84487565-SM-821F 921F Tier4

821F
921F
Tier 4
Wheel Loader
SERVICE MANUAL
Printed in U.S.A. Part number 84487565

1st edition English
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. April 2011
Racine Wisconsin 53404 U.S.A.
1001
Section
1001
GENERAL TORQUE SPECIFICATIONS

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

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

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

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

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

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

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

Pound- Newton
Size Inches metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203
1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-ring Boss End

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

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

SAE
Dash Thread Pound- Newton 1-3/16-12 95 to 100 129 to 136
Size Tube OD Size Feet metres
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
19.0 mm
-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190
31.8 mm
-24 1-1/2 inch 2-12 150 to 180 200 to 254
38.1 mm
1002
Section
1002
FLUIDS AND LUBRICANTS

1002-2
TABLE OF CONTENTS
821F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
What is Selective Catalytic Reduction (SCR)? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Selective Catalytic Reduction (SCR) - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1002-3
821F - CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. Quarts
Total system capacity ................................................................................................... 15.1 liters (16 U.S. Quarts)
Type of oil .........................................Case AKCELA No. 1 engine oil see engine oil recommendations on page 4
Engine Cooling System
Capacity.......................................................................................................................... 30 liters (32 U.S. Quarts)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons)
Type of Fuel............................................................................................. See Diesel fuel specifications on page 5
DEF (Diesel Exhaust Fluid) Tank
Capacity ................................................................................................................... 41.3 liters (43.6 U.S. Quarts)
Hydraulic System
Hydraulic Reservoir Refill Capacity ..........................................................................90.8 liters (24.0 U.S. Gallons)
Total System Capacity............................................................................................... 178 liters (47.0 U.S. Gallons)
Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts)
Type of Oil ....................................................................................................................................... Case Nexplore
Axles
Capacity
Front...................................................................................................................... 40.0 liters (42.3 U.S. Quarts)
Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts)
Type of Lubricant ............................................................................................................................. Case Nexplore
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
Brake System
Type of Fluid (Same as Hydraulic System)................................................................ Case AKCELA Hy-Tran Ultra®
1002-4
921F - CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. Quarts)
Total system capacity ................................................................................................... 15.1 liters (16 U.S. Quarts)
Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4
Engine Cooling System
Capacity.......................................................................................................................... 30 liters (32 U.S. Quarts)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons)
Type of Fuel............................................................................................. See Diesel fuel specifications on page 5
DEF (Diesel Exhaust Fluid) Tank
Capacity ................................................................................................................... 41.3 liters (43.6 U.S. Quarts)
Hydraulic System
Hydraulic Reservoir Refill Capacity ........................................................................... 110 liters (29.0 U.S. Gallons)
Total System Capacity............................................................................................... 200 liters (53.0 U.S. Gallons)
Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts)
Type of Oil ....................................................................................................................................... Case Nexplore
Axles
Capacity
Front...................................................................................................................... 42.0 liters (44.4 U.S. Quarts)
Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts)
Type of Lubricant............................................................................................................................. Case Nexplore
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
1002-5
ENGINE OIL RECOMMENDATIONS

Case AKCELA No. 1 Engine oil is recommended
for use in your Case engine. Case AKCELA No. 1
Engine Oil will lubricate your engine correctly
under all operating conditions.
If Case AKCELA No. 1 Multi-Viscosity Oil is not
available, use only oil meeting API engine oil service
category CH-4 (preferred) or CG-4.
S e e t h e c h a r t b e l ow fo r
recommended viscosity at
ambient air temperature
ranges.
BD03A102
NOTE: Do not put performance
additives or other oil additive
products in the engine
crankcase. The oil change
RH99K130
intervals given in this manual
are according to tests with Case
AKCELA lubricants.
BC02N250
1002-6
TRANSMISSION TEMPERATURE CHART
RCPH10WHL435BAH3
DIESEL FUEL SYSTEM

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

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

API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60°C (140°F)
Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above
Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ..................................................................................................... 0.05%
1002-7
What is Selective Catalytic Reduction (SCR)?

