 52
E
F
STEP 51
C
B
A
D
A
B
A
BS01D177A
A. ORANGE-BLACK
B. YELLOW-BLACK
C. RED-BLACK
D. GREEN-BLACK
E. PILOT PRESSURE HOSE
F. PILOT TANK HOSE

Connect hoses to two-lever controller and install in
hose mounting grommet halves as shown above. Go
to Step 56.
BS01D177B
A. ORANGE-BLACK
B. YELLOW-BLACK
C. RED-BLACK
D GREEN-BLACK
E PILOT PRESSURE HOSE
F PILOT TANK HOSE

Connect hoses to joystick controller and install in
to Step 56.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-15
STEP 53
STEP 54
D
G
B
C
D
F
E
A
B
C
A
B
G
F
BS01D178A
F
BS01D178B
A.
B.
C.
D.
ORANGE-BLACK
YELLOW-BLACK
RED-BLACK
GREEN-BLACK
E.
F.
G.
H.
YELLOW-WHITE
RED-WHITE
PILOT PRESSURE HOSE
PILOT TANK HOSE

Connect hoses to joystick and one-lever controller
and install in hose mounting grommet halves as
shown above. Go to Step 56.
Bur 6-42700
A.
B.
C.
D.
ORANGE-BLACK
YELLOW-BLACK
RED-BLACK
GREEN-BLACK
E.
F.
G.
H.
YELLOW-WHITE
RED-WHITE
PILOT PRESSURE HOSE
PILOT TANK HOSE

Connect hoses to three-lever controller and install in
to Step 56.
Issued 8-01
Printed in U.S.A.
Copyright
9007-16
STEP 55
STEP 57
G
E
F
I
12
13
BD01D269
Install both halves of hose mounting grommet (12

and 13).
STEP 58
B
E
F
J
I
G
H
BS01D180
A.
B.
C.
D.
E.
ORANGE-BLACK
YELLOW-BLACK
RED-BLACK
GREEN-BLACK
YELLOW-WHITE
F.
G.
H.
I.
J.
RED-WHITE
ORANGE-WHITE
GREEN-WHITE
PILOT PRESSURE HOSE
PILOT TANK HOSE

Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
shown above. Go to Step 56.
BD01D271
Install access panel.
STEP 59
STEP 56
9
11
8
10
14
15
BD01D267
BD01D390
Install solenoid valve (14) in valve body (15).
Bur 6-42700
Connect rear chassis wiring harness connector (10)

and front wiring harness connector (11) to bulkhead
connectors following tags installed during removal.
Connect two wires to ground stud (9) following tags
installed during removal. Connect wire to B+ power
stud following tag installed during removal and
position boot (8) over stud. Remove and discard
tags.
Issued 8-01
Printed in U.S.A.
Copyright
9007-17
STEP 60
STEP 63
7
BD01D264A
BD01D262
If machine is equipped with a heater, install two

grommets (7) (if dislodged during removal) and
heater hoses (4 and 5) up into cab.
Connect transmission wiring harness connector to

bulkhead connector following tag installed during
STEP 61
STEP 64
4
5
6
7
BD01D265
BD01D261
Make sure grommets (7) are installed completely in

cab holes. Install clamps (6 an d 3) o n ho ses.
Connect hoses (4 and 5) and position clamps (6 and
3) as shown.
At RH rear, bottom of cab, connect ground strap to

rear chassis.
STEP 65
STEP 62
2
1
BD01D259
Install skirting under each side and front of cab.

BD01D263
If machine is equipped with windshield washers,

connect front (1) and rear (2) windshield washer
nozzle hoses to supply hoses following tags installed
during removal. Install two new tie straps. Remove
and discard tags.
Bur 6-42700
Issued 8-01
Printed in U.S.A.
Copyright
9007-18
STEP 66
STEP 69
Open hood.
STEP 70
BD00M031
Check that hydraulic oil drain cap is tig ht. Fill

hydraulic reservoir with 68.5 liters (18 gallons) of
MS-1209 Hy-Tran Ultra fluid.
BD01D140
Put battery disconnect switch in ON position. Close

hood.
STEP 67
STEP 71
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.
BD00M031
If machine is equipped with a heater and coolant was

drained, check that coolant drain cap is tight.
STEP 68
If coolant was drained, fill engine coolant system with
a solution of 50% Ethylene Glycol and 50% water.
Cooling system capacity is 34.1 liters (9 gallons).
Install radiator cap. Fill coolant reservoir up to FULL
mark on reservoir.
Bur 6-42700

is removed. To remove radiator cap: let system cool,
radiator cap.
STEP 72
STEP 73
Issued 8-01
Printed in U.S.A.
Copyright
Section
9010
CASE CORPORATION
700 State Street
Bur 6-42710

Printed in U.S.A.
August, 2001
9010
CAB GLASS INSTALLATION
Copyright
9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bur 6-42710
Issued 8-01
Printed in U.S.A.
Copyright
9010-3
PREPARATION FOR GLASS REPLACEMENT

1. Remove all of the damaged glass section and
the silicone sealant from the window frame
2. Remove all the adhesive from the window frame.
3. The window frame recesses must be free of oil
and dust. Clean the frame with rubbing alcohol
with a clean rag. Do not reuse the rag.
5. Clean the new glass section. Apply a 25 mm (1

inch) wide band of glass primer (349-110) to the
black ceramic painted edges of the window.
6. When replacing a front window section, a
silicone forming tool is needed, refer to Figure 2.
Use the template and instructions provided to
make the tool.
4. Apply a 25 mm (1 inch) wide band of metal

primer (349-108) to the window recesses.
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must
be installed within 5 minutes. If the glass is not
installed within the 5 minute period, the adhesive
must be removed and applied again.
1. Apply a 10 mm (3/8 inch) diameter bead of
ad he sive (3 45 -1 35 ) to the p rim ed su rfac e
approximately 12 mm (1/2 inch) from edge.
2. The adhesive may be applied either to the
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
3. For front glass installations install a glass spacer

12 mm (1/2 inch) from each corner on bottom
edge of each glass section, refer to Figure 3.
4. Install the glass. The glass edges must not
contact the metal frame at any point.
5. For front glass installations position the glass to
maintain a uniform 3 mm (1/8 inch) gap between
front and front side glass sections.
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
windows. Use glass cleaning primer.
2. Apply masking tape to the inside edge of each
glass section next to the gap.
3. Apply the polyester tape on top of the masking
tape across the inside side gap. Do not push the
tape into the gap.
4. Apply masking tape to the outside edge of each
glass section. Align the edge of the tape with
edge of glass on both sections.
5. The tape must be smooth to get the best result
when using the silicone forming tool.
Bur 6-42710
6. Fill the joint with the clear silicone sealant

(114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
glass sections. The sealant must extend at least
1.5 mm (1/16 inch) above the outside surface of
the glass section for the length of the gap. Be
sure the sealant fills against the adhesive at each
end of the joint.
7. Remove the polyester tape from the inside joint.
8. Remove the extra silicone from the outside joint
by carefully sliding the forming tool down the
length of the joint. The tool must remain in
contact with th e glass sectio ns d uring this
process. Refer to Figure 2 for forming tool
template.
Issued 8-01
Printed in U.S.A.
Copyright
9010-4
9. Remove all the silicone from the forming tool

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.
13. Remove the inside joint masking tape.
4
498L93
1. FRONT RH SIDE GLASS

2. FRONT CENTER GLASS
3. SILICONE BEFORE
SMOOTHING
4. SILICONE AFTER
SMOOTHING
FIGURE 1. SILICONE APPLICATION
NOTE: Make the forming tool from 10 mm (3/8 inch)

plexiglass, or wood. Sand all radius and edges
smooth.
14. If two or more glass sections are being replaced,

use the procedure on the second joint.
15. Apply the gray silicone sealant above the front
center, front side or rear windows for additional
leak protection.
16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
each front side window replaced, refer to Figure
3.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.
6 MM
(1/2 INCH) R
120
120
4 MM
(3/16 INCH) R
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE

Bur 6-42710
Issued 8-01
Printed in U.S.A.
Copyright
9010-5
2
1
3
4
6
2
497L93
1. SIDE GLASS ADHESIVE

2. CENTER GLASS ADHESIVE
4. RIGHT HAND SIDE GLASS SPACER LOCATIONS

5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS
CENTER GLASS
FIGURE 3 SILICONE APPLICATION
NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
Bur 6-42710
Issued 8-01
Printed in U.S.A.
Copyright
9010-6
NOTES
Bur 6-42710
Issued 8-01
Printed in U.S.A.
Copyright
FUSE X
FUSE Y
FUSE Z
FUSE A'
FUSE B'
FUSE C'
FUSE D'
FUSE E'
FUSE F'
FUSE G'
SHEET 4 - 42F (99)

SHEET 4 - 34F (114)
SHEET 4 - 32F (144)
SHEET 4 - 1F CAB FRONT
SHEET 3 - 13F CAB PEDESTAL
SHEET 4 - 21F CAB REAR
SHEET 5 - 244F (68)
1_NC R-62
245F
7.5A
BEACON
NONE
FRONT FLOOD LAMPS & ILLUMINATION
REAR FLOOD LAMPS
HIGH BEAM LEFT
HIGH BEAM RIGHT
LOW BEAM LEFT
LOW BEAM RIGHT
TAIL LAMPS LEFT
TAIL LAMPS RIGHT
19X Or-1.0
19Z Or-1.0
18A Or-2.0
18B_A Or-0.8
18C_A Or-0.8
18C_B Or-0.8
18D_A Or-0.8
18E_A Or-0.8
18F_D Or-0.8
18F_E Or-0.8
18G_F Or-0.8
18G_G Or-0.8
X2
X1
Y2
Y1
Z2
Z1
A2'
A1'
B2'
B1'
C2'
C1'
D2'
D1'
E2'
FUSE L
FUSE M
FUSE N
FUSE P
FUSE R
FUSE S
FUSE T
FUSE U
FUSE V
FUSE W
10A
10A
5A
5A
5A
5A
5A
5A
1_U R-3.0
SHEET 4 - 59F (115)
41L_A K-2.0
SHEET 4 - 59F (115)
F2'
E1'
F1 '
G2'
G1'
41T_A K-1.0
SHEET 4 - 32F (114)
18F
19L Or-1.0
L2
19M_A Or-0.8
M2
19N_A Or-1.0
N2
19N_B Or-1.0
P2
19P_A Or-1.0
R2
19R_F Or-0.8
S2
19S Or-0.8
T2
19T_A Or-0.8
U2
19T_B Or-0.8
V2
19U_A Or-1.0
W2
19U_B Or-1.0
19V Or-0.8
18F
19W Or-1.0
SHEET 5 - 1F CAB FRONT CHASSIS

SHEET 5 - 28M (82)
41H K-2.0
SHEET 5 - 40F (69)

SHEET 2 - 19F (26)
SHEET 2 - 19F (26)
SHEET 4 - 23F CAB ROOF
SHEET 5 - 51F (80)
18F
7.5A
7.5A
10A
7.5A
7.5A
5A
7.5A
7.5A
7.5A
15A
RADIO
SECONDARY STEERING
SEAT COMPRESSOR
COUPLER/FAN REVERSER
SECONDARY STEERING
INSTRUMENT CLUSTER
TRANSMISSION CONTROL
DOME LAMP AND HORN
VOLTMETER
CIGARETTE LIGHTER
12P_A Or-1.0
12P_B Or-1.0
12K_A Or-1.0
12P_B Or-1.0
13P_B Or-1.0
L1
M1
N1
P1
R1
13D Or-1.0
S1
T1
1_Q R-1.0
13V Or-1.0
1_R R-3.0
U1
V1
W1
18F
1_B R-13.0
1_A R-1.0
156
FUSE A
FUSE B
FUSE C
FUSE D
FUSE E
FUSE F
FUSE G
FUSE H
FUSE J
FUSE K
241F
1_NB R-62
CRANKING
MOTOR
B+ STUD
14 LG-1.0
195
154
149
153
12V_B R-5.0
SHEET 6 - 258F (92)

194
D+
19N_B Or-1.0
1_E R-19
260M
A 5
12
A 11
10
18
87
6
86
85
190
1_C R-8.0
135
227F
0_GB Bk-2.0
250F
CAB B+
JUNCTION
BLOCK
14
13
18F
18F
SHEET 6 - 259F (91)
19L_B Or-1.0
SHEET 6 - 256F (92)
19L_A Or-1.0
SHEET 6 - 109M (96)
SHEET 2 - TO SPL_D15
SHEET 2 - 35F (35)
SHEET 5 SPL_D24
SHEET 3 - 56F (51)
SHEET 3 - 55F (52)
270F
1_X R-1.0
SHEET 6 - 269 RADIO

MEMORY FUSE
226F
238F
1_NA R-62
224F
228F
SHEET 4 - 59F (115)
1_H R-3.0
SPL_D16
1_K R-3.0
POS
15
18F
1_R R-3.0
1_NA R-62
239F
NEG
RELAY BOX
JUNCTION
BLOCK
21C_B W-1.0
132
225F
196
1_F R-8.0
191
155
240F
1_NB R-62
POS
193
18F
19W_A Or-3.0
30
A 16
249M 17
18F
18F
1 R-13.0
246M
6
30
87
87a
85
86
1_G R-3.0
1_J R-3.0
30
87
SHEET 3 - 104 (39)
0_V Bk-1.0
SHEET 3 - 171 (40)
0_G Bk-1.0
SHEET 5 - 2 (76)
0_F Bk-1.0
SHEET 5 - 3 (78)
0_W Bk-1.0
SHEET 3 - 136 (41)
0_X Bk-1.0
SHEET 5 - 158 (56)
7
86
85
172
173
0_GC Bk-2.0
13M Or-1.0
139F ENGINE HARNESS
139M DISCONNECT HARNESS
A B
A B
0_J Bk-1.0
SHEET 4 - 128F REAR HOOD
0_D Bk-2.0
SHEET 4 - SPL_E4
A B C
A B C
28T_A W-1.0
236F
235F
0_Q Bk-1.0
SHEET 3 - 87 (53)
0_BJ Bk-1.0
SHEET 5 - 265F AIR CONDITIONING DIODE MODULE
75 OHMS
RESISTOR
216F
19R_A Or-0.8
13C Or-1.0
14 LG-1.0
0_BG Bk-1.0
0_BF Bk-1.0
0_BH Bk-1.0
0_BG Bk-1.0
ENGINE HARNESS
152
SHEET 3 - 138 (43)
0_BA Bk-1.0
150
SECONDARY STEERING
MODULE HARNESS
0_BE Bk-1.0
SHEET 3 - 117 (44)
SPL_B1
15 15
9 9
11 11
1 1
2 2
30 30
22M 22F
0_DL Bk-0.8
0_DAB Bk-0.8
REAR CHASSIS
GROUND WELD
STUD ()
FRONT ENGINE
BLOCK GROUND
STUD ()
0_NA Bk-62
0_NB Bk-62
234F
233F
232F
1
REAR CHASSIS
HARNESS
REAR CHASSIS
GROUND WELD
STUD ()
0_Y Bk-13.0
167
SHEET 5 - SPL_A1
SHEET 5 - 90M (66)
0_CE Bk-1.0
SHEET 5 - SPL_A2
2
CAB GROUND
WELD STUD ()
BRAIDED_STRAP_2
BRAIDED STRAP
CAB STUD
1
CAB GROUND
WELD STUD ()
LOWER PEDESTAL
GROUND
SCREW ()
206F
REAR CHASSIS
GROUND WELD
STUD ()
REAR CHASSIS
GROUND WELD
STUD ()
0_Y Bk-13.0
161
176
UPPER PEDESTAL
GROUND
SCREW ()
SHEET 6 - 254F (92)
0_AJ Bk-2.0
0_AK Bk-1.0
145
REAR
CHASSIS
HARNESS
0_RA Bk-5.0
FRONT
CHASSIS
HARNESS
220F
221F
251F
CONVERTER
HARNESS
SHEET 5 - 242F (68)
0_ND Bk-62
SHEET 6 - 253F (93)
0_DAX Bk-0.8
SHEET 5 - 140M DIODE MODULE
0_DU Bk-1.0
213F
30
87
87a
85
86
IGNITION SWITCH
CIRCUIT
BREAKER A
12.5 AMP
0_DV Bk-0.8
144
50G_G Bk-0.8
SHEET 2 - SPL_D7
0_DB Bk-0.8
SHEET 3 - 89M (54)
0_DX Bk-0.8
0_DA Bk-0.8
SHEET 4 - 204F (102)
0_DAT Bk-0.8
SHEET 4 - SPL_D14
1
2
3
4
5
6
63M TIME DELAY MODULE

DELAY POWER-2-WAY
TIME DELAY POWER
TIME DELAY MODULE GROUND
RESET SIGNAL
IGNITION SWITCH POWER
NONE
SHEET 6 - 259F (91)
0_DQ Bk-0.8
SHEET 2 - 19F (26)
0_DP Bk-0.8
SHEET 2 - 19F (26)
0_DAV Bk-0.8
SHEET 2 - 108F (28)
SHEET 3 - 75 (45)
0_RB Bk-3.0
261F
143
H2
H1
J2
J1
K2
K1
13R Or-1.0
18F
AA
SEE NOTE 4
SHEET 5 - 140M DIODE

MODULE
SHEET 3 - 13F CAB
PEDESTAL
30
87
87A
85
86
13P_A Or-1.0
21K_A W-0.8
21C_F W-0.8
14
30
87
87a
85
86
SPL_D21
1A_E R-0.8
1
2
3
4
5
6
30
87
87A
85
86
21C_E W-0.8
0_DH Bk-0.8
0_DJ Bk-0.8
25T_E LU-0.8

MODULE
54F
12
SHEET 4 - SPL_D14
0_DAS Bk-0.8
SHEET 3 - 13F CAB

PEDESTAL
37R_C P-0.8
SPL_D18
SHEET 2 - 19F (26)
13K_F Or-0.8
25T_D LU-0.8
SPL_D22
222F
CIGAR
LIGHTER
HARNESS
223F
13
1A_B R-0.8
5
1
3
2
4
6
BAT
IGN
ST
ACC
69
12K_C Or-0.8
21K W-0.8
13K Or-0.8
1A_A R-0.8
SHEET 5 SPL_D13
0_DJ Bk-0.8
0_S Bk-3.0
19F Or-1.0
47F
63M
18
0_DAC Bk-0.8
SHEET 4 - 24M CAB ROOF
0_DR Bk-1.0
0_DT Bk-1.0
0_PD Bk-1.0
SHEET 6 - 109M (92)
64 64
182
92
62 62
28C_A W-0.8
25T_C LU-0.8
13M 13F
PEDESTAL CAB MAIN
HARNESS HARNESS
28C W-0.8
25T_B LU-0.8
25T_A LU-0.8
12K_B Or-0.8
21K_A W-0.8
56 56
46 46
0_DS Bk-1.0
63 63
52 52
11
1
FRONT CHASSIS
GROUND WELD
STUD ()
0_AH Bk-5.0
SHEET 5 - 35F (75)
0_DAD Bk-1.0
252F
REAR CHASSIS
GROUND WELD
STUD ()
0_DAR Bk-1.0
G1
219F
CAB
HARNESS
243F
REAR
CHASSIS
STUD
218F
23C_A W-0.8
57F
13D Or-1.0
SHEET 5 - 28M (82)
13K_D Or-0.8
13C_B Or-0.8
13C_C Or-0.8
30
87
87A
85
86
58
1A_D R-0.8
0_DY Bk-1.0
F1
G2
217F 217M
SHEET 4 - 211F FLASHER

CIRCUIT BREAKER B
1_L R-3.0
177
CAB
GROUND
JUNCTION
BLOCK ()
E1
F2
13C_D Or-0.8
214F
SHEET 5 - 29M (85)
D1
E2
1_S R-3.0
TRANSMISSION CAB MAIN