The main components of the SCR system include the • Keep container tightly closed.
SCR catalyst, the Diesel Exhaust Fluid (DEF)/ • Keep container in a cool, well-ventilated area.
AdBlue® injection unit, the DEF/AdBlue® tank, and
the DEF/AdBlue® dosing control unit. • Keep away from heat and direct sunlight.
Thawing
How does Selective Catalytic Reduction
• The machine is equipped with an internal tank
(SCR) work?
heater to thaw frozen DEF/AdBlue®. The machine
During combustion, harmful Nitrogen Oxide (NOx) will still function until the DEF/AdBlue® begins to
molecules are formed in the exhaust. By injecting a flow. The SCR system will then function normally.
DEF/AdBlue® solution into the exhaust prior to a
• Do not heat DEF/AdBlue® for long periods of time
catalyst, the NOx can be converted to harmless
at temperatures above 30 °C (86 °F). This causes the
elemental Nitrogen and water. This happens when
solution to decompose, which very slowly decreases
the NOx molecules react inside the catalyst with the
the expected shelf life.
heat generated by the engine and the ammonia in
the DEF/AdBlue® solution. NOTICE: Do not use an anti-gelling or freeze point
improver in your DEF/AdBlue®. The 32.5 % solution
During cold engine operation at low engine coolant
and ambient air temperatures, water vapor will be is specifically designed to provide the optimum NOx
visible from the exhaust when the engine operates. reduction properties. Any further blending or adjust-
This water vapor will resemble steam or light white ing of the DEF/AdBlue® mixture will lessen its ability
smoke and will dissipate as the engine and machine to perform correctly and may cause damage to the
components warm and is considered normal. SCR components.
NOTE: After engine shutdown, the SCR system will Handling and supply of additives, if any.
perform a purge cycle, which permits the supply • Personal Protective Equipment (PPE) is not
module to continue to run for up to 70 seconds. This required under normal conditions. If splashing is
is to be considered normal and requires no action likely, wear eye protection. For prolonged or repeated
from the operator. contact, imper vious gloves are recommended.
Follow the precautions listed in the SAFETY
What is Diesel Exhaust Fluid
INFORMATION chapter when handling any service
(DEF)/AdBlue®? fluid.
DEF/AdBlue® is a non-toxic aqueous urea solution ( • No additives are required.
3 2 .5 % ) w i th a s l i g h t a m m o n i a o d o r u s e d to
NOTICE: Contaminated DEF/AdBlue® can affect the
chemically reduce NOx emissions from heavy-duty
diesel powered vehicles. performance of your machine. Follow all instructions
in this manual when handling DEF/AdBlue®.
DEF/AdBlue® is neither explosive nor harmful to the
environment and is classified under the minimum-risk Shelf life
category of transpor table fluids. DEF/AdBlue® Constant ambient storage temperature and
quality is defined by ISO 22241-1. The
minimum shelf life
American Petroleum Institute (API®) has a Less than or equal to 10 °C (50 °F) 36 months
voluntary certification program for DEF/AdBlue®. To
Less than or equal to 25 °C (77 °F) ¹ 18 months
ensure DEF/ AdBlue® satisfies the requirements of
Less than or equal to 30 °C (86 °F) 12 months
ISO 22241. DEF/AdBlue®. API Diesel Exhaust Fluid
Certification Mark is a registered trademark of API in Less than or equal to 35 °C (95 °F) 6 months
the United States and or other countries. Greater than 35 °C (95 °F) -²
¹ To prevent decomposition of DEF/AdBlue®,
Storage, handling, and transport
prolonged transportation or storage above 25 °C (77
NOTICE: Storage temperatures above 30 °C (86 °F) °F) should
greatly reduce the shelf life of DEF/AdBlue®. be avoided.
DEF/AdBlue® has a typical shelf life of 6-12 months.
² Significant loss of shelf life: check every batch
Refer to the SHELF LIFE table below. In order for before use. See your [Brand] dealer for more
DEF/AdBlue® to remain in a usable condition, stor- information on testing.
age requirements need to be met.
• Store between -11 °C (12 °F) and 30 °C (86 °F).
• Use only an approved DEF/AdBlue® container.
1002-8
NOTE: The main factors taken into account to define Glossary Acronym Definition
the shelf life in the previous figures are the ambient DEF Diesel Exhaust Fluid
storage temperature and the initial alkalinity of ISO International Organization
DEF/AdBlue®. The difference in evaporation for Standardization
between vented and non-vented storage containers
is an additional factor. MSDS Material Safety Data Sheet
NOTE: The information in this table is for reference NOx Nitrogen Oxide
only and has been provided by the International
PPE Pe r s o n a l Protective
Organization for Standardization, Document number Equipment
ISO 22241-3 Diesel engines - NOx reduction agent
AUS 32 - Part 3: Handling, transportation and stor- SCR Selective Catalytic
Reduction
age.
Disposal ULSD Ultra Low Sulfur Diesel
• Dispose of DEF/AdBlue® and any filter
accumulations in accordance with all applicable
Federal, State, and local laws governing waste
disposal.
For machines sold in California CNH must warrant
the diesel emission control system in the application
for which it is sold or leased to be free from defects in
design, materials, workmanship, or operation of the
diesel emission control system which cause the
diesel emission control system to fail to conform to
the emission control performance level it was verified
to, or to the requirements in the California Code of
Regulations, Title 13, Sections 2700 to 2706, and
2710, for the periods of time listed below, provided
there has been no abuse, neglect, or improper
maintenance of your diesel emission control system,
vehicle or equipment, as specified in the owner’s
manuals. Where a warrantable condition exists, this
warranty also covers the engine from damage
caused by the diesel emission control system,
subject to the same exclusions for abuse, neglect or
improper maintenance of your vehicle or equipment.
Please review your owner’s manual for other
warranty information. The diesel emission control
system may include a core part (e.g., particulate
filter, diesel oxidation catalyst, selective catalytic
reduction converter) as well as hoses, connectors,
and other emission-related assemblies.
1002-9
SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS

Requirements Diesel Exhaust Fluid (DEF)/AdBlue®
The operator must maintain appropriate consumption
DEF/AdBlue® levels at all times. The SCR system is NOTE: DEF/AdBlue® consumption is highly
compatible with up to 7% bio-diesel fuel. dependent on engine loads, humidity levels,
Diesel Exhaust Fluid (DEF)/AdBlue® DEF/AdBlue® fluid concentration, and engine speed.
The “typical” consumption is only a guideline to verify
refilling
proper function of the SCR system. CNH
The DEF/AdBlue® tank cap (1) can be identified by recommends to fill the DEF/AdBlue® tanks at every
the “blue” color of the cap. A fitting under the cap fuel refilling interval.
prevents the insertion of a diesel fill nozzle.
NOTE: If any DEF/AdBlue® spills or contacts any
surface other than the storage tanks, immediately
clean the affected surface with clear water.
DEF/AdBlue® will cause corrosion on painted and
unpainted metallic surfaces, and may distort some
plastic and rubber components.
It i s r e c o m m e n d e d t h a t D E F /A d B l u e ® f i l l i n g
equipment should be used having a fill nozzle/pump
with the correct length and diameter, triggered by the
magnet in the tank filler neck and with overfill flow cut
out.
This will ensure that:
● The screen in the filler neck will not be damaged.
● Impurities are not entering the DEF/AdBlue® tank.
The standardized DEF/AdBlue® nozzle matches
the filler neck diameter.
● The DEF/AdBlue® tank is not overfilled, as the
DEF/AdBlue® pump will stop when the
DEF/AdBlue® tank is full.
● DEF/AdBlue® is not pumped in the fuel tank, as
the DEF/AdBlue® nozzle cannot pump when the
magnet is not sensed.
NOTICE: Refilling with a funnel is not recommended
as this may lead to damage of the screen in the filler
neck.
NOTE: The information above has been provided by
the International Organization for Standardization
(ISO), Document number ISO 22241-4 Diesel
engines - NOx reduction agent AUS 32 - Part 4:
Refilling interface.
1002-10
MAINTENANCE SCHEDULE
FREQUENCY IN HOURS
Initial Service
LUBRICATE
SERVICE
REPLACE
NUMBER
CHANGE
SERVICE POINTS
ADJUST
INTERVAL
CHECK
CLEAN
DRAIN
ITEM
2 Radiator Coolant Level *