HARNESS HARNESS
0_DZ Bk-2.0
C1
D2
13K_C Or-1.0
SPL_D17
SHEET 5 - 1F CAB-FRONT
CHASSIS
13C_D Or-0.8
14_B LG-0.8
0_DAU Bk-0.8
15 15
13K_C Or-1.0
15
23 23
94M 94F
ENGINE TRANSMISSION
HARNESS HARNESS
0_BD Bk-1.0
SHEET 5 - SPL_C1
0_CD Bk-1.0
13C_A Or-1.0
14_A LG-1.0
0_HC Bk-1.0
0_HA Bk-1.0
0_HB Bk-1.0
1 1
5 5
58F
1_T R-3.0
13R Or-1.0
0_DF Bk-0.8
0_DE Bk-0.8
13K_B Or-1.0
13K_A Or-1.0
30
87
87A
85
86
48F
SPL_D25
19R_E Or-0.8
0_BC Bk-1.0
A A
B B
C C
1_M R-3.0
0_BB Bk-2.0
151
30
87
87a
85
86
DIODE
MODULE
215F
1_P R-0.8
13V Or-1.0
0_DG Bk-0.8
0_DH Bk-0.8
13K_E Or-0.8
17
19R_D Or-0.8
268
30
87
87A
85
86
30
87
87a
85
86
262F
HOLD PULL-IN
C2
13P_A Or-1.0
21 21
41.5 ohms
1.1 ohm
at 20C (68F) at 20C (68F)
B1
11 11
65F REAR CHASSIS HARNESS

65M ENGINE HARNESS
28T W-1.0
49F
1 1
A1
B2
12P_A Or-1.0
0_DC Bk-0.8
0_DF Bk-0.8
12K_A Or-1.0
12K_B Or-0.8
REAR CAB
CHASSIS MAIN
HARNESS HARNESS
103
2.2 ohms at 25C (77F)
1
1
30
87
87A
85
86
21M 21F
A A
B B
97
0_U Bk-2.0
AIR CONDITIONING
DIODE HARNESS
28P W-1.0
21C_D W-1.0
1_A R-1.0
opens 133C (55.45.4F)

closes 1.54.5C (34.78.1F)
134
B B
A A
231F 230F
165
16
SPL_G1
A A
21C_C W-1.0
B B
0_GA Bk-2.0
SPL_G2
93M 93F
FUEL AND STARTER REAR
RELAYS HARNESS CHASSIS
HARNESS
21C_A W-1.0
13C Or-1.0
163
164
192
30
87
87a
85
86
A2
18F
10
SHEET 4 - 33F (114)
SHEET 6 - 255F (92)
1_V R-5.0
SHEET 5 - 30F (83)

SHEET 2 - 53F (35)
SHEET 5 - 35F (75)
SHEET 5 SPL_D23
19A_N Or-0.8
19A_P Or-0.8
19B_A Or-0.8
19C_A Or-1.0
19C_D Or-1.0
19D_A Or-1.0
19E Or-1.0
19F Or-1.0
19G Or-2.0
19H Or-1.0
19J_A Or-1.0
19K_A Or-1.0
1A_C R-0.8
13K_G Or-0.8
162
0_E Bk-1.0
1 1
23F W-2.0
133F 133M
FUEL AND STARTER ENGINE
RELAYS HARNESS HARNESS
13M_A Or-1.0
160
SHEET 3 - SPL_E9
13C_E Or-1.0
REAR ENGINE
BLOCK GROUND
STUD()
0_P Bk-1.0
23F_A W-2.0
137
1_N R-3.0
0_NC Bk-62
237F
19E Or-1.0
28P_A W-0.8
0_DG Bk-0.8
0_DC Bk-0.8
28C_A W-0.8
30
87
87A
85
86
52F
1_D R-2.0
NEG
7.5A
5A
5A
5A
10A
5A
15A
5A
10A
10A
FLASHER MODULE
RIDE AND PILOT CONTROL
PARKING BRAKE
ETHER START
ENGINE SHUTDOWN
BLOWER SWITCH
BACKUP ALARM
FRONT WIPER & WASHER MOTOR
REAR WIPER & WASHER MOTOR
SHEET 2 - 70 (27)
5
CONVERTER
HARNESS
247F
SHEET 1 - POWER CONTROL AND DISTRIBUTION

COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Batteries
Alternator
Starter Motor
Starting Relay
Fuel Relay
Ether Start Relay - Number 6
Ether Start Switch
Neutral Start Relay - Number 8
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Ignition Switch
Ignition Relay - Number 1
Accessory Relay - Number 3
Voltmeter Relay - Number 12
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
Torque Converter Output Temperature Sender
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Transmission Solenoid Valve and Temperature Sensors

Transmission Kick-down Switch
Declutch Switch
FNR Switch
Backup Alarm Relay - Number 7
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
2
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y
Instrument Cluster
Pilot Control Relay - Number 10
Parking Brake Relay - Number 9
Fan Reversing Switch (Option)
Fan Reversing Solenoid (Option)
Relay Socket - Number 11
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.
68.
68A.
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW
SHOWS POWER - MASTER DISCONNECT SWITCH IN ON POSITION

SHOWS POWER - KEY SWITCH IN ON POSITION
21C_C W-1.0
0_GA Bk-2.0
3
2
1.
2.
3.
4.
5.
SPLICE IDENTIFICATION
CIRCUIT CROSSING (NOT CONNECTED)
CIRCUIT CONNECTED
WIRE IDENTIFICATION
MALE CONNECTOR
10
A A
B B
1 1
SHEET 6 - 253F (54)
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
FEMALE CONNECTOR
CONNECTOR IDENTIFICATION
HARNESS IDENTIFICATION
INDICATES PARTIAL CONNECTOR
CIRCUIT IDENTIFICATION
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
Detent Switch
Bucket Control Valve Electromagnetic Detents
Rollback Pressure Switch (Option)
Float Solenoid
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.

Ride Control Switch
Ride Control Relay - Number 4
Front Wiper Motor
Rear Wiper Motor
Horn Relay - Number 5
ACTUATOR SYMBOLS
5 6
SPL_G2
=
=
=
=
=
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
2. WIRE COLOR SYMBOL
3. WIRE SIZE
36. Backup Alarm Disable Switch

(TUV road approved machines only)
37. Backup Alarm
38. Brake Warning Pressure Switch
39. Coolant Level Sender
40. Fuel Level Sender
41. Hydraulic Oil Temperature Sender
42. Hydraulic Filter Restriction Switch
43. Engine Coolant Temperature Sender
44. Air Filter Restriction Switch
45. Program Reset Switch
46. Parking Brake Switch
11
15
SCHEMATIC SHEET NUMBER FOR CIRCUIT CONTINUATION

CONNECTION POINT ON SCHEMATIC
COMPONENT NUMBER (IF ASSIGNED)
COMPONENT NUMBER
INDICATES INTERNALLY GROUNDED COMPONENT
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
LIGHT EMITTING DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
CONTACT SYMBOLS
1
P
3
Horn
Seat Compressor and Switch (Option)
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch Lockout Relay - Number 14
Compressor Clutch
Power Converter - 24 volts to 12 volts (Option)
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.

Radio Power Converter - 24 volts to 12 volts (Option)
Left Speaker (Option)
Beacon Switch
Rotating Beacon
Brake Lamps Relay - Number 15
Hazard Switch
Turn Signal, Hi/Low Beam, and Horn Switch
FUSE AND CIRCUIT BREAKER

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
Flasher Module
Left-Hand Rear Combination Lamp
Right-Hand Rear Combination Lamp
Left-Hand Front Combination Lamp
Right-Hand Front Combination Lamp
Left-Hand Rear Work Lamp
Right-Hand Rear Work Lamp
Left-Hand Front Work Lamp
Right-Hand Front Work Lamp
High/Low Beam Relay - Number 13
License Plate Lamp
117. Dome Lamp

118. Courtesy Lamp
NOTES
1. 209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
2. Resistors part of ground wire assembly.
3. 64M and 64F connected for North American machines, opposite side steady ON.
64M and 64F disconnected for European machines, opposite side OFF.
4. 217F and 217M disconnected when engine shutdown relay special feature is installed.
ELECTRICAL SCHEMATIC
521D Z-BAR, 521D XR, and 521D XT WHEEL LOADER
Additional copies of this Hydraulic and Electrical Schematic can be ordered through
Technical Publications Distribution System. The Part Number is 6-40841
BC02D077
Copyright
FUSE X
FUSE Y
FUSE Z
FUSE A'
FUSE B'
FUSE C'
FUSE D'
FUSE E'
FUSE F'
FUSE G'
241F
1_NB R-62
14 LG-1.0
CRANKING
MOTOR
B+ STUD
30 R-1.0
154
5 4 3 2 1
194
5 4 3 2 1
15
153
19X Or-1.0
19Z Or-1.0
18A Or-2.0
18B_A Or-0.8
18C_A Or-0.8
18C_B Or-0.8
18D_A Or-0.8
18E_A Or-0.8
18F_D Or-0.8
18F_E Or-0.8
18G_F Or-0.8
18G_G Or-0.8
X2
X1
Y2
Y1
Z2
Z1
A2'
A1'
B2'
B1'
C2'
C1'
D2'
D1'
E2'
FUSE L
FUSE M
FUSE N
FUSE P
FUSE R
FUSE S
FUSE T
FUSE U
FUSE V
FUSE W
10A
10A
5A
5A
5A
5A
5A
5A
1_U R-3.0
SHEET 4 - 59F (115)
41L_A K-2.0
SHEET 4 - 59F (115)
F2'
E1'
F1 '
G2'
G1'
41T_A K-1.0
SHEET 4 - 32F (114)
18F
19L Or-1.0
L2
19M_A Or-0.8
M2
19N_A Or-1.0
N2
19N_B Or-1.0
P2
19P_A Or-1.0
R2
19R_F Or-0.8
S2
19S Or-0.8
T2
19T_A Or-0.8
U2
19T_B Or-0.8
V2
19U_A Or-1.0
W2
19U_B Or-1.0
19V Or-0.8
18F
19W Or-1.0

SHEET 5 - 28M (82)
41H K-2.0
SHEET 5 - 40F (69)

SHEET 2 - 19F (26)
SHEET 2 - 19F (26)
SHEET 5 - 51F (80)
18F
1 Y_C R-2.0
0_BL BK-2.0
A A
B B
1 Y_B R-2.0
0_BK BK-2.0
A A
B B
NOTE 5
12V_B R-5.0
SHEET 6 - 258F (92)
246M
1_B R-13.0
1_Y R-8.0
30
289
87
86
+ 3C (55.4 _
+ 5.4F)
OPENS AT 13_
+ 4.5C (34.7 _
+ 8.1F)
CLOSES AT 1.5_
85
193
40A
283
NOTE 7
191
1_C R-8.0
135
21C_D W-1.0
132
0_UB Bk-2.0
1 A
30
87
0_ BK Bk-2.0
192
162
0_V Bk-1.0
SHEET 3 - 171 (40)
0_G Bk-1.0
SHEET 5 - 2 (76)
0_F Bk-1.0
SHEET 5 - 3 (78)
0_W Bk-1.0
SHEET 3 - 136 (41)
189
10
17
A 16
15
14
13
18F
18F
18F
249M
18F
0_D Bk-2.0
SHEET 4 - SPL_E4
A B
A B
163
164
282
150A
0_BC Bk-1.0
AIR CONDITIONING
DIODE HARNESS
0_BJ Bk-1.0
SHEET 5 - 265F AIR CONDITIONING DIODE MODULE
236F
235F
SPL_B1
0_BE Bk-1.0
SHEET 4 - 59F (115)
1_H R-3.0
SPL_D16
SHEET 5 - 30F (83)

SHEET 2 - 53F (35)
SHEET 5 - 35F (75)
SHEET 5 SPL_D23
1_G R-3.0
1_V R-5.0
30
87
87a
85
86
SHEET 6 - 255F (92)
16
19 19
28GC_A W-0.8
20 20
1 1
11 11
30
87
87A
85
86
12P_A Or-1.0
0_DC Bk-0.8
0_DF Bk-0.8
12K_A Or-1.0
12K_B Or-0.8
49F
21 21
22 22
23 23
19R_E Or-0.8
A A
B B
CC
30
87
87a
85
86
SPL_D25
14_C LG-0.8
2.26-2.76K OHMS
AT 20C (68F)
15 15
9 9
11 11
1 1
2 2
30 30
48F
1_M R-3.0
SHEET 5 - 1F CAB-FRONT
CHASSIS
94M 94F
22M 22F
0_DL Bk-0.8
0_DAB Bk-0.8
REAR CHASSIS
GROUND WELD
STUD (-)
0_Y Bk-13.0
BRAIDED_STRAP_2
BRAIDED STRAP
CAB STUD
1
CAB GROUND
WELD STUD (-)
LOWER PEDESTAL
GROUND
SCREW (-)
206F
0_AK Bk-1.0
SHEET 6 - 254F (92)
219F
FRONT
CHASSIS
HARNESS
145
220F
CAB
HARNESS
0_RA Bk-5.0
221F
251F
CONVERTER
HARNESS
SHEET 5 - 242F (68)
0_ND Bk-62
243F
REAR
CHASSIS
STUD
SHEET 6 - 253F (93)
SHEET 5 - 140M DIODE MODULE
0_DU Bk-1.0
REAR CHASSIS
GROUND WELD
STUD (-)
FRONT CHASSIS
GROUND WELD
STUD (-)
0_AH Bk-5.0
213F
30
87
87a
85
86
IGNITION SWITCH
CIRCUIT
BREAKER A
12.5 AMP
144
222F
CIGAR
LIGHTER
HARNESS
0_S Bk-3.0
261F
143
SHEET 5 - 28M (82)
0_DAR Bk-1.0
SHEET 5 - 35F (75)
50G_G Bk-0.8
SHEET 2 - SPL_D7
0_DB Bk-0.8
SHEET 3 - 89M (54)
1
2
3
4
5
6
63M TIME DELAY MODULE

DELAY POWER-2-WAY
TIME DELAY POWER
TIME DELAY MODULE GROUND
RESET SIGNAL
IGNITION SWITCH POWER
NONE
223F
C1
D2
D1
E2
E1
F2
F1
G2
G1
H2
H1
J2
J1
K2
K1
13R Or-1.0
18F
SHEET 4 - 202F (102)
23C_A W-0.8
19F Or-1.0
AA
SEE NOTE 4

MODULE
SHEET 3 - 13F CAB
PEDESTAL
30
87
87A
85
86
13P_A Or-1.0
21K_A W-0.8
21C_F W-0.8
21C_G W-0.8
21C_E W-0.8
0_DH Bk-0.8
0_DJ Bk-0.8
25T_E LU-0.8
14
30
87
87a
85
86
SPL_D21
1A_E R-0.8
1
2
3
4
5
6
30
87
87A
85
86
54F
SHEET 3 - 13F CAB
PEDESTAL
37R_C P-0.8
SPL_D18
12
SHEET 4 - SPL_D14
0_DAS Bk-0.8

MODULE
SHEET 2 - 19F (26)
13K_F Or-0.8
25T_D LU-0.8
SPL_D22
0_DBA Bk-0.8
0_DX Bk-0.8
0_DA Bk-0.8
SHEET 5 - 203F (89)
0_DAT Bk-0.8
SHEET 4 - SPL_D14
0_DQ Bk-0.8
SHEET 2 - 19F (26)
0_DP Bk-0.8
SHEET 2 - 19F (26)
0_DAV Bk-0.8
SHEET 2 - 108F (28)
SHEET 3 - 75 (45)
5
1
3
2
4
6
BAT
IGN
13
ST
ACC
69
13M 13F
1 2 3 4 5 6
A B C D E F
1
0_DS Bk-1.0
0_DR Bk-1.0
0_DT Bk-1.0
11C
SHEET 6 - 109M (92)
247F
202
12K_C Or-0.8
21K W-0.8
13K Or-0.8
1A_A R-0.8
97
SHEET 5 SPL_D13
0_DAC Bk-0.8
0_PD Bk-1.0
1A_B R-0.8
PREHEATER
LIGHT
5
CONVERTER
HARNESS
30
87
87A
85
86
47F
63M
18
0_DJ Bk-0.8
0_RB Bk-3.0
SHEET 6 - 259F (91)
0_DY Bk-1.0
0_DAD Bk-1.0
252F
0_DAX Bk-0.8
0_DV Bk-0.8
0_AJ Bk-2.0
SHEET 5 - SPL_A2
2
REAR CHASSIS
GROUND WELD
STUD (-)
167
SHEET 5 - SPL_A1
176
CAB GROUND
WELD STUD (-)
218F
REAR
CHASSIS
HARNESS
0_Y Bk-13.0
161
SHEET 5 - 90M (66)
0_CE Bk-1.0
REAR CHASSIS
GROUND WELD
STUD (-)
CAB
GROUND
JUNCTION
BLOCK ()
234F
REAR CHASSIS
HARNESS
C2
13P_A Or-1.0
13C_D Or-0.8
214F
0_DZ Bk-2.0
13K_D Or-0.8
13C_B Or-0.8
13C_C Or-0.8
58
1_L R-3.0

HARNESS HARNESS
0_NB Bk-62
UPPER PEDESTAL
GROUND
SCREW (-)
30
87
87a
85
86
SPL_D17
SHEET 5 - 29M (85)
13K_C Or-1.0
57F
23 23
233F
232F
B1
217F 217M
SHEET 4 - 211F FLASHER

CIRCUIT BREAKER B
13D Or-1.0
0_NA Bk-62
A1
B2
13K_C Or-1.0
15
13C_D Or-0.8
14_B LG-0.8
0_DAU Bk-0.8
15 15
58F
1_T R-3.0
13R Or-1.0
0_DF Bk-0.8
0_DE Bk-0.8
13K_B Or-1.0
13K_A Or-1.0
30
87
87A
85
86
1_S R-3.0
13C_A Or-1.0
14_A LG-1.0
0_HC Bk-1.0
0_HA Bk-1.0
0_HB Bk-1.0
1 1
5 5
A A
B B
C C
DIODE
MODULE
19R_A Or-0.8
1_P R-0.8
13V Or-1.0
0_DG Bk-0.8
0_DH Bk-0.8
13K_E Or-0.8
17
19R_D Or-0.8
216F
30
87
87A
85
86
30
87
87a
85
86
1A_D R-0.8
FRONT ENGINE
BLOCK GROUND
STUD (-)
A2
SHEET 4 - 204F (102)
21C_E W-0.8
1_P R-0.8
31T Y-0.8
177
REAR CHASSIS
GROUND WELD
STUD (-)
19A_N Or-0.8
19A_P Or-0.8
19B_A Or-0.8
19C_A Or-1.0
19C_D Or-1.0
19D_A Or-1.0
19E Or-1.0
19F Or-1.0
19G Or-2.0
19H Or-1.0
19J_A Or-1.0
19K_A Or-1.0
SHEET 4 - 33F (114)
1_N R-3.0
215F
ENGINE TRANSMISSION
HARNESS HARNESS
0_BD Bk-1.0
SHEET 5 - SPL_C1
0_CD Bk-1.0
SHEET 2 - TO SPL_D15
SHEET 2 - 35F (35)
SHEET 5 SPL_D24
SHEET 3 - 56F (51)
SHEET 3 - 55F (52)
1_J R-3.0
75 OHMS
RESISTOR
0_BG Bk-1.0
SHEET 3 - 117 (44)
SHEET 6 - 109M (96)
262F
152
SECONDARY STEERING
MODULE HARNESS
228F
13C Or-1.0
14 LG-1.0
0_BG Bk-1.0
0_BF Bk-1.0
0_BH Bk-1.0
0_BA Bk-1.0
19L_A Or-1.0
REAR CAB
CHASSIS MAIN
HARNESS HARNESS
290
150
SHEET 6 - 256F (92)
SHEET 6 - 269 RADIO

MEMORY FUSE
226F
133M
0_BC Bk-1.0
SHEET 3 - 138 (43)
19L_B Or-1.0
21M 21F
268
ENGINE HARNESS
1_X R-1.0
7.5A
5A
5A
5A
5A
5A
15A
5A
10A
10A
FLASHER MODULE
RIDE AND PILOT CONTROL
PARKING BRAKE
GRID HEATER CONTROLLER (NOTE 7)
ENGINE SHUTDOWN
BLOWER SWITCH
BACKUP ALARM
FRONT WIPER & WASHER MOTOR
REAR WIPER & WASHER MOTOR
SHEET 6 - 259F (91)
26 26
SHEET 3 - 87 (53)
224F
0_NC Bk-62
237F
11B
0_Q Bk-1.0
CAB B+
JUNCTION
BLOCK
21C_D W-1.0
1_A R-1.0
31T_A Y-1.0
1
1
12.7 OHMS
AT 20C (68F)
270F
SHEET 5 - 244F (68)
0_U Bk-2.0
165
18F
1_NC R-62
139F ENGINE HARNESS

139M DISCONNECT HARNESS
231F 230F
1_R R-3.0
250F
13M Or-1.0
SPL_B2
NOTE 7
SHEET 4 - 128F REAR HOOD
FUSE A
FUSE B
FUSE C
FUSE D
FUSE E
FUSE F
FUSE G
FUSE H
FUSE J
FUSE K
18F
28GC_B W-1.0
0_UA Bk-2.0
SPL_G1
279M
276M 276F
RELAY
HARNESS
REAR
NOTE 7
CHASSIS HARNESS
13C Or-1.0
0_J Bk-1.0
18F
18
227F
238F
1_NA R-62
NEG
A A
B B
0_UC Bk-2.0
85 1
SHEET 5 - 158 (56)
W1
260M
1_K R-3.0
POS
28GC_C W-1.0
86 2
0_X Bk-1.0
V1
A 11
225F
1_DA R-19
13M_A Or-1.0
160
286
NOTE 7
13C_E Or-1.0
REAR ENGINE
BLOCK GROUND
STUD()
190
RELAY BOX 284
JUNCTION
BLOCK
137
11
SHEET 3 - 104 (39)
11A
285
195
245F
155
1_NA R-62
239F
NEG
156
278
1Z R-19
291
SHEET 3 - SPL_E9
1_Q R-1.0
13V Or-1.0
1_R R-3.0
U1
A 5
19W_A Or-3.0
1_E R-62
240F
1_NB R-62
POS
100 A AT 22V
0_ BL Bk-2.0
0_E Bk-1.0
T1
12
18F
1_F R-8.0
NOTE 6
0_P Bk-1.0
13D Or-1.0
S1
1_A R-1.0
151
P1
R1
19N_B Or-1.0
10
287
1.9 OHMS AT 20C (68F)
281
0_ BM Bk-1.0
N1
1Y_A R-8.0
ENGINE HARNESS
M1
288
NOTE 7
31C_G OR-1.0
1
2
12P_A Or-1.0
12P_B Or-1.0
12K_A Or-1.0
12P_B Or-1.0
13P_B Or-1.0
L1
1.9 OHMS AT 20C (68F)
280
A A
B B
7.5A
7.5A
10A
7.5A
7.5A
5A
7.5A
7.5A
7.5A
15A
RADIO
SECONDARY STEERING
SEAT COMPRESSOR
COUPLER/FAN REVERSER
SECONDARY STEERING
INSTRUMENT CLUSTER
DOME LAMP AND HORN
VOLTMETER
CIGARETTE LIGHTER
182
92
1
2
3
4
5
6
7
8
9
10
1A_C R-0.8
13K_G Or-0.8
RELAY ENGINE
HARNESS HARNESS
277M 277F
1
1
1 Y_E R-2.0
2
2
1 Y_D R-2.0
3
3
31U W-1.0
31U_X W-1.0
4
4
13C_H OR-1.0
30
87
87A
85
86
SHEET 4 - 42F (99)

SHEET 4 - 34F (114)
SHEET 4 - 32F (144)
L
BS
W G DFM
B- B1+
1 R-13.0
30
87
87a
85
86
149
7.5A
BEACON
NONE
FRONT FLOOD LAMPS & ILLUMINATION
REAR FLOOD LAMPS
HIGH BEAM LEFT
HIGH BEAM RIGHT
LOW BEAM LEFT
LOW BEAM RIGHT
TAIL LAMPS LEFT
TAIL LAMPS RIGHT
12K_B Or-0.8
21K_A W-0.8
63 63
64 64
56 56
62 62
28C W-0.8
52 52
25T_C LU-0.8
46 46
25T_B LU-0.8
25T_A LU-0.8
SHEET 2 - 70 (27)
GRID HEATER CONTROLLER

INDICATOR LIGHT
NONE
FEED BACK OF GH
ALTERNATOR D+
CRANKING POWER
GRID HEATER ON SIGNAL
SWITCHED POWER
GROUND
NONE
TEMP SENDER SIGNAL
18L_D Bk-0.8
31Y_B Y-0.8
18L_C Or-0.8
0_DBA Bk-0.8
PEDESTAL CAB MAIN

HARNESS HARNESS
201
1
2
3
4
5
6
7
8
9
10
9 9
11 11
28GP W-1.0
14_C LG-0.8
21C_G W-0.8
28GC W-0.8
19E Or-1.0
0_DBB Bk-0.8
SPL_D26
SHEET 1 - POWER CONTROL AND DISTRIBUTION

COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
11A.
Batteries
Alternator
Starter Motor
Starting Relay
Fuel Filter Heater Relay - Number 16
Second Fuel Filter Heater
Grid Heater Relay - Number 15 (Option)
11B.
11C.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

Declutch Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y
Program Reset Switch

Instrument Cluster
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
1. SPLICE IDENTIFICATION
2. CIRCUIT CROSSING (NOT
CONNECTED)
3. CIRCUIT CONNECTED
4. WIRE IDENTIFICATION
10
A A
B B
1 1
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
SHEET 6 - 253F (54)
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
57.
58.
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.

Detent Switch
Float Solenoid
ACTUATOR SYMBOLS
5 6
SPL_G2
2
=
=
=
=
=
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE
34. FNR Switch

35. Backup Alarm Relay - Number 7
37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
68.
68A.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.

Ride Control Switch
Front Wiper Motor
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
Rear Wiper Motor

Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
CONTACT SYMBOLS
1
P
3
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.

Beacon Switch
Rotating Beacon
103. Hazard Switch

104. Turn Signal, Hi/Low Beam, and Horn
Switch
105. Flasher Module
106. Left-Hand Rear Combination Lamp
107. Right-Hand Rear Combination Lamp
108. Left-Hand Front Combination Lamp
109. Right-Hand Front Combination Lamp
110. Left-Hand Rear Work Lamp
111. Right-Hand Rear Work Lamp
112. Left-Hand Front Work Lamp
113. Right-Hand Front Work Lamp
114. Five Position Rotary Lamp

Switch
115. High/Low Beam Relay Number 13
116. License Plate Lamp
117. Dome Lamp
118. Courtesy Lamp
NOTES
1.
2.
3.
4.
5.
6.
7.
209M and 209F disconnected when backup alarm disable switch is installed (TUV road approved machines only).
Resistors part of ground wire assembly.
64M and 64F connected for North American machines, opposite side steady ON. 64M and 64F disconnected for European machines, opposite side OFF.
217F and 217M disconnected when engine shutdown relay special feature is installed.
Used only on 621D.
On 521D connector 289 connected to fuel filter heater switch; on 621D connector 291 connected.
Used only when grid heater option installed.
ELECTRICAL SCHEMATIC P.I.N. JEE0135501AND ABOVE

521D Z-BAR, 521D XR, and 521D XT WHEEL LOADERS
Additional copies of this Hydraulic and Electrical Schematic can be ordered throughTechnical Publications Distribution System. The Part Number is 6-49280
BC02M033
Copyright
33
Used in place of
transmission enable switch
before Serial Number JEE0133334
33
199F
P/N 409726A1
JOYSTICK CONTROLLER
5
6
1
2
4
3
Or-0.8
34
Used in place of FNR switch

before Serial Number JEE0133334
SINGLE AXIS CONTROLLER
34
199F
N
Y
K
P
N
F
5
6
1
2
4
3
7
8
5
4
34
6
1
3
2
SHEET 5 - SPL_D13
SHEET 4 - 42F (99)
SHEET 4 - SPL_D8
SHEET 4 - 42F (99)
32J_C Y-0.8
32J_B Y-0.8
26E LU-0.8
19A_D Or-0.8
19A_E Or-0.8
36
32J_A Y-0.8
19A_F Or-0.8
7
8
5
4
9
6
1
10
3
2
5
6
1
2
4
3
19A_B Or-0.8
26J LU-0.8
26F_A LU-0.8
26R_A LU-0.8
32J_B Y-0.8
5
6
1
2
4
3
102 TRANSMISSION CONTROL

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TRANSMISSION SOLENOID VALVE Y1

OUTPUT SWITCHED POWER VPSI
VALVE BODY TEMPERATURE SIGNAL
VALVE BODY TEMPERATURE RETURN
NONE
NONE
NONE
NONE
NONE
NONE
NONE
25S_A LU-0.8
CLUTCH
NUMBER
K4
KR
K1
K3
KV
K2
19F
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
25K LU-0.8
25L LU-0.8
25M LU-0.8
25N LU-0.8
25P LU-0.8
25J LU-0.8
25S LU-0.8
36T P-0.8
36R_C P-0.8
25K LU-0.8
25L LU-0.8
25M LU-0.8
25N LU-0.8
25P LU-0.8
25J LU-0.8
25S LU-0.8
36T P-0.8
32F Y-1.0
0_HE Bk-1.0
25D LU-1.0
19A Or-1.0
36R_A P-1.0
36G P-1.0
MODULATED AND CURRENT CONTROLLED 102
11
22
510 OHMS 31
16 16
17 17
18 18
19 19
20 20
21 21
22 22
5 5
31 31
28 28
10 10
29 29
24 24
12 12
13 13
14 14
7 7
11 11
9 9
8 8
25A W-0.8
0_HD Bk-1.0
25C W-0.8
25B W-0.8
32F Y-1.0
36R_B P-1.0
25K_A LU-0.8
25L_A LU-0.8
25M_A LU-0.8
25N_A LU-0.8
25P_A LU-0.8
25J_A LU-0.8
56
10
32
55
9
51
39
17
4
62
36T_A P-0.8
32F_A Y-0.8
0_DN Bk-0.8
25D_A LU-0.8
19A_M Or-0.8
46
49
19
3
42
41
36R_E P-0.8
36G_A P-1.0
25A_A LU-0.8
0_DM Bk-0.8
25C_A LU-0.8
25B_A LU-0.8
19F TECM
VALVE BODY TEMPERATURE SENDER
TRANSMISSION FILTER MAINTENANCE SWITCH
OUTPUT SPEED SENSOR GROUND
OUTPUT SPEED SIGNAL
TEMPERATURE/FILTER RETURN
ENGINE SPEED SIGNAL
SPEED SENSOR GROUND
INTERMEDIATE SPEED
TURBINE SPEED SIGNAL
56
10
32
55
9
51
39
17
4
62
46
49
19
3
42
41
22M 22F
HARNESS HARNESS
36R_A P-1.0
SPL_H1
36R_D P-1.0
22
11
36G P-1.0
142
3521 ohms at 20C (68F)
24
19
20
21
22
11
22
33
100
0_HE Bk-1.0
25D LU-1.0
19A Or-1.0
11
22
101
25A W-0.8
0_HF Bk-0.8
11
22
95
0_HG Bk-0.8
25C W-0.8
22
11
96
0_HH Bk-0.8
25B W-0.8
SPL_H2
49_L S-0.8
SHEET 5 - 45F (77)
49_T S-1.0
SHEET 4 - 42F (99)
35A_E Y-0.8
NOTE 1
AA
209M 209F
SHEET 1 - 18F FUSE BLOCK
35A_E Y-0.8
35
35A_D Y-0.8
35C Y-0.8
19A_P Or-0.8
53F
19F
19F TECM
DIAGNOSTIC TECM GROUND
TRANSMISSION ENABLE LAMP SIGNAL
NONE
BACKUP ALARM PULL-DOWN
RIDE CONTROL SWITCHED POWER VPS2
NONE
OUTPUT SWITCHED POWER VPS1
NONE
DIAGNOSTIC SIGNAL
NONE
DIAGNOSTIC SIGNAL
FNR FORWARD SIGNAL
PARKING BRAKE RELAY OUT
TRANSMISSION KICKDOWN SIGNAL
TIME DELAY FUSED POWER
NONE
CONTROLLER AREA NETWORK H
CONTROLLER AREA NETWORK L
NONE
TRANSMISSION AUTO SIGNAL
FNR REVERSE SIGNAL
TRANSMISSION ENABLE SIGNAL
NONE
NONE
NONE
NONE
NONE
NONE
NONE
FORWARD SIGNAL
FNR NEUTRAL SIGNAL
CAB SWITCHED POWER
NONE
NONE
NONE
NONE
NONE
NONE
RIDE CONTROL RELAY SINK
NONE
NONE
NONE
NONE
1ST AND 4TH GEAR SIGNAL
REVERSE SIGNAL
3RD AND 4TH GEAR SIGNAL
DECLUTCH SWITCH
NEUTRAL SIGNAL
1
2
5
6
7
8
11
12
13
14
15
16
18
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
37
38
40
43
44
45
47
48
50
52
53
54
57
58
59
60
61
63
64
65
66
67
68
SHEET 5 - 45F (77)
35R_D Y-0.8
35A_F Y-0.8
30 30
87 87
87a 87A
85 85
86 86
25S_C LU-0.8
25S_B LU-0.8
26
FORWARD REVERSE NEUTRAL

1 2 3 4 1 2 3 1 2 3 4
23
SPL_D12
25S_A LU-0.8
0_DW Bk-0.8
19H Or-1.0
197M 197F
FNR CAB MAIN
HARNESS HARNESS
26N_A LU-0.8
SHEET 4 - 42F (99)
35R_C Y-0.8
118F
19A_C Or-0.8
26F_B LU-0.8
26R_B LU-0.8
26N_B LU-0.8
198
25
10
7 7
8 8
9
6
5
1 1
4
3 3
2 2
0_DAW Bk-1.0
1
2
5
6
7
8
11
12
13
14
15
16
18
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
37
38
40
43
44
45
47
48
50
52
53
54
57
58
59
60
61
63
64
65
66
67
68
SHEET 1 - 221F GROUND CAB

0_DP Bk-0.8
0_DQ Bk-0.8
32J_C Y-0.8
35C Y-0.8
58H_B W-0.8
SHEET 5 - 50F (72)
0_DAV Bk-0.8
37D_A P-0.8
3
5
2
6
4
1
37D_A P-0.8
37E P-0.8
26F_B LU-0.8
52P_A W-0.8
25Y_B LU-0.8
19T_A Or-0.8
37E P-0.8
SHEET 3 - 55F (52)
10
7 7
8 8
9
6
5
4
1
3 3
2 2
108F

50H_A Y-0.5
50L_B G-0.5
50L_C G-0.5
50L_A G-0.5
25H LU-0.8
26R_B LU-0.8
26E LU-0.8
28
30
SHEET 3 - 13F CAB

PEDESTAL
SPL_D5
SHEET 5 - 44F (71)

SHEET 5 - 44F (71)
0_DAM Bk-1.0
49_Q S-1.0
25H LU-0.8
19A_Q Or-0.8
19A_L Or-0.8
19A_S Or-0.8
19A_N Or-0.8
25F_A LU-0.8
26N_B LU-0.8
19A_K Or-0.8
19A_K Or-0.8
SHEET 5 - 50F (72)
0_DD Bk-0.8
25Z_A LU-0.8
25R_A LU-0.8
25W_A LU-0.8
25G_B LU-0.8
25T_D LU-0.8
19T_B Or-0.8
31
0_JB Bk-1.0
BB
41F
10
7 7
8 8
9
6
5
1 1
4
3 3
2 2
174
SHEET 4 - SPL_J1
19A_D Or-0.8
2.5K ohm
resistor
10 10
7 7
8 8
1
6
5
4
9 9
3 3
2 2
SHEET 5 - 36F (54)

SHEET 5 - 36F (54)
0_DAK Bk-1.0
49_N S-1.0
SPL_D15
19A_T Or-0.8
26 26
23 23
22 22
20 20
19 19
17 17
2 2
6 6
30 30
31 31
128F
REAR
CHASSIS
HARNESS
35R_B Y-1.0
19A_A Or-1.0
25G LU-1.0
21F 21M
CAB REAR CHASSIS
MAIN HARNESS
HARNESS
19A_M Or-0.8
10
7
8
1
6
5
4
9
3
2
P/N 409725A1
19A_E Or-0.8
19A_C Or-0.8
0_DAE Bk-1.0
0_DAP Bk-1.0
49_G S-0.8
49_R S-1.0
128M
HOOD
HARNESS
AA
BB
4
37
35R_A Y-1.0
175
32
Normally Closed
Opens at 24.1 bar (350 psi)
25G_A LU-0.8
25G_B LU-0.8
19A_R Or-0.8
38F
SHEET 1 - SPL_D18
29
2 1
2 1
SPL_D11
25Y_C LU-0.8
20M
19A_U Or-0.8
183
1 2 3 4 1 2 3 4 1 2 3 4
183 TRANSMISSION SHIFTER

A
B
C
D
NONE
THIRD AND FOURTH GEAR SIGNAL
FIRST AND FOURTH GEAR SIGNAL
A
B
C
D
A
B
C
D
R
Y
K
S
A
B
C
D
A
B
C
D
25W LU-0.8
25Z LU-0.8
25Y LU-0.8
25W LU-0.8
25Z LU-0.8
25Y LU-0.8
70
INDICATES HIGH (24 VOLTS)
1 2 3 4 1 2 3 4 1 2 3 4
A
B
C
D
Bk
G
U
19A_H Or-0.8
25F LU-0.8
25R LU-0.8
25T_A LU-0.8
SHEET 3 - 72 (46)
SHEET 1 - 92 (11)
27
TRANSMISSION CONTROL POWER

FORWARD SIGNAL
REVERSE SIGNAL
NEUTRAL SIGNAL
50G_C R-0.5
SPL_K3
INDICATES HIGH (24 VOLTS)
25F LU-0.8
25R LU-0.8
SPL_K2
50G_A Bk-0.8
48
49
50
24
47
44
45
27
33
37
34
48
49
50
24
47
44
45
27
33
37
34
25W_A LU-0.8
25Z_A LU-0.8
25Y_A LU-0.8
25F_A LU-0.8
25R_A LU-0.8
13M 13F
PEDESTAL CAB MAIN
HARNESS HARNESS
50G_B Bk-0.5
LOCATED NEAR INSTRUMENT

CLUSTER CONNECTOR 76
50G_E Bk-0.5
SPL_D6
50G_D Bk-0.8
SPL_D7
50G_G Bk-0.8
50G_F R-0.5
LOCATED NEAR TECM
CONNECTOR 19F
SHEET 2 - TRANSMISSION CONTROLS

COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Batteries
Alternator
Starter Motor
Starting Relay
Fuel Relay
Ether Start Switch
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Declutch Switch
FNR Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y
Instrument Cluster
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.
68.
68A.
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
1.
2.
3.
4.
5.
CIRCUIT CONNECTED
WIRE IDENTIFICATION
MALE CONNECTOR
10
A A
B B
1 1
SHEET 6 - 253F (54)
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
Detent Switch
Float Solenoid
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.

Ride Control Switch
Front Wiper Motor
Rear Wiper Motor
ACTUATOR SYMBOLS
5 6
SPL_G2
2
=
=
=
=
=
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE

37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
CONTACT SYMBOLS
1
P
3
Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.