13 Tires *
16 Hydraulic Filter *
Variable 12 Alternator, AC, Drive Belt *
Periodic
(* ) 31 Air cleaner * *
19 Bleed Fuel Filter of Condensation *
28 Clean SCR system DEF tank filter *
XX Fire extinguisher *
Every 10 Hours 1 Check Engine Oil Level 10
13 Check Engine Coolant Level 50

3 Check Transmission Oil Level 50
Every 50 Hours 4 Check Hydraulic Oil Level 50
5&6 Grease Bucket Mounting Fittings 50
7 Grease machine and attachments 50
16 Change Engine Oil and Filters 100
18 Replace Fuel Filters 100
20 Change Hydraulic Filter 100
First 100 Hours
25 Change Oil in Axles 100
13 Check wheel torque 100
28 Clean in-line DEF supply filter 100
Lubricate The Steering Cylinder Pivots - Rod And
8 100
Closed End (4 Fittings)
Every 100 Hours 9 Grease Front Drive Shaft Support Bearing 100
10 Lubricate Loader Lift & Cylinder Pivots (10) Z-bar 100
10 Lubricate Loader Lift & Cylinder Pivots (18) XT 100
11 Check Cab Air Filter 250
Every 250 14 Check Tire Pressure & Wheel Torque 4 250

Hours 12 Check Drive Belt 250
XX Trans Clutch Calibration (See Section 6002) 250 1000
14 Check Axle Oil Level 500
15 Check Battery Electrolyte Level 500
Every 500 16 Change Engine Oil and Filter 500

Hours XX Check ROPS 500
18 Drain Fuel Tank Condensation & Water Separator 500
19 Replace Fuel Filter 500
1002-11
20 Replace Hydraulic Oil filter 1000

21 Grease Articulation Fittings 1000
24 Change crankcase filter 1000 1000
23 Replace Drive Belt
Every 1000
11 Replace Cab Air Filter 1000
Hours
26 Change Transmission Oil and Filter 1000
XX Check Injector Calibration 1000
XX Check Valve Adjustment (Engine Manual) 1000
XX Trans Clutch Calibration (See Section 6002) 1000
21 Change Front & Rear Axle Oil 1500
Every 1500
26 Change Transmission Oil and Filter 1500
Hours
28 Clean in-line DEF filter
29 Change Hydraulic Oil 2000
30 Change Coolant 2000
Every 2000
31 Replace Engine Air Cleaner 2000
Hours
32 Lubricate cab and door 2000
XX Valve Clearance (Engine Manual) 2000
Every 3000
XX Replace DEF supply module filter 3000
Hours
Every 6000 XX Engine Injectors (Engine Manual) 6000

Hours XX Fuel Pump (Engine Manual) 6000 6000
1002-12
MAINTENANCE POINTS
84397762
See your Operators manual for maintenance of If you operate the machine in severe conditions,
safety related items and for detailed information of lubricate and service the machine more frequently.
the ser vice items on this char t. Operators and
service manuals are available for this machine from
your dealer.
Section
1003
1003
METRIC CONVERSION CHART
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

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

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

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

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

litre/min. 0.219 969 gallon/min. (Imperial)
1003-4
U.S. to Metric
MULTIPLY BY TO OBTAIN
Area: square foot 0.092 903 square meter

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

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

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

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

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

cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact
Section
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
2000
2000-2
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2000-3
ENGINE
Removal STEP 5
STEP 1
BD02N160
Put a 30 liter (32 U.S. quart) container below radiator

BD03A040
drain. Remove radiator cap. Remove cap and drain
Park machine on a level surface and lower bucket to coolant into container. Install cap after coolant has
ground. Put articulation lock in LOCKED position. drained. Install radiator cap.
STEP 2 STEP 6
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD02N160
Put a 15.1 liter (16 U.S. quart) container below

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

battery box. Raise the hood with the hood lift motor.
Put master disconnect switch in OFF position.
Remove both batte r y cove rs and disconn ec t
batteries from the machine.
2000-4
STEP 7 STEP 10
BD03A231 BD06F109
Double up a nylon lifting strap (1) and slide through Tag and disconnect hood wiring harness connector
the exhaust stack (2) on the hood. from rear chassis wiring harness connector.
STEP 8 STEP 11
1
BD03A230 BD03A227
Place a solid steel bar through the strap, raise the