Beacon Switch
Rotating Beacon
Hazard Switch

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
Flasher Module
License Plate Lamp
117. Dome Lamp

118. Courtesy Lamp
NOTES
BC02078
Copyright
19A_E Or-0.8
19A_C Or-0.8
0_DAE Bk-1.0
0_DAP Bk-1.0
49_G S-0.8
49_R S-1.0
10 10
7 7
8 8
1
6
5
4
9 9
3 3
2 2
32J_C Y-0.8
32J_B Y-0.8
26E LU-0.8
19A_D Or-0.8
19A_E Or-0.8
199F
SINGLE AXIS CONTROLLER
34
N
Y
K
P
N
F
5
6
1
2
4
3
7
8
5
4
34
32J_A Y-0.8
19A_F Or-0.8
7
8
5
4
9
6
1
10
3
2
6
1
3
2
36
5
6
1
2
4
3
19A_B Or-0.8
26J LU-0.8
26F_A LU-0.8
26R_A LU-0.8
5
6
1
2
4
3
32J_B Y-0.8
102 TRANSMISSION CONTROL

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

OUTPUT SWITCHED POWER VPSI
VALVE BODY TEMPERATURE SIGNAL
VALVE BODY TEMPERATURE RETURN
NONE
NONE
NONE
NONE
NONE
NONE
NONE
25S_A LU-0.8
19F
25K LU-0.8
25L LU-0.8
25M LU-0.8
25N LU-0.8
25P LU-0.8
25J LU-0.8
25S LU-0.8
36T P-0.8
36R_C P-0.8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
25K LU-0.8
25L LU-0.8
25M LU-0.8
25N LU-0.8
25P LU-0.8
25J LU-0.8
25S LU-0.8
36T P-0.8
32F Y-1.0
0_HE Bk-1.0
25D LU-1.0
19A Or-1.0
36R_A P-1.0
36G P-1.0
Q MODULATED AND CURRENT CONTROLLED 102
23
25A W-0.8
0_HD Bk-1.0
25C W-0.8
25B W-0.8
32F Y-1.0
36R_B P-1.0
11
22
510 OHMS 31
16 16
17 17
18 18
19 19
20 20
21 21
22 22
5 5
31 31
28 28
10 10
29 29
24 24
12 12
13 13
14 14
7 7
11 11
9 9
8 8
25K_A LU-0.8
25L_A LU-0.8
25M_A LU-0.8
25N_A LU-0.8
25P_A LU-0.8
25J_A LU-0.8
56
10
32
55
9
51
39
17
4
62
36T_A P-0.8
32F_A Y-0.8
0_DN Bk-0.8
25D_A LU-0.8
19A_M Or-0.8
46
49
19
3
42
41
36R_E P-0.8
36G_A P-1.0
25A_A LU-0.8
0_DM Bk-0.8
25C_A LU-0.8
25B_A LU-0.8
56
10
32
55
9
51
39
17
4
62
46
49
19
3
42
41
19F TECM
VALVE BODY TEMPERATURE SENDER
TRANSMISSION FILTER MAINTENANCE SWITCH
OUTPUT SPEED SENSOR GROUND
OUTPUT SPEED SIGNAL
TEMPERATURE/FILTER RETURN
ENGINE SPEED SIGNAL
SPEED SENSOR GROUND
INTERMEDIATE SPEED
TURBINE SPEED SIGNAL
22M 22F
HARNESS HARNESS
36R_A P-1.0
SPL_H1
36R_D P-1.0
22
11
36G P-1.0
142
3521 ohms at 20C (68F)
24
19
20
21
22
11
22
33
100
0_HE Bk-1.0
25D LU-1.0
19A Or-1.0
11
22
101
25A W-0.8
0_HF Bk-0.8
22
11
95
0_HG Bk-0.8
25C W-0.8
22
11
96
0_HH Bk-0.8
25B W-0.8
SPL_H2
35
49_T S-1.0
SHEET 4 - 42F (99)
NOTE 1
AA
209M 209F
35A_E Y-0.8
35A_D Y-0.8
35C Y-0.8
19A_P Or-0.8
53F
19F
19F TECM
TRANSMISSION ENABLE LAMP SIGNAL
NONE
BACKUP ALARM PULL-DOWN
RIDE CONTROL SWITCHED POWER VPS2
NONE
NONE
DIAGNOSTIC SIGNAL
NONE
DIAGNOSTIC SIGNAL
FNR FORWARD SIGNAL
PARKING BRAKE RELAY OUT
NONE
NONE
TRANSMISSION AUTO SIGNAL
FNR REVERSE SIGNAL
TRANSMISSION ENABLE SIGNAL
NONE
NONE
NONE
NONE
NONE
NONE
NONE
FORWARD SIGNAL
FNR NEUTRAL SIGNAL
CAB SWITCHED POWER
NONE
NONE
NONE
NONE
NONE
NONE
RIDE CONTROL RELAY SINK
NONE
NONE
NONE
NONE
1ST AND 4TH GEAR SIGNAL
REVERSE SIGNAL
3RD AND 4TH GEAR SIGNAL
DECLUTCH SWITCH
NEUTRAL SIGNAL
1
2
5
6
7
8
11
12
13
14
15
16
18
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
37
38
40
43
44
45
47
48
50
52
53
54
57
58
59
60
61
63
64
65
66
67
68
SHEET 5 - 45F (77)
35R_D Y-0.8
35A_F Y-0.8
30 30
87 87
87a 87A
85 85
86 86
25S_C LU-0.8
25S_B LU-0.8
26

1 2 3 4 1 2 3 1 2 3 4
CLUTCH
NUMBER
K4
KR
K1
K3
KV
K2
SPL_D12
25S_A LU-0.8
49_L S-0.8
35A_E Y-0.8
198
25
SHEET 5 - 45F (77)
19H Or-1.0
197M 197F
FNR CAB MAIN
HARNESS HARNESS
26N_A LU-0.8
0_DW Bk-0.8
35R_C Y-0.8
118F
19A_C Or-0.8
26F_B LU-0.8
26R_B LU-0.8
26N_B LU-0.8
SHEET 4 - 42F (99)

0_DP Bk-0.8
0_DQ Bk-0.8
32J_C Y-0.8
1
2
5
6
7
8
11
12
13
14
15
16
18
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
37
38
40
43
44
45
47
48
50
52
53
54
57
58
59
60
61
63
64
65
66
67
68
35C Y-0.8
58H_B W-0.8
SHEET 5 - 50F (72)
37D_A P-0.8
3
5
2
6
4
1
37D_A P-0.8
37E P-0.8
26F_B LU-0.8
52P_A W-0.8
25Y_B LU-0.8
19T_A Or-0.8
37E P-0.8
SHEET 3 - 55F (52)
28
10
7 7
8 8
9
6
5
4
1
3 3
2 2
108F

50H_A Y-0.5
50L_B G-0.5
50L_C G-0.5
50L_A G-0.5
25H LU-0.8
26R_B LU-0.8
26E LU-0.8
0_DAV Bk-0.8
30
SHEET 3 - 13F CAB

PEDESTAL
SPL_D5
SHEET 5 - 44F (71)

SHEET 5 - 44F (71)
0_DAM Bk-1.0
49_Q S-1.0
25H LU-0.8
19A_Q Or-0.8
19A_L Or-0.8
19A_S Or-0.8
19A_N Or-0.8
25F_A LU-0.8
26N_B LU-0.8
19A_K Or-0.8
19A_K Or-0.8
SHEET 5 - 50F (72)
0_DD Bk-0.8
25Z_A LU-0.8
25R_A LU-0.8
25W_A LU-0.8
25G_B LU-0.8
25T_D LU-0.8
19T_B Or-0.8
31
0_JB Bk-1.0
BB
41F
10
7 7
8 8
9
6
5
1 1
4
3 3
2 2
174
SHEET 4 - SPL_J1
19A_D Or-0.8
JOYSTICK CONTROLLER
10
7 7
8 8
9
6
5
1 1
4
3 3
2 2
0_DAW Bk-1.0
0_DAK Bk-1.0
49_N S-1.0
SHEET 5 - 36F (54)

SHEET 5 - 36F (54)
SPL_D15
19A_T Or-0.8
19A_M Or-0.8
33
SHEET 5 - SPL_D13
SHEET 4 - 42F (99)
SHEET 4 - SPL_D8
SHEET 4 - 42F (99)
26 26
23 23
22 22
20 20
19 19
17 17
2 2
6 6
30 30
31 31
128F
REAR
CHASSIS
HARNESS
35R_B Y-1.0
19A_A Or-1.0
25G LU-1.0
21F 21M
CAB REAR CHASSIS
MAIN HARNESS
HARNESS
128M
HOOD
HARNESS
AA
BB
4
37
35R_A Y-1.0
175
32
Normally Closed
25G_A LU-0.8
25G_B LU-0.8
19A_R Or-0.8
38F
SHEET 1 - SPL_D18
29
2 1
2 1
SPL_D11
25Y_C LU-0.8
20M
19A_U Or-0.8
183
1 2 3 4 1 2 3 4 1 2 3 4

A
B
C
D
NONE
THIRD AND FOURTH GEAR SIGNAL
FIRST AND FOURTH GEAR SIGNAL
A
B
C
D
A
B
C
D
R
Y
K
S
A
B
C
D
A
B
C
D
25W LU-0.8
25Z LU-0.8
25Y LU-0.8
25W LU-0.8
25Z LU-0.8
25Y LU-0.8
70
Q INDICATES HIGH (24 VOLTS)
1 2 3 4 1 2 3 4 1 2 3 4
A
B
C
D
Bk
G
U
TRANSMISSION CONTROL POWER

FORWARD SIGNAL
REVERSE SIGNAL
NEUTRAL SIGNAL
SHEET 3 - 72 (46)
19A_H Or-0.8
25F LU-0.8
25R LU-0.8
25T_A LU-0.8
25F LU-0.8
25R LU-0.8
SHEET 1 - 92
27
SPL_K2
50G_C R-0.5
SPL_K3
Q INDICATES HIGH (24 VOLTS)
50G_A Bk-0.8
48
49
50
24
47
44
45
27
33
37
34
48
49
50
24
47
44
45
27
33
37
34
25W_A LU-0.8
25Z_A LU-0.8
25Y_A LU-0.8
25F_A LU-0.8
25R_A LU-0.8
13M 13F
PEDESTAL CAB MAIN
HARNESS HARNESS
50G_B Bk-0.5
LOCATED NEAR INSTRUMENT

CLUSTER CONNECTOR 76
50G_E Bk-0.5
SPL_D6
50G_D Bk-0.8
SPL_D7
50G_G Bk-0.8
50G_F R-0.5
LOCATED NEAR TECM
CONNECTOR 19F
SHEET 2 - TRANSMISSION CONTROLS

COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
11A.
Batteries
Alternator
Starter Motor
Starting Relay
11B.
11C.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

Declutch Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y

Instrument Cluster
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
CONNECTED)
10
A A
B B
1 1
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
SHEET 6 - 253F (54)
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
57.
58.
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.

Detent Switch
Float Solenoid
ACTUATOR SYMBOLS
5 6
SPL_G2
2
=
=
=
=
=
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE
34. FNR Switch

37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
68.
68A.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.

Ride Control Switch
Front Wiper Motor
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
Rear Wiper Motor

Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
CONTACT SYMBOLS
P
3
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.

Beacon Switch
Rotating Beacon
103. Hazard Switch

Switch
105. Flasher Module

Switch
117. Dome Lamp
118. Courtesy Lamp
NOTES
1.
2.
3.
4.
5.
6.
7.
Used only on 621D.
ELECTRICAL SCHEMATIC P.I.N. JEE0135501 AND ABOVE

BC02M034
Copyright
Normally Open
Closes at 62 bar (900 psi)
57
AA
BB
157
33R_A Y-1.0
0_L Bk-1.0
AA
BB
33R_B Y-1.0
0_M Bk-1.0
Normally Open
57
SPL_E10
86
SPL_E9
SHEET 1 - 160 ENGINE GROUND
0_P Bk-1.0
Normally Closed
AA
31D_C Y-0.8
BB
0_VA Y-0.8
274F 104
0_V Bk-1.0
0_N Bk-1.0
33P Y-1.0
BB
AA
88
38
33R_C Y-1.0
33P Y-1.0
31D Y-1.0
36H P-1.0
36F P-1.0
31H Y-1.0
52P W-1.0
41
AA
36H P-1.0
BB
0_W Bk-1.0
136
3521 ohms at 20C (68F)
21M
REAR
CHASSIS
HARNESS
36F P-1.0
141
S
275M
40
A B
A B
0_E Bk-1.0
171
15
4
3
13
16
14
18
15
4
3
13
16
14
18
33R_D Y-0.8
33P_A Y-0.8
31D_A Y-0.8
36H_A P-0.8
36F_A P-0.8
31H_A Y-0.8
52P_B W-0.8
21F
CAB
MAIN
HARNESS
31H Y-1.0
33 to 240 ohms
39
0_Q Bk-1.0
170
Normally Open
Closes at 2.8 bar (40 psi)
42
53
40.3 ohms at 20C (68F)
47
76 INSTRUMENT CLUSTER
CLUSTER MAIN FUSED POWER
INSTRUMENT CLUSTER FUSED DELAYED POWER
LOW BRAKE PRESSURE WARNING
COOLANT LEVEL SIGNAL
SECONDARY STEERING LOW PRESSURE SIGNAL
AIR FILTER RESTRICTION SWITCH SIGNAL
HYDRAULIC FILTER RESTRICTION SWITCH SIGNAL
ANALOG GROUND
PARKING BRAKE SIGNAL
AIR CONDITIONING TELLTALE
NONE
WORK LAMP TELLTALE SIGNAL
BEACON TELLTALE
NONE
HIGH BEAM TELLTALE
LEFT TURN SIGNAL
RIGHT TURN SIGNAL
ENGINE COOLANT TEMPERATURE SIGNAL
FUEL LEVEL SIGNAL
HYDRAULIC OIL TEMPERATURE SIGNAL
CONTROLLER AREA NETWORK T
ENGINE OIL PRESSURE SIGNAL
ENGINE SHUTDOWN SIGNAL
PROGRAM SIGNAL
RESET SIGNAL
UP COUNT SIGNAL
DOWN COUNT SIGNAL
REDUNDANT BRAKE SWITCH SIGNAL
PILOT LOCKOUT SIGNAL
NONE
BRAKE LAMP SIGNAL
PILOT CONTROL SIGNAL
SIGNAL GROUND
SIGNAL GROUND
SIGNAL GROUND
NONE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
52P W-1.0
2 1 87
2 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
19V_A Or-0.8
19S_B Or-0.8
33P_B Y-0.8
19V_A Or-0.8
31D_B Y-0.8
35X_F Y-0.8
31F_C Y-0.8
31H_B Y-0.8
31D_B Y-0.8
35X_F Y-0.8
31F_C Y-0.8
31H_B Y-0.8
33P_B Y-0.8
0_KP Bk-0.8
33U Y-0.8
61R_G Or-0.8
0_KP Bk-0.8
61R_G Or-0.8
42R_A Y-0.8
46_B K-0.8
42R_A Y-0.8
46_B K-0.8
18C_C Or-0.8
45L_F N-0.8
45R_F N-0.8
36C_C P-0.8
36F_B P-0.8
36H_B P-0.8
50T Bk-0.8
36P_C P-0.8
23C W-0.8
37P P-0.8
37R_B P-0.8
37U P-0.8
37D P-0.8
33R_E Y-0.8
31L Y-0.8
52C W-0.8
50L G-0.5
50H Y-0.5
50T Bk-0.8
18C_C Or-0.8
45L_F N-0.8
45R_F N-0.8
36C_C P-0.8
36F_B P-0.8
36H_B P-0.8
36P_C P-0.8
23C W-0.8
33R_E Y-0.8
52C W-0.8
50L G-0.5
50H Y-0.5
44_G T-0.8
53C W-0.8
0_KQ Bk-0.8
0_KE Bk-0.8
0_KD Bk-0.8
0_KQ Bk-0.8
0_KE Bk-0.8
SPL_K1
6
7 7
8 8
10
4
9
1 1
5
3 3
2 2
75
76
45
44_G T-0.8
53C W-0.8
0_KR Bk-0.8
0_KM Bk-0.8
0_KD Bk-0.8
37R_A P-0.8
19S_A Or-0.8
19C Or-0.8
19A_G Or-0.8
1
29
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
28
30
31
32
54
26
35
36
38
53
39
25
2
68
43
40
1
29
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
28
30
31
32
54
26
35
36
38
53
39
25
2
68
43
40
19V Or-0.8
33P_A Y-0.8
31D_A Y-0.8
35X_E Y-0.8
31F_B Y-0.8
31H_A Y-0.8
0_DAU Bk-0.8
SHEET 1 - 22F CAB TRANSMISSION
61R_F Or-0.8
SHEET 5 - SPL_D1
42R_C DU-0.8
46_A K-0.8
SHEET 4 - 32F (114)

18C_B Or-0.8
45L_E N-0.8
45R_C N-0.8
36C_B P-0.8
36F_A P-0.8
36H_A P-0.8

SHEET 4 - SPL_D10
SHEET 4 - SPL_D20
36P_B P-0.8
23C_A W-0.8
33R_D Y-0.8
52C_A W-0.8
50L_A G-0.5
50H_A Y-0.5
44_F T-0.8
53C_A W-0.8
0_DAB Bk-0.8
0_DAC Bk-0.8
0_DL Bk-0.8
37R_C P-0.8
19S Or-0.8
19C_C Or-0.8
19A_S Or-0.8
52
48
30 30
87 87
87a 87A
85 85
86 86
51
SHEET 1 - 57F (58)

SHEET 2 - SPL_D5
SHEET 2 - 19F (26)
10
7 7
8 8
1
9
5
6
4
3 3
2 2
37
0_KJ Bk-0.8
0_KH Bk-0.8
49_C S-0.8
49_B S-0.8
19C_D Or-1.0
19C_E Or-1.0
53P_C W-0.8
53P_B W-0.8
53P_A W-0.8
53C_A W-0.8
19C_E Or-1.0
SHEET 2 - 19F (26)

SHEET 5 - 36F (59)
0_DB Bk-0.8
SHEET 4 - SPL_D9
A B 89M
A B

SHEET 1 - 222F RELAY GROUND
SHEET 1 - 63M (18)
SHEET 5 - SPL_D24
SHEET 2 - SPL_D15
54
29.9 ohms at 20C (68F) Joystick
27.4 ohms at 20C (68F) Single Axis
13M 13F
PEDESTAL CAB MAIN
HARNESS HARNESS
0_KM Bk-0.8
0_KL Bk-0.8
49_E S-0.8
37R_A P-0.8
37R_B P-0.8
37P P-0.8
1A_B R-0.8
SHEET 1 - 69 (13)
6
7 7
8 8
4
10
5
1 1
9
3 3
2 2
74
49
0_KL Bk-0.8
0_KK Bk-0.8
49_E S-0.8
49_D S-0.8
3521 ohms at 20C (68F)

BB
AA
138
43
0_BE Bk-1.0
36C P-1.0
SHEET1 - SPL_B1
37D P-0.8
37U P-0.8
19S_A Or-0.8
36C_B P-0.8
31F_B Y-0.8
36P_B P-0.8
36C_A P-1.0
31F_A Y-1.0
36P_A P-1.0
4 4
3 3
6 6
13 13
7 7
6 6
31F Y-1.0
117
148
50
SHEET 2 - 70 (27)
0_BD Bk-1.0
36P P-1.0
94F 94M
TRANSMISSION ENGINE
HARNESS HARNESS
0_KK Bk-0.8
0_KJ Bk-0.8
49_D S-0.8
49_C S-0.8
33U Y-0.8
19A_H Or-0.8
19A_G Or-0.8
56F
22F 22M
CAB MAIN TRANSMISSION
HARNESS HARNESS
9
7 7
8 8
5
6
10
4
1
3 3
2 2
72
19D_A Or-1.0
19D_B Or-1.0
52P_B W-0.8
52P_A W-0.8
52C_A W-0.8
55F
19S_B Or-0.8
46
30 30
87 87
87a 87A
85 85
86 86
SHEET1 - SPL_B1
A B
A B
COMMON
Normally Closed
NORMALLY
OPEN
NORMALLY
CLOSED
91 OHM RESISTOR
YELLOW WIRE
(NOTE 2)
240 OHM RESISTOR

BLACK WIRE
(NOTE 2)
44
Normally Open
Closes at 0.06 bar ( 0.928 psi)
ENGINE GROUND
SHEET 4 - 71 (103)
SHEET 4 - 71 (103)
31L Y-0.8
19C Or-0.8
SHEET 3 - INSTRUMENT CLUSTER

COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Batteries
Alternator
Starter Motor
Starting Relay
Fuel Relay
Ether Start Switch
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Declutch Switch
FNR Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
2
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y
Instrument Cluster
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.
68.
68A.
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
1.
2.
3.
4.
5.
CIRCUIT CONNECTED
WIRE IDENTIFICATION
MALE CONNECTOR
10
A A
B B
1 1
SHEET 6 - 253F (54)
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
Detent Switch
Float Solenoid
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.