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

harness clamp from cooler housing. Have another
person balance the hood and remove the hood hinge
BD03A228 mounting bolts (2) from the cooler frame.
Remove the pin from the top of the lifting motor.
2000-5
STEP 12 STEP 15
BD03A232 BD06F110
Carefully raise and remove hood from loader. Lower Loosen clamps on turbocharger and air cleaner,
hood onto suitable platform and disconnect lifting remove the intake hose.
equipment.
STEP 16
STEP 13
BD06F110
BD03A224 Loosen the clamp on the turbocharger for the after

Tag and disconnect engine wiring harness connector cooler inlet hose.
from air filter restriction switch.
STEP 17
STEP 14
BD03A115
BD03A225 Loosen the clamp on the after cooler and remove the
Loosen clamp on air cleaner intake hose and remove after cooler inlet hose from the machine.
the crankcase ventilation hose.
2000-6
STEP 18 STEP 21
BD06F112
BD06F111
Loosen the clamp on the intake manifold for the after Remove the air cleaner and muffler from the bracket.
cooler output hose.
STEP 22
STEP 19
BD06F113
BD03A118
Loosen the clamp on the after cooler and remove the

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

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

2000-7
STEP 23 STEP 26
BD06F115 BD06F118
Remove the drive belt from the engine. Tag and disconnect the wiring from the alternator.
STEP 24 STEP 27
BD06F116 BD06F119
Loosen clamps and remove lower cooler hose from Remove bolt securing wiring harness clamp to
the engine. engine.
STEP 25 STEP 28
1
1
2
2
BD06F117 BD06F120
If loader is equipped with air conditioning, identify, Remove bolt securing wiring harness clamp (1) to the
tag, and disconnect the engine wiring harness engine. Remove ground wires (2) from the engine.
connectors from air compressor clutch connector (1).
Remove the thre e m oun tin g b olts (2) for the
compressor and set the compressor on the left
battery cover.
2000-8
STEP 29 STEP 32
2 3
BD06F121 BD06F111
Tag and remove the wires from the starter solenoid Tag and remove the grid heater cable.
(3), remove the ground cable (2), and ground strap
(1) from the starter. STEP 33
NOTE: Move the starter cables away from the
engine, move the wiring harness away from the
engine.
STEP 30
BD03A142
Disconnect the wiring harness from the EDC 7

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

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

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

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

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

reservoir. Tag and remove the hydraulic lines from
the brake system pump, plug the lines and cap the
fittings.
2000-10
Installation
1
2 1
3 2
3
1 4
4 5
2
5
3 6
6
7
7
8 4
5
6
7
BS03B035
1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT

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

Tighten engine mounting bolts to a torque of 244 to coupling. Install six bolts to secure drive shaft to
298 Nm (180 to 220 lb-ft). engine coupling. Tighten the six bolts to a torque of
53 to 62 Nm (39 to 46 lb-ft).
STEP 45
Disconnect lifting equipment from engine lifting
brackets.
STEP 46
Connect engine oil drain hose to frame bracket.
2000-11
STEP 48 STEP 51
BD06F127 BD06F124
Install the lower cover for the drive shaft. Remove cap from fitting and plug from the hose,
connect fuel line (2). Connect fuel filter heater wires
STEP 49 (1). Remove and discard tag.
STEP 52
BD06F126
Connect and turn on vacuum pump to the hydraulic

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

BD06F125
Install bolt and clamp for fuel return hose. NOTE: Start the connector on the EDC 7 with lever
straight out from EDC 7. Use lever to pull connector
into position.
2000-12
STEP 54 STEP 57
2 3
BD06F111 BD06F121
Connect grid heater cable to grid heater. Remove Install the wires to the starter solenoid (3), install the
and discard tag. ground cable (2), and ground strap (1) to the starter.
Remove and discard tags.
STEP 55
STEP 58
3
1
2
2
1
BD06F122
BD06F120
Install the heater hose (2) to the rear of the engine,
mount the clamps (3), install the radiator hose (1). Install bolt securing wiring harness (1) clamp to the
engine. Install ground wires (2) to the engine.
STEP 56
STEP 59
BD06F146
Connect the engine coolant vent hose. BD06F119
Install bolt securing wiring harness clamp to engine.

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

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

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

clamps to a torque of 10.1 to 11.3 Nm (90 to 100
lb-inch).
2000-14
STEP 65 STEP 68
BD06F112 BD06F111
Place the muffler and air cleaner on the bracket. Tighten the clamp on the intake manifold for the after
Install mounting bolts in air cleaner and tighten, cooler output hose.
install the mounting bolts in the muffler and leave
loose at this time. STEP 69
STEP 66
BD03A115
Place the after cooler inlet hose on the machine.

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

BD03A118 cooler inlet hose.
Place the after cooler outlet hose on the machine.
Tighten the clamp on the after cooler.
2000-15
STEP 71 STEP 74
BD06F110 BD03A232
Install the intake hose and tighten the clamps on Carefully raise and place hood over loader.
turbocharger and air cleaner.
NOTE: Refer to step 7 and 8 of removal for lifting
procedure.
STEP 72
STEP 75
BD03A225
1
Install the crankcase ventilation hose and tighten the
BD03A227
clamp on air cleaner intake hose.
STEP 73
BD03A226
Have another person balance the hood, install the

hood hinge mounting bolts (2) to the cooler frame.
BD03A224 Install mount bolt (1) and backup alarm wiring
Connect engine wiring harness connector to air filter harness clamp to cooler housing.
restriction switch. Remove and discard tag.
2000-16
STEP 76 STEP 78
BD03A221
BD03A228
Install the pin from the top of the lifting motor, lower NOTE: If hood strut is not adjusted properly the
and remove lifting equipment. hood will be damaged.
When a hood is removed and replaced an initial
STEP 77 adjustment on the strut is necessary. Adjust between
the top of the lift motor adjusting jam nut (1) to the top
of the threads (2) to 20 mm (X). With the motor down
to its lowest point take a measurement between the
left hand side hood bumper and the counter weight,
record this measurement (Y). Use the following table
to adjust the strut (X).
Hood Adjustment Table
Y X Y X Y X Y X
(MM) (MM) (MM) (MM) (MM) (MM) (MM) (MM)
1 19 21 14 41 9 61 5
2 19 22 14 42 9 62 5
BD06F109
3 18 23 14 43 9 63 4
Connect hood wiring harness connector to rear
chassis wiring harness connector. Remove and 4 18 24 13 44 9 64 4
discard tag. 5 25 45 65
18 13 9 4
6 18 26 13 46 8 66 4
7 17 27 13 47 8 67 3
8 17 28 12 48 8 68 3
9 17 29 12 49 8 69 3
10 17 30 12 50 7 70 3
11 16 31 12 51 7 71 2
12 16 32 12 52 7 72 2
13 16 33 11 53 7 73 2
14 16 34 11 54 6 74 2
15 16 35 11 55 6 75 2
16 15 36 11 56 6 76 1
17 15 37 10 57 6 77 1
18 15 38 10 58 6 78 1
19 15 39 10 59 5 79 1
20 14 40 10 60 5 80 0
2000-17
STEP 79 STEP 85
BD02N160 BD06F108
Check and make sure that drain caps are tight. Lower the hood with the hood lift motor.
STEP 80 STEP 86
Install a new oil filter on engine. Fill engine with 13.25 Put articulation lock in OPERATING position.
liters (14 U.S. quarts) of Case AKCELA Engine Oil
(SAE 15W-40).
STEP 81
If hydraulic reservoir was drained, fill reservoir of the
821F with 90.8 liters (24.0 U.S. gallons) of Case
AKCELA Hy-Tran Ultra® fluid. Fill the reservoir of the
921F with 110 liters (29.0 U.S. gallons) of Case
AKCELA Hy-Tran Ultra® fluid.
STEP 82
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 30 liters (32 U.S. quarts). Install the
radiator cap. Fill the coolant reservoir up to the FULL
mark on the reservoir.
STEP 83
Connect the batteries, install battery covers, put
master disconnect switch in ON position.
STEP 84
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
an d wat er. Wh en the coo lan t is at o pe ra ting
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.
2000-18
RADIATOR
Removal STEP 5
STEP 1
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP 2
BD06F128
Remove bolt and washer securing LH fender.