Ride Control Switch
Front Wiper Motor
Rear Wiper Motor
ACTUATOR SYMBOLS
5 6
SPL_G2
=
=
=
=
=
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE

37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
CONTACT SYMBOLS
1
P
3
Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.

Beacon Switch
Rotating Beacon
Hazard Switch

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
Flasher Module
License Plate Lamp
117. Dome Lamp

118. Courtesy Lamp
NOTES
BC02D079
Copyright
Normally Open
57
AA
BB
157
33R_A Y-1.0
0_L Bk-1.0
AA
BB
33R_B Y-1.0
0_M Bk-1.0
Normally Open
57
SPL_E10
86
SPL_E9
0_P Bk-1.0
Normally Closed
AA
31D_C Y-0.8
BB
0_VA Y-0.8
274F 104
0_V Bk-1.0
0_N Bk-1.0
33P Y-1.0
BB
AA
88
38
33R_C Y-1.0
33P Y-1.0
31D Y-1.0
36H P-1.0
36F P-1.0
31H Y-1.0
52P W-1.0
41
AA
36H P-1.0
BB
0_W Bk-1.0
136
3521 ohms at 20C (68F)

141
40
A B
A B
0_E Bk-1.0
171
15
4
3
13
16
14
18
21M
REAR
CHASSIS
HARNESS
36F P-1.0
S
275M
15
4
3
13
16
14
18
33R_D Y-0.8
33P_A Y-0.8
31D_A Y-0.8
36H_A P-0.8
36F_A P-0.8
31H_A Y-0.8
52P_B W-0.8
21F
CAB
MAIN
HARNESS
31H Y-1.0
33 to 240 ohms
0_Q Bk-1.0
39
170
Normally Open
42
53
40.3 ohms at 20C (68F)
47
76 INSTRUMENT CLUSTER
CLUSTER MAIN FUSED POWER
INSTRUMENT CLUSTER FUSED DELAYED POWER
LOW BRAKE PRESSURE WARNING
COOLANT LEVEL SIGNAL
AIR FILTER RESTRICTION SWITCH SIGNAL
HYDRAULIC FILTER RESTRICTION SWITCH SIGNAL
ANALOG GROUND
AIR CONDITIONING TELLTALE
NONE
WORK LAMP TELLTALE SIGNAL
BEACON TELLTALE
NONE
HIGH BEAM TELLTALE
LEFT TURN SIGNAL
RIGHT TURN SIGNAL
ENGINE COOLANT TEMPERATURE SIGNAL
FUEL LEVEL SIGNAL
HYDRAULIC OIL TEMPERATURE SIGNAL
ENGINE OIL PRESSURE SIGNAL
ENGINE SHUTDOWN SIGNAL
PROGRAM SIGNAL
RESET SIGNAL
UP COUNT SIGNAL
DOWN COUNT SIGNAL
REDUNDANT BRAKE SWITCH SIGNAL
PILOT LOCKOUT SIGNAL
NONE
BRAKE LAMP SIGNAL
PILOT CONTROL SIGNAL
SIGNAL GROUND
SIGNAL GROUND
SIGNAL GROUND
NONE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
52P W-1.0
2 1 87
2 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
19V_A Or-0.8
19S_B Or-0.8
33P_B Y-0.8
19V_A Or-0.8
31D_B Y-0.8
35X_F Y-0.8
31F_C Y-0.8
31H_B Y-0.8
31D_B Y-0.8
35X_F Y-0.8
31F_C Y-0.8
31H_B Y-0.8
33P_B Y-0.8
0_KP Bk-0.8
33U Y-0.8
61R_G Or-0.8
0_KP Bk-0.8
61R_G Or-0.8
42R_A Y-0.8
46_B K-0.8
42R_A Y-0.8
46_B K-0.8
18C_C Or-0.8
45L_F N-0.8
45R_F N-0.8
36C_C P-0.8
36F_B P-0.8
36H_B P-0.8
50T Bk-0.8
36P_C P-0.8
23C W-0.8
37P P-0.8
37R_B P-0.8
37U P-0.8
37D P-0.8
33R_E Y-0.8
31L Y-0.8
52C W-0.8
50L G-0.5
50H Y-0.5
50T Bk-0.8
18C_C Or-0.8
45L_F N-0.8
45R_F N-0.8
36C_C P-0.8
36F_B P-0.8
36H_B P-0.8
36P_C P-0.8
23C W-0.8
33R_E Y-0.8
52C W-0.8
50L G-0.5
50H Y-0.5
44_G T-0.8
53C W-0.8
0_KQ Bk-0.8
0_KE Bk-0.8
0_KD Bk-0.8
0_KQ Bk-0.8
0_KE Bk-0.8
SPL_K1
6
7 7
8 8
10
4
9
1 1
5
3 3
2 2
75
76
45
44_G T-0.8
53C W-0.8
0_KR Bk-0.8
0_KM Bk-0.8
0_KD Bk-0.8
37R_A P-0.8
19S_A Or-0.8
19C Or-0.8
19A_G Or-0.8
1
29
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
28
30
31
32
54
26
35
36
38
53
39
25
2
68
43
40
19V Or-0.8
33P_A Y-0.8
31D_A Y-0.8
35X_E Y-0.8
31F_B Y-0.8
31H_A Y-0.8
0_DAU Bk-0.8
61R_F Or-0.8
SHEET 5 - SPL_D1
42R_C DU-0.8
46_A K-0.8
SHEET 4 - 32F (114)

18C_B Or-0.8
45L_E N-0.8
45R_C N-0.8
36C_B P-0.8
36F_A P-0.8
36H_A P-0.8

SHEET 4 - SPL_D10
SHEET 4 - SPL_D20
36P_B P-0.8
23C_A W-0.8
33R_D Y-0.8
52C_A W-0.8
50L_A G-0.5
50H_A Y-0.5
44_F T-0.8
53C_A W-0.8
0_DAB Bk-0.8
0_DAC Bk-0.8
0_DL Bk-0.8
37R_C P-0.8
19S Or-0.8
19C_C Or-0.8
19A_S Or-0.8
52
SHEET 2 - SPL_D5
SHEET 2 - 19F (26)
19C_D Or-1.0
19C_E Or-1.0
53P_C W-0.8
53P_B W-0.8
53P_A W-0.8
53C_A W-0.8
19C_E Or-1.0
SHEET 4 - SPL_D9
A B 89M
A B

SHEET 1 - 222F RELAY GROUND
SHEET 1 - 63M (18)
SHEET 5 - SPL_D24
SHEET 2 - SPL_D15
54
29.9 ohms at 20C (68F) Joystick
27.4 ohms at 20C (68F) Single Axis
SHEET 1 - 69 (13)
6
7 7
8 8
4
10
5
1 1
9
3 3
2 2
74
49
0_KL Bk-0.8
0_KK Bk-0.8
49_E S-0.8
49_D S-0.8
3521 ohms at 20C (68F)

BB
AA
138
43
0_BE Bk-1.0
36C P-1.0
SHEET 1 - SPL_B1
37D P-0.8
37U P-0.8
19S_A Or-0.8
36C_B P-0.8
31F_B Y-0.8
36P_B P-0.8
36C_A P-1.0
31F_A Y-1.0
36P_A P-1.0
4 4
3 3
6 6
13 13
7 7
6 6
31F Y-1.0
0_BD Bk-1.0
36P P-1.0
94F 94M
TRANSMISSION ENGINE
HARNESS HARNESS
SHEET 2 - 70 (27)
0_KJ Bk-0.8
0_KH Bk-0.8
49_C S-0.8
49_B S-0.8

SHEET 5 - 36F (59)
0_DB Bk-0.8
117
148
50
33U Y-0.8
19A_H Or-0.8
19A_G Or-0.8
SHEET 2 - 19F (26)
56F
0_KK Bk-0.8
0_KJ Bk-0.8
49_D S-0.8
49_C S-0.8
10
7 7
8 8
1
9
5
6
4
3 3
2 2
37
48
30 30
87 87
87a 87A
85 85
86 86
51
SHEET 1 - 57F (58)
22F 22M
CAB MAIN TRANSMISSION
HARNESS HARNESS
9
7 7
8 8
5
6
10
4
1
3 3
2 2
72
19D_A Or-1.0
19D_B Or-1.0
52P_B W-0.8
52P_A W-0.8
52C_A W-0.8
55F
19S_B Or-0.8
46
30 30
87 87
87a 87A
85 85
86 86
13M 13F
PEDESTAL CAB MAIN
HARNESS HARNESS
0_KM Bk-0.8
0_KL Bk-0.8
49_E S-0.8
37R_A P-0.8
37R_B P-0.8
37P P-0.8
1A_B R-0.8
1
29
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
28
30
31
32
54
26
35
36
38
53
39
25
2
68
43
40
SHEET 1 - SPL_B1
1 2
A B
COMMON
Normally Closed
NORMALLY
OPEN
NORMALLY
CLOSED
91 OHM RESISTOR
YELLOW WIRE
(NOTE 2)
240 OHM RESISTOR

BLACK WIRE
(NOTE 2)
44
Normally Open
Closes at - 0.06 bar (- 0.928 psi)
ENGINE GROUND
SHEET 4 - 71 (103)
SHEET 4 - 71 (103)
31L Y-0.8
19C Or-0.8
SHEET 3 - INSTRUMENT CLUSTER

COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
11A.
Batteries
Alternator
Starter Motor
Starting Relay
11B.
11C.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

Declutch Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y

Instrument Cluster
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
CONNECTED)
10
A A
B B
1 1
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
SHEET 6 - 253F (54)
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
57.
58.
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.

Detent Switch
Float Solenoid
ACTUATOR SYMBOLS
5 6
SPL_G2
2
=
=
=
=
=
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE
34. FNR Switch

37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
68.
68A.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.

Ride Control Switch
Front Wiper Motor
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
Rear Wiper Motor

Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
CONTACT SYMBOLS
1
P
3
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.

Beacon Switch
Rotating Beacon
103. Hazard Switch

Switch
105. Flasher Module

Switch
117. Dome Lamp
118. Courtesy Lamp
NOTES
1.
2.
3.
4.
5.
6.
7.
Used only on 621D.

BC02M035
Copyright
31 1
H
R
45 1
2 1
5 1
104
L 1 1
B 1
185
184
19B Or-0.8
67
45A N-0.8
66
0_KF Bk-0.8
187
64D Or-0.8
6
7 7
8 8
9
4
5
1
10
3 3
2 2
71
0_KH Bk-0.8
49_B S-0.8
49_A S-0.8
SHEET 3 - 37 (48)
SHEET 3 - 37 (48)
45H N-0.8
1B R-0.8
1B R-0.8
45H N-0.8
49_A S-0.8
64D Or-0.8
45A N-0.8
19B Or-0.8
45B N-0.8
64C Or-0.8
0_KG Bk-0.8
106
64C Or-0.8
45B N-0.8
68
A 1
186
103
0_KG Bk-0.8
107
65 67 51 55 69 66 70 42 41
REVERSE
STOP
TURN
TAIL
REVERSE
65 67 51 55 69 66 70 42 41
18G_C Or-1.0
0_J Bk-1.0
A A
C C
0_JA Bk-1.0
SPL_J1
128F 128M
REAR HOOD
CHASSIS HARNESS
HARNESS
1 6 2 3 4 5
1 6 2 3 4 5 127
116
SHEET 2 - 174 (37)
0_JB Bk-1.0
30 30
87 87
87a 87A
85 85
86 86
102
0_D Bk-2.0
SHEET 1 - 164 ENGINE
SPL_E4
GROUND
18G_A Or-1.0
SPL_E2
35A_C K-1.0
35A_A K-1.0
18F_A Or-1.0
0_DX Bk-0.8
64C_A Or-0.8
SHEET 5 - 51F (80)
19B_A Or-0.8
10
7 7
8 8
9
6
5
4
1
3 3
2 2
42F
99
1B_E R-0.8
SPL_D9
44_F T-0.8
SHEET 5 - 203F (89)
44_E T-0.8
0_DK Bk-0.8
0_DA Bk-0.8
204F
SHEET 1 - SPL_D17
SPL_E8
35A_C K-1.0
18F_A Or-1.0
18G_D Or-1.0
45R_A N-1.0
45L_A N-1.0
44_C T-1.0
1B_A R-1.0
44 T-1.0
SPL_E1
7
5
9
12
10
8
28
29
21M
REAR
CHASSIS
HARNESS
SHEET 2 - 53F (35)

35A_D Y-08
18F_D Or-0.8
18G_F Or-0.8
45R_B N-0.8
45L_B N-0.8
44_D T-0.8
1B_D R-0.8
44A_B T-0.8
7
5
9
12
10
8
28
29
1_M R-3.0
211F
FLASHER
CIRCUIT
BREAKER B
12.5 AMPERES

41L_A K-2.0
41H K-2.0
41J_A K-2.0
1_H R-3.0
64D_A Or-0.8
SHEET 1 - SPL_D16
212F
3
4
1
8
6
3
4
1
8
6
56b
56a
56
30
S
SHEET 2 - 118F (36)

SHEET 2 - 199F (33)
SHEET 2 - 199F (33)
SHEET 2 - 118F (36)
0_DAW Bk-1.0
0_DAP Bk-1.0
49_R S-1.0
49_T S-1.0
46_C K-1.0
19X Or-1.0
115
59F
1B_F R-0.8
SPL_D19
21F
CAB
MAIN
HARNESS
1B_B R-0.8
0_A Bk-1.0
45L_A N-1.0
44_A T-1.0
AA
BB
168
45R_A N-1.0
18G_A Or-1.0
35A_B K-1.0
0_C Bk-1.0
44_B T-1.O
1 6 2 3 4 5
1 6 2 3 4 5 125
18G_E Or-1.0
0_JC Bk-1.0
13M PEDESTAL HARNESS

13F CAB MAIN HARNESS
45B_A N-0.8
TAIL
1B_C R-0.8
45H_A N-0.8
49_F S-0.8
64D_A Or-0.8
45A_A N-0.8
TURN
1B_E R-0.8
STOP
1 2
1 2 159
49_F S-0.8
49_U S-0.8
SHEET 5 - 210F (55)
49_G S-0.8
SHEET 2 - 199F (33)
49_S S-1.0
SPL_D8
0_MA Bk-1.0
62M FLASHER MODULE

FLASHER MODULE POWER
FLASHER OPP SIDE CONTROL
FLASHER MODULE GROUND
NONE
NONE
RIGHT-HAND TURN SIGNAL
LEFT-HAND TURN SIGNAL
RIGHT-HAND TURN SWITCH POWER
LEFT-HAND TURN SWITCH POWER
HAZARD SWITCH POWER
1
2
3
4
5
6
7
8
9
10
11
12

41J_B K-2.0
105
0_DAT Bk-0.8
1B_B R-0.8
45N_A N-0.8
0_DAN Bk-0.8
0_DAQ Bk-0.8
1
2
3
4
5
6
7
8
9
10
11
12
45R_E N-0.8
45L_D N-0.8
45B_A N-0.8
45A_A N-0.8
45H_A N-0.8
45N_B N-0.8
62M
SPL_D20
45R_C N-0.8
45L_E N-0.8
SPL_D10

25F A
A
B A C 33F
B A C
HD
45N_A N-0.8
1 1
64M 64F
NOTE 3
B A C 34F
B A C
TL F4 B1
2
41T_B K-1.0
Normally Open
SHEET 1 - 63M (18)
49_J S-0.8
SPL_D14
0_DAS Bk-0.8
41T_B K-1.0
101
3 4
3 4
SHEET 1 - 224F POWER CAB
49_K S-1.0
42C_A DU-1.0
19Z Or-1.0
SHEET 5 - 39F (61)
41T_A K-1.0

42R_C DU-0.8
18A Or-2.0
3 4
LAMPS
SWITCH
POSITION
DRIVE FLOOD ILLUMINATION
POSITION
AND TAIL
1
OFF
OFF
OFF
OFF
2
ON
OFF
OFF
OFF
3
ON
ON
OFF
ON
4
ON
ON
ON
ON
5
ON
OFF
ON
ON
114
108
109
HIGH
LOW
BEAM POSITION BEAM
TURN
3 6 4 2 5 1
3 6 4 2 5 1 6

G
F
O
A
Q
E
P
C
G
F
O
A
Q
E
P
C
SPL_M4
SPL_M3
0_DR Bk-1.0
49_S S-1.0
0_DS Bk-1.0
42C_A DU-1.0
A
B
C
D
E
F
G
H
24M
CAB
MAIN
HARNESS
TURN
A
B
C
D
E
F
G
H
SPL_M5
0_MN Bk-0.8
49_V S-0.8
0_MK Bk-1.0
42C_D DU-1.0
SPL_M2
SPL_M1
24F
CAB
ROOF
HARNESS
0_MC Bk-1.0
46_D K-1.0
BB
AA
85F
100
42R_E DU-1.0
0_MF Bk-1.0
AA
BB
80F
111
42R_D DU-1.0
0_ME Bk-1.0
AA
BB
83F
110
AA
BB
CC
84F
117
0_ML Bk-0.8
49_V S-0.8
BB
AA
77F
118
0_MJ Bk-1.0
42C_C DU-1.0
BB
AA
78F
113
42C_B DU-1.0
0_MH Bk-1.0
AA
BB
79F
112
3 6 4 2 5 1
3 6 4 2 5 1 8
SHEET 5 - SPL_A1
0_AL Bk-1.0
18B_A Or-0.8
18F_E Or-0.8
18D_A Or-0.8
45L_C N-0.8
18C_A Or-0.8
18G_G Or-0.8
18E_A Or-0.8
45R_D N-0.8
23M
CAB
ROOF
HARNESS
SPL_M6
0_MM Bk-0.8

0_MD Bk-1.0
46_D K-1.0
42R_F DU-1.0
0_MG Bk-1.0
19U_D Or-1.0
19U_D Or-1.0
0_MB Bk-0.8
HIGH
LOW
BEAM POSITION BEAM
C C
E E
H H
B B
D D
23F
CAB
MAIN
HARNESS
42R_B DU-0.8
F3 F2 B2
1
0_DU Bk-1.0
46_A K-0.8
46_C K-1.0
42R_B DU-0.8
0_DT Bk-1.0
19U_A Or-1.0
SHEET 1 - 206F CAB FLOOR WELD STUD

C A B 32F
C A B
IL F1 B3
2
1_N R-3.0
SHEET 5 - 82M (77)
0_AG Bk-1.0
SHEET 5 - SPL_A1
18B Or-1.0
18F Or-1.0
18D Or-1.0
45L N-1.0
18C Or-1.0
18G Or-1.0
18E Or-1.0
45R N-1.0
1F 1
CAB MAIN FRONT
HARNESS CHASSIS
HARNESS
SHEET 4 - LIGHTING
COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Batteries
Alternator
Starter Motor
Starting Relay
Fuel Relay
Ether Start Switch
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Declutch Switch
FNR Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
2
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y
Instrument Cluster
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.
68.
68A.
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
1.
2.
3.
4.
5.
CIRCUIT CONNECTED
WIRE IDENTIFICATION
MALE CONNECTOR
10
A A
B B
1 1
SHEET 6 - 253F (54)
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
Detent Switch
Float Solenoid
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.

Ride Control Switch
Front Wiper Motor
Rear Wiper Motor
ACTUATOR SYMBOLS
5 6
SPL_G2
=
=
=
=
=
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE

37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
CONTACT SYMBOLS
1
P
3
Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.