Remove LH fender.
STEP 6
BD03A040
Put articulation lock in LOCKED position.
STEP 3
Put master disconnect switch in OFF position.
STEP 4
BD02N160
Put a 30.0 liter (32.0 U.S. quart) container below

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

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

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

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

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

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

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

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

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

fender mounting bolt.
2000-21
STEP 18 STEP 21
BD06F131 BD03A120
Align the whole in the fender on the bolt. Have another person raise and hold the side panel
up into position. Apply Loctite 242 to the threads,
STEP 19 install the two mounting screws for the side panel
and torque to 6.5 ± 3.0 Nm (57.5 ± 26.5
pound-inches).
NOTE: Photo is of the oil cooler side of the machine,
the procedure is the same.
STEP 22
BD06F132
Align the slots in the fender with the tabs on the body
of the machine.
STEP 20
BD02N160
Check that coolant drain cap is tight.
STEP 23
capacity is 30 liters (32.0 U.S. quarts). Install the
radiator cap. Fill the coolant reservoir up to the FULL
mark on the reservoir.
DSC00105.TIF
Push the fender towards the front of the machine and

secure it using washer and bolt.
2000-22
STEP 24 WARNING: Hot coolant can spray out if radiator cap
Put master disconnect switch in ON position. is removed. To remove radiator cap: Let system cool,
STEP 25
radiator cap.
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately STEP 26
five minutes to completely mix the Ethylene Glycol
Put articulation lock in OPERATING position.
an d wate r. Wh en the coo lan t is at o pe ra ting
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
2002
Section
2002
STALL TEST
2002-2
TABLE OF CONTENTS
821F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2002-3
821F SPECIFICATIONS
Engine with 4 Speed Transmission
A. Low idle ..........................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................570 to 630 rpm
Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm
B. Maximum No Load RPM .............................................................................................................2100 to 2155 rpm
C. Converter Stall ............................................................................................................................1883 to 1963 rpm
D. Hydraulic Stall .............................................................................................................................1883 to 1963 rpm
E. Converter & Hydraulic Stall .........................................................................................................1497 to 1577 rpm
Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)

A. Low idle ..........................................................................................................................................870 to 930 rpm
NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd
gear.
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
2002-4
921F SPECIFICATIONS
A. Low idle ..........................................................................................................................................870 to 930 rpm

A. Low idle ..........................................................................................................................................870 to 930 rpm
NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd
gear.
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
2002-5
INSTRUMENT CLUSTER DISPLAYS

1. With the engine running, press the up or down
key and scroll through the information screens
and trip screens. The following sequence is using
the down key only.
NOTE: Pressing the escape key will return the LCD
back to the normal driving screen.
BD06F027
4. Info 2 will be displayed next. The Info 2 screen

will display coolant temperature, engine oil
temperature in either Fahrenheit or Celsius, as
well as oil pressure.
BD06F188
2. From the driving screen push the down arrow, as

shown.
BD06F184
5. Push the down button again for the Info 3 screen.

T h i s s c r e e n d i s p l ay s t h e t e m p e ra t u r e i n
Fahrenheit or Celsius of the transmission oil,
hydraulic oil, sump oil.
BD06F183
3. Info 1 is the first information screen using the

down arrow from the driving screen. It displays
engine RPM’s, speed, and fuel level.
2002-6
BD06F169
6. Press the down button again and the Trip 1

screen will display. The LCD provides two trip
computers. These will display since last reset the
total time in hours, the total fuel, and the average
fuel consumption per hour.
BD06F170
7. By continuing to scroll down, the fifth screen will

display the Trip 2 screen. Trip 1 and Trip 2
screens can be reset independently. The
previous screen can be accessed by using the
up arrow key.
2002-7
PROCEDURE TO HEAT THE OIL
Torque Converter Hydraulic System

1. Sit in the seat. 1. Apply the parking brake.
2. Start the engine and run the engine at low idle. 2. Start the engine and run at full throttle.
3. To measure the oil temperature with the 3. To measure the oil temperature with the
instrument cluster: instrument cluster:
A. Press the up or down arrow