Beacon Switch
Rotating Beacon
Hazard Switch

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
Flasher Module
License Plate Lamp
117. Dome Lamp

118. Courtesy Lamp
NOTES
BC01D080
Copyright
31 1
H
45 1
2 1
5 1
104
L 1 1
B 1
185
0_KG Bk-0.8
64C Or-0.8
184
45B N-0.8
68
19B Or-0.8
67
45A N-0.8
66
0_KF Bk-0.8
187
A 1
186
103
106
0_KH Bk-0.8
49_B S-0.8
49_A S-0.8
SHEET 3 - 37 (48)
SHEET 3 - 37 (48)
45H N-0.8
1B R-0.8
1B R-0.8
45H N-0.8
49_A S-0.8
64D Or-0.8
45A N-0.8
19B Or-0.8
45B N-0.8
64C Or-0.8
0_KG Bk-0.8
6
7 7
8 8
9
4
5
1
10
3 3
2 2
71
64D Or-0.8
107
65 67 51 55 69 66 70 42 41
REVERSE
STOP
TURN
TAIL
REVERSE
65 67 51 55 69 66 70 42 41
18G_C Or-1.0
0_J Bk-1.0
A A
C C
0_JA Bk-1.0
SPL_J1
128F 128M
REAR HOOD
CHASSIS HARNESS
HARNESS
1 6 2 3 4 5
1 6 2 3 4 5 127
116
SHEET 2 - 174 (37)
0_JB Bk-1.0
30 30
87 87
87a 87A
85 85
86 86
102
0_D Bk-2.0
SHEET 1 - 164 ENGINE
SPL_E4
GROUND
18G_A Or-1.0
SPL_E2
35A_C K-1.0
35A_A K-1.0
18F_A Or-1.0
0_DX Bk-0.8
64C_A Or-0.8
SHEET 5 - 51F (80)
19B_A Or-0.8
10
7 7
8 8
9
6
5
4
1
3 3
2 2
42F
99
1B_E R-0.8
SPL_D9
44_F T-0.8
SHEET 1 - 58F (17)
SHEET 1 - 49F (16)
44_E T-0.8
0_DG Bk-0.8
0_DC Bk-0.8
204F
SHEET 1 - SPL_D17
SPL_E8
35A_C K-1.0
18F_A Or-1.0
18G_D Or-1.0
45R_A N-1.0
45L_A N-1.0
44_C T-1.0
1B_A R-1.0
44 T-1.0
SPL_E1
7
5
9
12
10
8
28
29
21M
REAR
CHASSIS
HARNESS
35A_D Y-08
18F_D Or-0.8
18G_F Or-0.8
45R_B N-0.8
45L_B N-0.8
44_D T-0.8
1B_D R-0.8
44A_B T-0.8
7
5
9
12
10
8
28
29
SHEET 2 - 53F (35)

SHEET 2 - 118F (36)

SHEET 2 - 199F (33)
SHEET 2 - 199F (33)
SHEET 2 - 118F (36)
0_DAW Bk-1.0
0_DAP Bk-1.0
49_R S-1.0
49_T S-1.0
46_C K-1.0
19X Or-1.0
1_M R-3.0
FLASHER
CIRCUIT
BREAKER B
12.5 AMPERES
211F

41L_A K-2.0
41H K-2.0
41J_A K-2.0
1_H R-3.0
64D_A Or-0.8
SHEET 1 - SPL_D16
212F
3
4
1
8
6
3
4
1
8
6
56b
56a
56
30
S
115
59F
1B_F R-0.8
SPL_D19
21F
CAB
MAIN
HARNESS
1B_B R-0.8
0_A Bk-1.0
45L_A N-1.0
44_A T-1.0
AA
BB
168
45R_A N-1.0
18G_A Or-1.0
35A_B K-1.0
0_C Bk-1.0
44_B T-1.0
1 6 2 3 4 5
1 6 2 3 4 5 125
18G_E Or-1.0
0_JC Bk-1.0
13M PEDESTAL HARNESS

13F CAB MAIN HARNESS
45B_A N-0.8
TAIL
1B_C R-0.8
45H_A N-0.8
49_F S-0.8
64D_A Or-0.8
45A_A N-0.8
TURN
1B_E R-0.8
STOP
1 2
1 2 159
49_F S-0.8
49_U S-0.8
SHEET 5 - 210F (55)
49_G S-0.8
SHEET 2 - 199F (33)
49_S S-1.0
SPL_D8
0_MA Bk-1.0
1
2
3
4
5
6
7
8
9
10
11
12
62M FLASHER MODULE

FLASHER MODULE POWER
NONE
NONE
RIGHT-HAND TURN SIGNAL
LEFT-HAND TURN SIGNAL
RIGHT-HAND TURN SWITCH POWER
LEFT-HAND TURN SWITCH POWER
HAZARD SWITCH POWER

41J_B K-2.0
105
0_DAT Bk-0.8
1B_B R-0.8
45N_A N-0.8
0_DAN Bk-0.8
0_DAQ Bk-0.8
1
2
3
4
5
6
7
8
9
10
11
12
45R_E N-0.8
45L_D N-0.8
45B_A N-0.8
45A_A N-0.8
45H_A N-0.8
45N_B N-0.8
62M
SPL_D20
45R_C N-0.8
45L_E N-0.8
SPL_D10

25F A
A
B A C 33F
B A C
HD
45N_A N-0.8
1 1
64M 64F
NOTE 3
B A C 34F
B A C
TL F4 B1
2
41T_B K-1.0
Normally Open
SHEET 1 - 63M (18)
49_J S-0.8
SPL_D14
0_DAS Bk-0.8
41T_B K-1.0
101
3 4
3 4
SHEET 5 - 39F (61)
41T_A K-1.0
3 4
114

42R_C DU-0.8
18A Or-2.0
LAMPS
SWITCH
POSITION
DRIVE FLOOD ILLUMINATION
POSITION
AND TAIL
1
OFF
OFF
OFF
OFF
2
ON
OFF
OFF
OFF
3
ON
ON
OFF
ON
4
ON
ON
ON
ON
5
ON
OFF
ON
ON
108
HIGH
LOW
BEAM POSITION BEAM
TURN

G
F
O
A
Q
E
P
C
SPL_M4
SPL_M3
0_DR Bk-1.0
49_S S-1.0
0_DS Bk-1.0
42C_A DU-1.0
A
B
C
D
E
F
G
H
24M
CAB
MAIN
HARNESS
TURN
A
B
C
D
E
F
G
H
SPL_M5
0_MN Bk-0.8
49_V S-0.8
0_MK Bk-1.0
42C_D DU-1.0
SPL_M2
SPL_M1
24F
CAB
ROOF
HARNESS
0_MC Bk-1.0
46_D K-1.0
BB
AA
85F
100
42R_E DU-1.0
0_MF Bk-1.0
AA
BB
80F
111
42R_D DU-1.0
0_ME Bk-1.0
AA
BB
83F
110
AA
BB
CC
84F
117
0_ML Bk-0.8
49_V S-0.8
BB
AA
77F
118
0_MJ Bk-1.0
42C_C DU-1.0
BB
AA
78F
113
42C_B DU-1.0
0_MH Bk-1.0
AA
BB
79F
112
3 6 4 2 5 1
3 6 4 2 5 1 8
0_AL Bk-1.0
G
F
O
A
Q
E
P
C
23M
CAB
ROOF
HARNESS
SPL_M6
0_MM Bk-0.8
109
3 6 4 2 5 1
3 6 4 2 5 1 6
18B_A Or-0.8
18F_E Or-0.8
18D_A Or-0.8
45L_C N-0.8
18C_A Or-0.8
18G_G Or-0.8
18E_A Or-0.8
45R_D N-0.8
0_MD Bk-1.0
46_D K-1.0
42R_F DU-1.0
0_MG Bk-1.0
19U_D Or-1.0
19U_D Or-1.0
0_MB Bk-0.8

C C
E E
H H
B B
D D
23F
CAB
MAIN
HARNESS
HIGH
LOW
BEAM POSITION BEAM
0_DU Bk-1.0
46_A K-0.8
46_C K-1.0
42R_B DU-0.8
0_DT Bk-1.0
19U_A Or-1.0

42R_B DU-0.8
F3 F2 B2
SHEET 1 - 224F POWER CAB
49_K S-1.0
42C_A DU-1.0
19Z Or-1.0
C A B 32F
C A B
IL F1 B3
2
1_N R-3.0
SHEET 5 - 82M (77)
SHEET 5 - SPL_A1
0_AG Bk-1.0
SHEET 5 - SPL_A1
18B Or-1.0
18F Or-1.0
18D Or-1.0
45L N-1.0
18C Or-1.0
18G Or-1.0
18E Or-1.0
45R N-1.0
1F 1
CAB MAIN FRONT
HARNESS CHASSIS
HARNESS
SHEET 4 - LIGHTING
COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
11A.
Batteries
Alternator
Starter Motor
Starting Relay
11B.
11C.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

Declutch Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y

Instrument Cluster
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
CONNECTED)
10
A A
B B
1 1
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
SHEET 6 - 253F (54)
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
57.
58.
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.

Detent Switch
Float Solenoid
ACTUATOR SYMBOLS
5 6
SPL_G2
2
=
=
=
=
=
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE
34. FNR Switch

37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
68.
68A.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.

Ride Control Switch
Front Wiper Motor
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
Rear Wiper Motor

Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
CONTACT SYMBOLS
1
P
3
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.

Beacon Switch
Rotating Beacon
103. Hazard Switch

Switch
105. Flasher Module

Switch
117. Dome Lamp
118. Courtesy Lamp
NOTES
1.
2.
3.
4.
5.
6.
7.
Used only on 621D.

BC02M036
Copyright
30
87
87A
85
86
203F
22F 22M
CAB TRANSMISSION
MAIN HARNESS
HARNESS
SHEET 4 - 204F (102)
BB
AA
61R Or-1.0
61A Or-1.0
61C Or-1.0
87
83
99
ENGINE
HARNESS
267F
AIR CONDITIONING
DIODE HARNESS
265F
SPL_N1
61C_C Or-1.0 A
B
0_BJ Bk-1.0
C
1 1
2 2
3 3
4 4
29M
71
A
B
C
2 A
88
61T Or-1.0
84
90
SPL_D3
M
BB
AA
86
85
27M
61A_E Or-0.8
61R_E Or-0.8
SPL_D1
69
61A_C Or-0.8
61R_D Or-0.8
Normally Closed
61R_F Or-0.8
0_X Bk-1.0
52 W-1.0
56
10
7 7
8 8
9
6
5
1 1
4
3 3
2 2
210F
158
39.3 ohms at 20C (68F)
78
1 1
2 2
0_F Bk-1.0
68W Or-1.0
63W Or-1.0
76
1 1
2 2
0_G Bk-1.0
21M
REAR
CHASSIS
HARNESS
52_A W-0.8
68W_A Or-1.0
63W_A Or-0.8
21F
CAB
MAIN
HARNESS
7 7
8 8
5 5
10
9
6 6
1 1
4
3 3
2 2
45F
77
19K_D Or-0.8
19K_B Or-1.0
68C_A Or-1.0
68L_A Or-1.0
19K_C Or-1.0
68L_A Or-1.0
68L_B Or-0.8
DIODE
MODULE
68L_B Or-0.8
63L_B Or-0.8
0_DAX Bk-0.8
63H_B Or-0.8
13C_C Or-0.8
21C_F W-0.8
F F
A A
G G
19K_E Or-1.0
68C_B Or-1.0
68L_C Or-1.0
23F 23M
CAB ROOF
MAIN HARNESS
HARNESS
74
A
B
C
D
19C_C Or-0.8
19C_A Or-1.0
SPL_D24
A
B
C
D
81M
A
B
C
D
68L_C Or-1.0
19K_E Or-1.0
68C_B Or-1.0
0_MA Bk-1.0
60
63H_A Or-0.8
63L_A Or-0.8
19J_B Or-0.8
63C_A Or-0.8
0_DV Bk-0.8
57 57
58 58
60 60
59 59
61 61
0_KN Bk-0.8
1 1
2 2
3 3
4 4
5 5
6 6
35F
PARK INTERMITTENT LOW HIGH

24V
24V
24V
57_A W-0.8
0_DAL Bk-1.0
0_DAF Bk-1.0
19P_A Or-1.0
19P_B Or-1.0
24V
0_AJ Bk-2.0
SHEET 1 - 145 GROUND CAB
0_AL Bk-1.0
SHEET 4 - 6 (108)
0_AG Bk-1.0
SHEET 4 - 8 (109)
SHEET 1 - 245F (5) B+ STUD
244F
68
81
24V
SHEET 1 - 243F REAR CHASSIS GROUND STUD
0_ND Bk-62
SPL_A1
0_DAY Bk-1.0
0_DAF Bk-1.0
49_H S-0.8
49_U S-0.8
28.8 ohms at 20C (68F)
73
22.7 ohms at 20C (68F)
51_C W-1.0
0_CF Bk-1.0
AA
BB
264M
68A
39.3 ohms at 20C (68F)
2 2
1 1
66
5F
52_A W-0.8
19P_B Or-1.0
64A_A Or-0.8
N
X
U
W
D
V
H
J
K
S
R
L
T
M
B
57_A W-0.8
0_DAD Bk-1.0
58_A W-0.8
19M_A Or-0.8
19R_A Or-0.8
35X_E Y-0.8

SHEET 1 - SPL_D25
SPL_D13
54B_A W-0.8
56_J W-0.8
53B_B W-0.8
53P_C W-0.8
SHEET 4 - 34F (114)
0_DAH Bk-1.0
0_DAJ Bk-1.0
1F
CAB
MAIN
HARNESS
54B_A W-0.8
SPL_D2
54B_B W-0.8
55A W-0.8
0_DAJ Bk-1.0
0_DAK Bk-1.0
49_M S-1.0
49_N S-1.0
56_H W-0.8
53P_B W-0.8
70
SHEET 4 - SPL_D8
0_AC Bk-1.0
58_C W-1.0
0_DAH Bk-1.0
0_DAG Bk-1.0
49_K S-1.0
49_M S-1.0
SPL_C2
BB
AA
107M
54B_C W-0.8
N
X
U
W
D
V
H
J
K
S
R
L
T
M
B
64 Or-1.0
SHEET 1 - 176 REAR CHASSIS GROUND STUD
SPL_A7
58 W-1.0
19M_B Or-1.0
19R_B Or-1.0
35X_B Y-1.0
54B W-1.0
0_AA Bk-1.0
56_A W-1.0
54B W-1.0
56_C W-1.0
53B W-1.0
53P_D W-1.0
SPL_A3
1
FRONT
CHASSIS
HARNESS
SHEET 2 - 38F (31)

SHEET 2 - 38F (31)
AA
BB
CC
10
19M_B Or-1.0
19R_B Or-1.0
35X_C Y-1.0
51P_B W-1.0
0_AN Bk-1.0
SPL_A4
3
4
2
5
1
6
17M
53B_B W-0.8
56_G W-0.8
54B_C W-0.8
56_F W-0.8
55A W-0.8
56_E W-0.8
53B W-1.0
0_AF Bk-1.0
56_B W-1.0
0_CC Bk-1.0
SPL_C1
A
B
C
12F
A
B
C
12M
N.O.
COM
67
58_E W-1.0
53S_D W-1.0
0_AQ Bk-1.0
AA
BB
CC
DD
EE
F F
229M
0_AQ Bk-1.0
SPL_A6
2 2
1 1
65
39.7 ohms at 20C (68F)
58_D W-1.0
53S_D W-1.0
53S_C W-1.0
SPL_A5
24V
53S_C W-1.0
AA
BB
CC
53B_A W-1.0
0_AM Bk-1.0
56_D W-1.0
AA
BB
CC
200
62
XT MODELS: NORMALLY CLOSED
Z-BAR MODELS: NORMALLY OPEN
64A
58_F W-1.0
58A_A W-1.0
ROLLBACK PRESSURE
SWITCH (OPTION)
BB
AA
Normally Closed
272F
202F 271M
53S_A W-1.0
53P_D W-1.0
BB
AA
178M
AA
BB
53S_E W-1.0 C C
273F
64
SHEET 1 - 177 REAR ENGINE BLOCK GROUND STUD
DIODE
MODULE
58A_A W-1.0
13M 13F
PEDESTAL CAB
HARNESS MAIN
HARNESS
0_CD Bk-1.0
90M SECONDARY STEERING MODULE

SECONDARY STEERING IGNITION
SECONDARY STEERING MOTOR RELEASE
SECONDARY STEERING MODULE B+
SECONDARY STEERING CHASSIS GROUND
NONE
NONE
SECONDARY STEERING ACCESSORY
SECONDARY STEERING HIGH PRESSURE
NONE
SECONDARY STEERING SIGNAL GROUND
179F
24V
24V
0_CB Bk-1.0
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
90M
N.C.
RETURN-TO-DIG HARNESS
FOR XT CHASSIS
0_AP Bk-1.0
53S_B W-1.0
35X_D Y-1.0
51P_A W-1.0
0_CA Bk-1.0
FRONT SECONDARY
CHASSIS STEERING
HARNESS MODULE
HARNESS
NORMALLY
CLOSED
0_AK Bk-1.0
19M_C Or-1.0
1
2
3
4
5
6
180F 180M
51P_B W-1.0 A A
0_AN Bk-1.0 B B
35X_A Y-1.0 C C
131F
SHEET 3 - 56F (51)
1
2
3
4
5
6
63
0_AF Bk-1.0
SPL_A2
SPL_D4
3
4
2
5
1
6
19R_C Or-1.0
51_A W-1.0
1_W R-1.0
0_CE Bk-1.0
57 W-1.0
PINS 4 AND 6 ARE CONNECTED INTERNALLY

BY THE LIMIT SWITCH INSIDE MOTOR
SHEET 1 - 206F CAB GROUND WELD STUD
253F
68.2 ohms - Joystick

305 ohms - Single Axis
MOMENTARY
PUSH
24V PULSE
24V PULSE
1_NC R-50
146
HEIGHT CONTROL
75
35F WIPER AND WASHER SWITCH
BLOWER WIPER SEAT GROUND
FRONT WIPER WASHER FUSED POWER
FRONT WASHER PUMP
FRONT WIPER PARK
FRONT WIPER HIGH SPEED
FRONT WIPER LOW SPEED
51_B W-1.0
181
0_AD Bk-1.0
RETURN-TO-TRAVEL
0_DAR Bk-1.0
19J_A Or-1.0
19J_B Or-0.8
63W_A Or-0.8
63C_A Or-0.8
63H_A Or-0.8
63L_A Or-0.8
63H_B Or-0.8
63L_B Or-0.8
1_W R-1.0
80
242F
SHEET 4 - SPL_M6
SHEET 1 - 57F (58)

SHEET 1 - 54F (12)
30
87
87a
85
86

49_P S-1.0
49_H S-0.8
RETURN-TO-DIG
63H Or-0.8
63L Or-0.8
19J Or-0.8
63C Or-0.8
1 1
60
58S W-0.8
19C_B Or-1.0
0_DAE Bk-1.0
10
7 7
8 8
9
6
5
4
1
3 3
2 2
36F
59

61
A
B
C
D
64C_A Or-0.8
19U_C Or-0.8
SHEET 3 - 56F (51)
1 1
82M
F
A
C
B
D
E
140M
30
87
87A
85
86
51F
58_B W-0.8
68W_A Or-1.0
68C_A Or-1.0
79
F
A
C
B
D
E
19K_A Or-1.0
SHEET 2 - 41F (30)
SHEET 2 - 199F (33)
10
7 7
8 8
9
6
5
1 1
4
3 3
2 2
39F
61
SHEET 2 - 118F (36)
SHEET 2 - 118F (36)
SPL_D23
0_DW Bk-0.8
49_L S-0.8
SHEET 2 - 41F (30)
0_AB Bk-1.0
57 W-1.0
27 27
24 24
25 25
0_DAM Bk-1.0
0_DAL Bk-1.0
49_Q S-1.0
49_P S-1.0
55
BB
AA
19U_B Or-1.0
19U_C Or-0.8
64A_A Or-0.8
64 Or-1.0
10 10
3
8
7
6
5
1 1
9 9
4
2 2
40F
61A_D Or-0.8
1 A
208F
SHEET 2 - 19F (26)

SHEET 2 - 19F (26)
0_DD Bk-0.8
58H_B W-0.8
147
AIR CONDITIONING DIODE HARNESS

USED ONLY ON LOADERS WITH BOTH
AIR CONDITIONING AND TAPE DECK
207F
4 3
0_DZ Bk-2.0
W
R
Bk
DIODE
MODULE
10
7 7
8 8
9
5
6 6
4
1
3 3
2 2
44F
SHEET 1 - 268 REAR ENGINE BLOCK

GROUND STUD
62L Or-1.0
62M Or-2.0
62H Or-2.0
58S W-0.8
58_A W-0.8
58_B W-0.8
0_AA Bk-1.0
B
C
L
M
H
30
87
87A
85
86
50F
61C_E Or-1.0
19G Or-2.0
61T Or-1.0
72
98
266M
1
2
6
5
4
3
30F
30
87
87a
85
86
61C_D Or-1.0
94F 94M
TRANSMISSION ENGINE
HARNESS HARNESS
1
2
6
5
4
3
Normally Open
0_AR Bk-1.0
89
61A_B Or-0.8
61A_C Or-0.8
61R_B Or-0.8
61R_C Or-0.8
61R_D Or-0.8
61C_B Or-0.8
0_DK Bk-0.8
61R_C Or-0.8
3 3
2 2
4 4
8 8
10 10
12 12
14 14
16 16
17 17
18 18
19 19
61R_A Or-1.0
61A_A Or-1.0
61C_A Or-1.0
56_B W-1.0
30
87
87a
85
86
27 27
26 26
25 25
61R_B Or-0.8
61A_B Or-0.8
61C_B Or-0.8
DIODE
MODULE
ROLLBACK PRESSURE SWITCH

JUMPER HARNESS FOR XT CHASSIS
Normally Open
SHEET 5 - MACHINE CONTROLS

RADIO MEMORY
AFTER S/N JEE0133334
1
2
96
1_X R-1.0
18_H Or-0.8
Fuse H 7.5 A
SHEET 1 - 246M ON 18F FUSE BLOCK CONTACT 5
SHEET 1 - 247F CAB GROUND J-BLOCK
19L_A Or-1.0
0_PD Bk-1.0
AA
BB
109M
24V/12V
CONVERTER
94
SHEET 1 - 270F CAB B+ J-BLOCK
92
18_H Or-0.8
AA
65C Or-0.8
0_PC Bk-0.8
BB
110F
6
3
2
1
4
5
6
8
14
5
4
11
2
9
7
10
3
12
13
1
65C_B Or-0.8
0_QC Bk-0.8
0_QA Bk-0.8
65L_A Or-0.8
0_QB Bk-0.8
65R_A Or-0.8
6
3
2
1
4
5
114F 114M
0_PA Bk-0.8
BB
AA
65L Or-0.8
112M
97
6
8
14
5
4
11
2
9
7
10
3
12
13
1
SHEET 1 - 250F CAB B+ J BLOCK
1_V R-5.0
24V
IGN
255F
256F
254F
258F
19L_B Or-1.0
12V_B R-5.0
12V_A R-30
SHEET 1 - 18F FUSE BLOCK CONTACT 6
REMOTE
24V
REMOTE
RADIO
TOP CAB
GROUND
WELD STUD
SHEET 1 - 251F CAB GROUND J BLOCK
0_RA Bk-5.0
GND
12V
257F
91
TAPE DECK
113
0_PB Bk-0.8
BB
AA
65R Or-0.8
111M
98
95
SHEET 1 - 252F OUTLET GROUND (CAB GROUND WELD STUD)

B
AA
BB
0_RB Bk-3.0
1 1
2 2
19W_A Or-3.0
0_S Bk-3.0
1. 24V REMOTE RADIO (ALL CIRCUITS SHOWN INCLUDING BOX B BUT EXCLUDING BOXES A AND C (109M CONNECTED TO 110F))
2. 24V REMOTE RADIO WITH TAPE DECK (ALL CIRCUITS SHOWN INCLUDING BOXES B AND C BUT EXCLUDING BOX A (109M CONNECTED TO 110F))
3. 24V RADIO READY (ALL CIRCUITS SHOWN EXCLUDING BOXES A, B, AND C (109M CONNECTED TO 110F))
4. 12V RADIO READY (ALL CIRCUITS SHOWN INCLUDING BOX A BUT EXCLUDING BOXES B AND C)
82
259F
93
253F
BB
AA

0_DY Bk-1.0
19N_A Or-1.0

28M
CIGAR LIGHTER OPTION

AIR SEAT OPTION
24 VOLT - 12 VOLT POWER CONVERTER OPTION
RADIO OPTIONS
SHEET 6 - OPTIONS
COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Batteries
Alternator
Starter Motor
Starting Relay
Fuel Relay
Ether Start Switch
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Declutch Switch
FNR Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
2
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y
Instrument Cluster
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.
68.
68A.
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
1.
2.
3.
4.
5.
CIRCUIT CONNECTED
WIRE IDENTIFICATION
MALE CONNECTOR
10
A A
B B
1 1
SHEET 6 - 253F (54)
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
Detent Switch
Float Solenoid
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.

Ride Control Switch
Front Wiper Motor
Rear Wiper Motor
ACTUATOR SYMBOLS
5 6
SPL_G2
=
=
=
=
=
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE

37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
CONTACT SYMBOLS
1
P
3
Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.

Beacon Switch
Rotating Beacon
Hazard Switch

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
Flasher Module
License Plate Lamp
117. Dome Lamp

118. Courtesy Lamp
NOTES
BC02D081
Copyright
30
87
87A
85
86
203F
22F 22M
CAB TRANSMISSION
MAIN HARNESS
HARNESS
SHEET 1 - 220F
BB
AA
61R Or-1.0
61A Or-1.0
61C Or-1.0
87
83
99
ENGINE
HARNESS
267F
AIR CONDITIONING
DIODE HARNESS
265F
SPL_N1
61C_C Or-1.0 C
B
0_BJ Bk-1.0
A
1 1
2 2
3 3
4 4
29M
71
C
B
A
2 A
88
61T Or-1.0
84
90
SPL_D3
M
BB
AA
86
85
27M
61A_E Or-0.8
61R_E Or-0.8
SPL_D1
Normally Closed
69
61A_C Or-0.8
61R_D Or-0.8
61R_F Or-0.8
0_X Bk-1.0
52 W-1.0
56
10
7 7
8 8
9
6
5
1 1
4
3 3
2 2
210F
158
39.3 ohms at 20C (68F)
78
1 1
2 2
0_F Bk-1.0
68W Or-1.0
63W Or-1.0
76
1 1
2 2
0_G Bk-1.0
21M
REAR
CHASSIS
HARNESS
52_A W-0.8
68W_A Or-1.0
63W_A Or-0.8
21F
CAB
MAIN
HARNESS
7 7
8 8
5 5
10
9
6 6
1 1
4
3 3
2 2
45F
77
19K_D Or-0.8
SHEET 2 - 118F (36)

SHEET 2 - 118F (36)
SPL_D23
DIODE
MODULE
19K_B Or-1.0
68C_A Or-1.0
68L_A Or-1.0
19K_C Or-1.0
68L_A Or-1.0
68L_B Or-0.8
68L_B Or-0.8
63L_B Or-0.8
0_DAX Bk-0.8
63H_B Or-0.8
13C_C Or-0.8
21C_F W-0.8
19K_E Or-1.0
68C_B Or-1.0
68L_C Or-1.0
F F
A A
G G
23F 23M
CAB ROOF
MAIN HARNESS
HARNESS
74
A
B
C
D
1 1
60
19C_C Or-0.8
19C_A Or-1.0
A
B
C
D
81M
A
B
C
D
68L_C Or-1.0
19K_E Or-1.0
68C_B Or-1.0
60
75
63H_A Or-0.8
63L_A Or-0.8
19J_B Or-0.8
63C_A Or-0.8
0_DV Bk-0.8
57 57
58 58
60 60
59 59
61 61
63H Or-0.8
63L Or-0.8
19J Or-0.8
63C Or-0.8
0_KN Bk-0.8
1 1
2 2
3 3
4 4
5 5
6 6
35F
PARK INTERMITTENT LOW HIGH
35F WIPER AND WASHER SWITCH

BLOWER WIPER SEAT GROUND
FRONT WIPER WASHER FUSED POWER
FRONT WASHER PUMP
FRONT WIPER PARK
FRONT WIPER HIGH SPEED
FRONT WIPER LOW SPEED
24V
24V
24V
MOMENTARY
PUSH
24V
57_A W-0.8
0_DAL Bk-1.0
0_DAF Bk-1.0
19P_A Or-1.0
19P_B Or-1.0
0_AJ Bk-2.0
0_AL Bk-1.0
SHEET 4 - 6 (108)
0_AG Bk-1.0
SHEET 4 - 8 (109)
0_DAY Bk-1.0
0_DAF Bk-1.0
49_H S-0.8
49_U S-0.8
244F
68
81
SHEET 1 - 243F REAR CHASSIS GROUND STUD
0_ND Bk-62
SPL_C2
BB
AA
70
28.8 ohms at 20C (68F)
73
22.7 ohms at 20C (68F)
51_C W-1.0
0_CF Bk-1.0
AA
BB
264M
107M
68A
39.3 ohms at 20C (68F)
SHEET 4 - SPL_D8
0_AC Bk-1.0
58_C W-1.0
2 2
1 1
66
5F
52_A W-0.8
19P_B Or-1.0
64A_A Or-0.8
N
X
U
W
D
V
H
J
K
S
R
L
T
M
B
57_A W-0.8
0_DAD Bk-1.0
0_DAH Bk-1.0
0_DAG Bk-1.0
49_K S-1.0
49_M S-1.0
SPL_D13
58_A W-0.8
19M_A Or-0.8
19R_A Or-0.8
35X_E Y-0.8

SHEET 1 - SPL_D25
54B_A W-0.8
56_J W-0.8
53B_B W-0.8
53P_C W-0.8
SHEET 4 - 34F (114)
0_DAH Bk-1.0
0_DAJ Bk-1.0
1F
CAB
MAIN
HARNESS
54B_A W-0.8
SPL_D2
54B_B W-0.8
55A W-0.8
54B_C W-0.8
N
X
U
W
D
V
H
J
K
S
R
L
T
M
B
64 Or-1.0
0_DAJ Bk-1.0
0_DAK Bk-1.0
49_M S-1.0
49_N S-1.0
SHEET 1 - 176 REAR CHASSIS GROUND STUD
SPL_A7
58 W-1.0
19M_B Or-1.0
19R_B Or-1.0
35X_B Y-1.0
54B W-1.0
0_AA Bk-1.0
56_A W-1.0
54B W-1.0
56_C W-1.0
53B W-1.0
53P_D W-1.0
SPL_A3
1
FRONT
CHASSIS
HARNESS
SHEET 2 - 38F (31)

SHEET 2 - 38F (31)
AA
BB
CC
10
19M_B Or-1.0
19R_B Or-1.0
35X_C Y-1.0
51P_B W-1.0
0_AN Bk-1.0
SPL_A4
C
+
3
4
2
5
1
6
HEIGHT CONTROL
68.2 ohms - Joystick

305 ohms - Single Axis
53B_B W-0.8
56_G W-0.8
54B_C W-0.8
56_F W-0.8
55A W-0.8
56_E W-0.8
3
4
2
5
1
6
17M
53B W-1.0
0_AF Bk-1.0
56_B W-1.0
0_CC Bk-1.0
SPL_C1
A
B
C
12F
A
B
C
12M
N.O.
COM
67
58_E W-1.0
53S_D W-1.0
0_AQ Bk-1.0
AA
BB
CC
DD
EE
F F
229M
0_AQ Bk-1.0
SPL_A6
2 2
1 1
65
0_CB Bk-1.0
0_CD Bk-1.0
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
90M
90M SECONDARY STEERING MODULE

SECONDARY STEERING IGNITION
SECONDARY STEERING MOTOR RELEASE
SECONDARY STEERING MODULE B+
SECONDARY STEERING CHASSIS GROUND
NONE
NONE
SECONDARY STEERING ACCESSORY
SECONDARY STEERING HIGH PRESSURE
NONE
SHEET 1 - 177 REAR ENGINE BLOCK GROUND STUD
N.C.
53B_A W-1.0
0_AM Bk-1.0
56_D W-1.0
AA
BB
CC
200
C
+
62
XT MODELS: NORMALLY CLOSED
Z-BAR MODELS: NORMALLY OPEN
RETURN-TO-DIG HARNESS
FOR XT CHASSIS
0_AP Bk-1.0
53S_B W-1.0
35X_D Y-1.0
51P_A W-1.0
0_CA Bk-1.0
FRONT SECONDARY
CHASSIS STEERING
HARNESS MODULE
HARNESS
NORMALLY
CLOSED
0_AK Bk-1.0
19M_C Or-1.0
1
2
3
4
5
6
180F 180M
51P_B W-1.0 A A
0_AN Bk-1.0 B B
35X_A Y-1.0 C C
131F
SHEET 3 - 56F (51)
1
2
3
4
5
6
63
0_AF Bk-1.0
SPL_A2
SPL_D4
56_H W-0.8
53P_B W-0.8
19R_C Or-1.0
51_A W-1.0
1_W R-1.0
0_CE Bk-1.0
57 W-1.0
DIODE
MODULE
64A
179F
39.7 ohms at 20C (68F)
58_D W-1.0
53S_D W-1.0
53S_C W-1.0
SPL_A5
53S_C W-1.0
58_F W-1.0
58A_A W-1.0
AA
BB
CC
BB
AA
Normally Closed
272F
202F 271M
PINS 4 AND 6 ARE CONNECTED INTERNALLY

BY THE LIMIT SWITCH INSIDE MOTOR
SHEET 1 - 206F CAB GROUND WELD STUD
SHEET 1 - 245F RELAY BOX

JUNCTION BLOCK
SPL_A1
24V
24V
263F
24V
24V
24V PULSE
24V PULSE
1_NC R-50
146
RETURN-TO-TRAVEL
0_DAR Bk-1.0
19J_A Or-1.0
19J_B Or-0.8
63W_A Or-0.8
63C_A Or-0.8
63H_A Or-0.8
63L_A Or-0.8
63H_B Or-0.8
63L_B Or-0.8
51_B W-1.0
181
0_AD Bk-1.0
RETURN-TO-DIG
SHEET 1 - 57F (58)

SHEET 1 - 54F (12)
1_W R-1.0
80
242F
SHEET 4 - SPL_M6
0_MA Bk-1.0
30
87
87a
85
86

49_P S-1.0
49_H S-0.8
0_DAE Bk-1.0
10
7 7
8 8
9
6
5
4
1
3 3
2 2
36F
59

61
A
B
C
D
SPL_D24
SHEET 3 - 56F (51)
1 1
82M
F
A
C
B
D
E
140M
58S W-0.8
19C_B Or-1.0
68W_A Or-1.0
68C_A Or-1.0
79
F
A
C
B
D
E
19K_A Or-1.0
64C_A Or-0.8
19U_C Or-0.8
58_B W-0.8
SHEET 2 - 199F (33)
10
7 7
8 8
9
6
5
1 1
4
3 3
2 2
39F
61
0_DW Bk-0.8
49_L S-0.8
SHEET 2 - 41F (30)
30
87
87A
85
86
51F
0_AB Bk-1.0
57 W-1.0
27 27
24 24
25 25
SHEET 2 - 41F (30)
55
22
11
0_DAM Bk-1.0
0_DAL Bk-1.0
49_Q S-1.0
49_P S-1.0
64 Or-1.0
10 10
3
8
7
6
5
1 1
9 9
4
2 2
40F
61A_D Or-0.8
1 A
208F
19U_B Or-1.0
19U_C Or-0.8
64A_A Or-0.8
147
AIR CONDITIONING DIODE HARNESS

USED ONLY ON LOADERS WITH BOTH
AIR CONDITIONING AND TAPE DECK
207F
4 3
0_DZ Bk-2.0
W
R
Bk
DIODE
MODULE
10
7 7
8 8
9
5
6 6
4
1
3 3
2 2
44F
SHEET 1 - 268 REAR ENGINE BLOCK

GROUND STUD
62L Or-1.0
62M Or-2.0
62H Or-2.0
SHEET 2 - 19F (26)

SHEET 2 - 19F (26)
0_DD Bk-0.8
58H_B W-0.8
0_AA Bk-1.0
B
C
L
M
H
58S W-0.8
58_A W-0.8
58_B W-0.8
30
87
87A
85
86
50F
61C_E Or-1.0
19G Or-2.0
61T Or-1.0
72
98
266M
1
2
6
5
4
3
30F
30
87
87a
85
86
61C_D Or-1.0
94F 94M
TRANSMISSION ENGINE
HARNESS HARNESS
1
2
6
5
4
3
Normally Open
0_AR Bk-1.0
89
61A_B Or-0.8
61A_C Or-0.8
61R_B Or-0.8
61R_C Or-0.8
61R_D Or-0.8
61C_B Or-0.8
0_DA Bk-0.8
61R_C Or-0.8
3 3
2 2
4 4
8 8
10 10
12 12
14 14
16 16
17 17
18 18
19 19
61R_A Or-1.0
61A_A Or-1.0
61C_A Or-1.0
56_B W-1.0
30
87
87a
85
86
27 27
26 26
25 25
61R_B Or-0.8
61A_B Or-0.8
61C_B Or-0.8
58A_A W-1.0
13M 13F
PEDESTAL CAB
HARNESS MAIN
HARNESS
53S_A W-1.0
53P_D W-1.0
BB
AA
178M
AA
BB
53S_E W-1.0 C C
273F
64
DIODE
MODULE
ROLLBACK PRESSURE SWITCH

JUMPER HARNESS FOR XT CHASSIS
Normally Open
SHEET 5 - MACHINE CONTROLS

RADIO MEMORY
AFTER S/N JEE0133334
1
2
96
1_X R-1.0
18_H Or-0.8
Fuse H 7.5 A
19L_A Or-1.0
0_PD Bk-1.0
AA
BB
109M
18_H Or-0.8
AA
65C Or-0.8
0_PC Bk-0.8
BB
110F
24V/12V
CONVERTER
6
3
2
1
4
5
65C_B Or-0.8
0_QC Bk-0.8
0_QA Bk-0.8
65L_A Or-0.8
0_QB Bk-0.8
65R_A Or-0.8
6
3
2
1
4
5
114F 114M
0_PA Bk-0.8
BB
AA
65L Or-0.8
112M
97
95
92
6
8
14
5
4
11
2
9
7
10
3
12
13
1
6
8
14
5
4
11
2
9
7
10
3
12
13
1
1_V R-5.0
SHEET 1 - 250F CAB B+ J BLOCK

24V
REMOTE
RADIO
IGN
24V
255F
256F
254F
258F
19L_B Or-1.0
12V_B R-5.0
12V_A R-30
SHEET 1 - 18F FUSE BLOCK CONTACT 6
REMOTE
TOP CAB
GROUND
WELD STUD
GND
0_RA Bk-5.0
SHEET 1 - 251F CAB GROUND J BLOCK
12V
257F
91
TAPE DECK
113
0_PB Bk-0.8
BB
AA
65R Or-0.8
111M
98
94
SHEET 1 - 270F CAB B+ J-BLOCK
SHEET 1 - 252F OUTLET GROUND (CAB GROUND WELD STUD)

B
AA
BB
0_RB Bk-3.0
1. 24V REMOTE RADIO (ALL CIRCUITS SHOWN INCLUDING BOX B BUT EXCLUDING BOXES A AND C (109M CONNECTED TO 110F))
2. 24V REMOTE RADIO WITH TAPE DECK (ALL CIRCUITS SHOWN INCLUDING BOXES B AND C BUT EXCLUDING BOX A (109M CONNECTED TO 110F))
3. 24V RADIO READY (ALL CIRCUITS SHOWN EXCLUDING BOXES A, B, AND C (109M CONNECTED TO 110F))
4. 12V RADIO READY (ALL CIRCUITS SHOWN INCLUDING BOX A BUT EXCLUDING BOXES B AND C)
19W_A Or-3.0
0_S Bk-3.0

BB
AA
82
259F
93
253F
1 1
2 2
0_DY Bk-1.0
19N_A Or-1.0

28M
CIGAR LIGHTER OPTION

AIR SEAT OPTION
24 VOLT - 12 VOLT POWER CONVERTER OPTION
RADIO OPTIONS
SHEET 6 - OPTIONS
COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
11A.
Batteries
Alternator
Starter Motor
Starting Relay
11B.
11C.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Ignition Switch
Time Delay Module
Output Speed Sensor
Engine Speed Sensor
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

Declutch Switch
Bk
DU
G
K
LG
=
=
=
=
=
BLACK
DARK BLUE
GREEN
PINK
LIGHT GREEN
LU
N
Or
P
R
23F_A W-2.0
LIGHT BLUE
BROWN
ORANGE
PURPLE (VIOLET)
RED
S
T
U
W
Y

Instrument Cluster
=
=
=
=
=
GRAY
TAN
BLUE
WHITE
YELLOW

21C_C W-1.0
0_GA Bk-2.0
3
2
CONNECTED)
10
A A
B B
1 1
14_B LG-0.8
6.
7.
8.
9.
10.
7
8
21M 21F
XXXX XXXX
SHEET 6 - 253F (54)
FEMALE CONNECTOR
11.
12.
13.
14.
15.
12
13
10
D+
+
9
11
14
54
2 2
93M 93F
XXXX XXXX
57.
58.
59.
60.
61.
62.
63.
64.
64A.
65.
66.
67.

Detent Switch
Float Solenoid
ACTUATOR SYMBOLS
5 6
SPL_G2
2
=
=
=
=
=
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
CIRCUIT LEGEND
WIRE IDENTIFICATION
1. WIRE NUMBER
3. WIRE SIZE
34. FNR Switch

37. Backup Alarm
11
15

COMPONENT NUMBER
12
A
B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12A.
12B.
LEVER RELEASED
LEVER ACTUATED
LIQUID LEVEL FLOAT
PRESSURE
HAND OPERATED
TEMPERATURE
COIL
VARIABLE RESISTOR
RESISTOR
DIODE
MOMENTARY CONTACT
MAINTAINED CONTACT
68.
68A.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.

Ride Control Switch
Front Wiper Motor
HOUSINGS
1
V
2
M
5
1.
2.
3.
4.
5.
VACUUM SWITCH
PRESSURE SWITCH
TEMPERATURE SWITCH
MOTOR
LAMP
Rear Wiper Motor

Horn
Blower Switch
Blower Motor
Thermostat Switch
Compressor Clutch
CONTACT SYMBOLS
1
P
3
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
1. SINGLE POLE,
SINGLE THROW
2. SINGLE POLE,
DOUBLE THROW
3. DOUBLE POLE,
SINGLE THROW
4. DOUBLE POLE,
DOUBLE THROW

1
A2
A1
1. FUSE
2. CIRCUIT BREAKER,
AUTOMATIC RESET
3. CIRCUIT BREAKER,
MANUAL RESET
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.

Beacon Switch
Rotating Beacon
103. Hazard Switch

Switch
105. Flasher Module

Switch
117. Dome Lamp
118. Courtesy Lamp
NOTES
1.
2.
3.
4.
5.
6.
7.
Used only on 621D.

BC02M037
Copyright
40
12
14
38
41
16
13
19
S3
S1
DS2
P
39
LS
BR3
P
R
18
32
20
BR1
31
17
Pst
LOCK
45 BAR
(653 PSI)
35
BR2
30 BAR
(435 PSI)
UNLOCK
SX
241 BAR
(3495 PSI)
24
LS
37
20
25
S
DS1
S2
16
15
11
250 BAR
(3626 PSI)
XT MODELS
10
38
0.7 L/min
XT MODELS
12
XY
XZ
Z-BAR and
XR MODELS
NOTE 3
XT MODELS
a1
b1
290 BAR
(4206 PSI)
A1
XY
XZ
B1
XY
XZ
Z-BAR and XR MODELS

TANK
M1
NOTE 1
Z-BAR and
XR MODELS
193
BAR
(2799 PSI)
21
30
136.2
BAR
(1975 PSI)
M2
A2
136
BAR
(1972 PSI)
IN
22A
a2
34
TANK
M1
6-8 BAR
(87-116 PSI)
b2
B2
M2
IN
22
2
T
3
a3
b3
33
290 BAR
(4206 PSI)
A3
B3
290 BAR
(4206 PSI)
4
27
26
FR1
NOTE 2
b4
a4
FR2
2
LR
EF
LS
23
X1
1
240 BAR
(3481 PSI)
S2
S1
29
L1
2
Y
Z1
X2
LOGIC
VALVE
MP
MX
MA
36
T
B4
PP
A4
290 BAR
(4206 PSI)
CF
SEQUENCE
VALVE
1
290 BAR
(4206 PSI)
SOLENOID
VALVE A
RELIEF
VALVE
L
A
M
28
42
42
COMPONENTS
1. RIDE CONTROL VALVE (OPTION)
2. RIDE CONTROL ACCUMULATOR (OPTION)
PRECHARGE: 14.5 BAR (250 PSI)
CAPACITY: 3.78 LITRES (231 CU IN.)
3. RIDE CONTROL ACCUMULATOR BLEEDER VALVE
4. LIFT CYLINDERS)
BORE: 101.60 MM (4.00 IN)
ROD: 57.15 MM (2.25 IN)
STROKE: 783.00 MM (30.83 IN)
5. BUCKET CYLINDER
BORE: 114.30 MM (4.50 IN)
ROD: 63.50 MM (2.50 IN)
STROKE: 529.40 MM (20.84 IN)
DISPLACEMENT: 462 CC/REV (28.2 CU IN./REV)
7. STEERING CYLINDERS (2)

BORE: 63.5 MM (2.50 IN)
ROD: 34.93 MM (1.375 IN)
STROKE: 489.20 MM (19.26 IN)
8. AUXILIARY STEERING MOTOR AND PUMP
(OPTION - NORTH AMERICAN MODELS)
9. AUXILIARY STEERING PRIORITY VALVE
RELIEF PRESSURE: 240.3 BAR (3481 PSI)
2.4 BAR (35 PSI)
11. STEERING PRESSURE DIAGNOSTIC COUPLER
12. BRAKE ACCUMULATORS (2)
PRECHARGE: 55 1.7 BAR (800 25 PSI)
CAPACITY: 0.95 LITRE (58 CU IN.)
13. BRAKE VALVE AND ACCUMULATOR CHARGING VALVE

CUT-IN: 157 +10 BAR (2277 +145 PSI)
CUT-OUT: 193 3 BAR (2800 43 PSI)
14. BRAKE WARNING PRESSURE SWITCH
141 BAR (2045 PSI) RISING
117 BAR (1697 PSI) FALLING
4.1 BAR (60 PSI)
16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
17. REAR BRAKE CYLINDERS
MODULATION PRESSURE: 56 +6 BAR (856 +87 PSI)
18. FRONT BRAKE CYLINDERS
19. PARKING BRAKE CYLINDER
20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC FITTINGS (2)
21. FAN DRIVE MOTOR

22. FAN REVERSING VALVE (OPTION)
RELIEF SETTING: 135 BAR (1960 PSI)
22A. FAN VALVE (STANDARD)
RELIEF SETTING: 136.2 BAR (2306 PSI)
23. BRAKE HYDRAULIC PUMP
24. COUPLER LOCKING VALVE (OPTION)
25. COUPLER LOCKING CYLINDERS (2) (OPTION)
26. IMPLEMENT HYDRAULIC PUMP
CUTOFF: 280 BAR (4061 PSI)
DELTA: 22 BAR (319 PSI)
START OF TORQUE LIMIT DESTROKE: 159 BAR (2306 PSI)
NOTES
27. HYDRAULIC FILTER ASSEMBLY
BYPASS VALVE: 3.4 BAR (50 PSI)
WARNING SWITCH: 2.7 BAR (40 PSI)
28. HYDRAULIC RESERVOIR
TOTAL VOLUMN: 83.3 LITRES (22 U.S. GALLONS)
OIL CAPACITY: 56.8 LITRES (15 U.S. GALLONS)
29. HYDRAULIC RESERVOIR BREATHER
20 MICRON BREATHER
30. HYDRAULIC COOLER (OPTION)
31. PILOT PRESSURE ACCUMULATOR
PRECHARGE: 13.8 1.7 BAR (200 25 PSI)
32. PILOT PRESSURE DIAGNOSTIC COUPLER
33. FLOAT SWITCH - CLOSES AT 24 BAR (350 PSI)
34. CONTROLLER WITH TWO SPOOL LOADER VALVE

TWO LEVER OR JOYSTICK CONTROLLER
34. CONTROLLER WITH THREE SPOOL LOADER VALVE
THREE LEVER OR JOYSTICK WITH ONE LEVER CONTROLLER
34. CONTROLLER WITH FOUR SPOOL LOADER VALVE
JOYSTICK WITH TWO LEVER CONTROLLER
TWO SPOOL (STANDARD)
THREE SPOOL (OPTION)
FOUR SPOOL (OPTION)
36. PUMP PRESSURE DIAGNOSTIC COUPLER
37. LOAD SENSING PRESSURE DIAGNOSTIC COUPLER
38. REDUNDANT BRAKE PRESSURE SWITCH (2)
CLOSES AT 62 BAR (900 PSI)
39. AUXILIARY STEERING LOAD SENSE

SOLENOID VALVE (OPTION - NORTH
AMERICAN MODELS)
PRECHARGE: 97 BAR (1407 PSI)
PRESSURE DIAGNOSTIC COUPLER
42. 100 MESH STRAINER (2)
1. CHECK AND RELIEF VALVES INTEGRAL TO

MOTOR NOT USED WITH FAN REVERSER.
2. REVERSE FLOW CHECK VALVE (OPTION)
USED ONLY WITH RIDE CONTROL.
3. Z-BAR AND XR MODELS - 290 BAR (4206 PSI)
XT MODELS - 183 BAR (2654 PSI)
HYDRAULIC SYMBOLS
PRESSURE
COMPONENT
CROSSING LINES
CHECK VALVE
FILTER OR SCREEN
LINE CONNECTION
RESTRICTOR
OIL COOLER
RETURN
LOAD SENSE
PILOT PRESSURE
HYDRAULIC SCHEMATIC
521D Z-BAR, 521D XR and 521D XT WHEEL LOADERS
BC02D082
Copyright
40
12
14
38
6
16
13
19
S3
S1
DS2
P
39
LS
BR3
P
R
18
32
20
BR1
31
17
Pst
LOCK
45 BAR
(653 PSI)
35
BR2
30 BAR
(435 PSI)
UNLOCK
SX
241 BAR
(3495 PSI)
24
LS
37
20
25
S
DS1
S2
16
15
11
250 BAR
(3626 PSI)
XT MODELS
10
38
0.7 L/min
XT MODELS
12
XY
XZ
Z-BAR and
XR MODELS
NOTE 3
XT MODELS
a1
b1
290 BAR
(4206 PSI)
A1
XY
XZ
B1
XY
XZ
Z-BAR and XR MODELS

TANK
M1
NOTE 1
Z-BAR and
XR MODELS
193
BAR
(2799 PSI)
21
30
136.2
BAR
(1975 PSI)
M2
A2
136
BAR
(1972 PSI)
IN
22A
a2
34
TANK
M1
6-8 BAR
(87-116 PSI)
b2
B2
M2
IN
22
2
T
3
a3
b3
33
290 BAR
(4206 PSI)
A3
B3
290 BAR
(4206 PSI)
4
27
26
FR1
NOTE 2
b4
a4
FR2
2
LR
EF
LS
23
X1
1
240 BAR
(3481 PSI)
S2
S1
29
L1
2
Y
Z1
X2
LOGIC
VALVE
MP
MX
MA
36
T
B4
PP
A4
290 BAR
(4206 PSI)
CF
SEQUENCE
VALVE
1
290 BAR
(4206 PSI)
SOLENOID
VALVE A
RELIEF
VALVE
L
A
M
28
41
41
COMPONENTS
1. RIDE CONTROL VALVE (OPTION)
2. RIDE CONTROL ACCUMULATOR (OPTION)
PRECHARGE: 14.5 BAR (250 PSI)
CAPACITY: 3.78 LITRES (231 CU IN.)
3. RIDE CONTROL ACCUMULATOR BLEEDER VALVE
4. LIFT CYLINDERS)
BORE: 101.60 MM (4.00 IN)
ROD: 57.15 MM (2.25 IN)
STROKE: 783.00 MM (30.83 IN)
5. BUCKET CYLINDER
BORE: 114.30 MM (4.50 IN)
ROD: 63.50 MM (2.50 IN)
STROKE: 529.40 MM (20.84 IN)
7. STEERING CYLINDERS (2)

BORE: 63.5 MM (2.50 IN)
ROD: 34.93 MM (1.375 IN)
STROKE: 489.20 MM (19.26 IN)
8. AUXILIARY STEERING MOTOR AND PUMP
9. AUXILIARY STEERING PRIORITY VALVE
RELIEF PRESSURE: 240.3 BAR (3481 PSI)
2.4 BAR (35 PSI)
11. STEERING PRESSURE DIAGNOSTIC COUPLER
12. BRAKE ACCUMULATORS (2)
PRECHARGE: 55 1.7 BAR (800 25 PSI)
13. BRAKE VALVE AND ACCUMULATOR CHARGING VALVE

CUT-IN: 157 +10 BAR (2277 +145 PSI)
CUT-OUT: 193 3 BAR (2800 43 PSI)
14. BRAKE WARNING PRESSURE SWITCH
141 BAR (2045 PSI) RISING
117 BAR (1697 PSI) FALLING
4.1 BAR (60 PSI)
16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
17. REAR BRAKE CYLINDERS
18. FRONT BRAKE CYLINDERS
19. PARKING BRAKE CYLINDER
20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC FITTINGS (2)
21. FAN DRIVE MOTOR

22. FAN REVERSING VALVE (OPTION)
RELIEF SETTING: 135 BAR (1960 PSI)
22A. FAN VALVE (STANDARD)
RELIEF SETTING: 136.2 BAR (2306 PSI)
23. BRAKE HYDRAULIC PUMP
24. COUPLER LOCKING VALVE (OPTION)
25. COUPLER LOCKING CYLINDERS (2) (OPTION)
26. IMPLEMENT HYDRAULIC PUMP
CUTOFF: 280 BAR (4061 PSI)
DELTA: 22 BAR (319 PSI)
START OF TORQUE LIMIT DESTROKE: 159 BAR (2306 PSI)
NOTES
27. HYDRAULIC FILTER ASSEMBLY
BYPASS VALVE: 3.4 BAR (50 PSI)
WARNING SWITCH: 2.7 BAR (40 PSI)
28. HYDRAULIC RESERVOIR
TOTAL VOLUMN: 83.3 LITRES (22 U.S. GALLONS)
OIL CAPACITY: 56.8 LITRES (15 U.S. GALLONS)
29. HYDRAULIC RESERVOIR BREATHER
20 MICRON BREATHER
30. HYDRAULIC COOLER (OPTION)
31. PILOT PRESSURE ACCUMULATOR
PRECHARGE: 13.8 1.7 BAR (200 25 PSI)
32. PILOT PRESSURE DIAGNOSTIC COUPLER
33. FLOAT SWITCH - CLOSES AT 24 BAR (350 PSI)
34. CONTROLLER WITH TWO SPOOL LOADER VALVE

TWO LEVER OR JOYSTICK CONTROLLER
34. CONTROLLER WITH THREE SPOOL LOADER VALVE
THREE LEVER OR JOYSTICK WITH ONE LEVER CONTROLLER
34. CONTROLLER WITH FOUR SPOOL LOADER VALVE
JOYSTICK WITH TWO LEVER CONTROLLER
TWO SPOOL (STANDARD)
THREE SPOOL (OPTION)
FOUR SPOOL (OPTION)
36. PUMP PRESSURE DIAGNOSTIC COUPLER
37. LOAD SENSING PRESSURE DIAGNOSTIC COUPLER
38. REDUNDANT BRAKE PRESSURE SWITCH (2)
CLOSES AT 62 BAR (900 PSI)
39. AUXILIARY STEERING LOAD SENSE

SOLENOID VALVE (OPTION - NORTH
AMERICAN MODELS)
PRECHARGE: 97 BAR (1407 PSI)
CAPACITY: 0.16 LITRE (9.8 CU IN.)
41. 100 MESH STRAINER (2)
1. CHECK AND RELIEF VALVES INTEGRAL TO

MOTOR NOT USED WITH FAN REVERSER.
2. REVERSE FLOW CHECK VALVE (OPTION)
USED ONLY WITH RIDE CONTROL.
3. Z-BAR AND XR MODELS - 290 BAR (4206 PSI)
XT MODELS - 183 BAR (2654 PSI)
HYDRAULIC SYMBOLS
PRESSURE
COMPONENT
CROSSING LINES
CHECK VALVE
FILTER OR SCREEN
LINE CONNECTION
RESTRICTOR
OIL COOLER
RETURN
LOAD SENSE
PILOT PRESSURE
HYDRAULIC SCHEMATIC P.I.N. JEE0135501 AND ABOVE

521D Z-BAR, 521D XR and 521D XT WHEEL LOADERS
BC02M038

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Copyright

Section Index - General

Standard Torque Specifications

Fluids and Lubricants

Metric Conversion Chart

Loctite Product Chart

Section Index - Engines

Engine and Radiator Removal and Installation

For Engine Repair, See the Engine Service Manual

Section Index - Fuel System

For Fuel System Repair, See the Engine Service Manual

Section Index - Electrical

Removal and Installation of Starter and Alternator

Electrical Specifications and Troubleshooting

Electrical Specifications and Troubleshooting P.I.N. JEE0135501 and Above

Information and Diagnostic Center

Section Index - Steering

Removal and Installation of Steering Components

Steering Specifications, Pressure Checks, and Troubleshooting

Steering Control Valve

Steering Priority Valve

Auxiliary Steering Motor and Pump

Copyright 2003 Case Corporation

Section Index - Power Train

Removal and Installation of Power Train Components

Transmission Specifications, Pressure Checks, and Troubleshooting

Front and Rear Axle

Front and Rear Axle P.I.N. JEE0135501 and Above

Drive Shafts, Center Bearing, and Universal Joints

Wheels and Tires

Transmission Control Valve

Section Index - Brakes

Removal and Installation of Brake Components

Hydraulic Brake Troubleshooting

Section Index - Hydraulics

Removal and Installation of Hydraulic Components

Hydraulic Specifications, Troubleshooting, and Pressure Checks

Cleaning the Hydraulic System

Coupler Solenoid Locking Valve

Pilot Pressure Accumulator and Ride Control Accumulator

Section Index - Mounted Equipment

Pedals and Levers

Air Conditioner System Service

Removal and Installation of Air Conditioning Components For Systems with

ROPS Cab and ROPS Canopy

Cab Glass Installation

Electrical Schematic Foldouts and Hydraulic Schematic Foldout

Electrical Schematic Foldouts and Hydraulic Schematic Foldout P.I.N

NOTE: Case Corporation reserves the right to make improvements in design or

Copyright 2003 Case Corporation

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

Copyright 2001 Case Corporation

1999 Case Corporation

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

NOTE: Use thick nuts with Grade 8 bolts.

TORQUE SPECIFICATIONS - METRIC HARDWARE

Grade 10.9 Bolts, Nuts, and Studs

Grade 8.8 Bolts, Nuts, and Studs

Grade 12.9 Bolts, Nuts, and Studs

Usually the torque values specified for grade 10.9 fasteners

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS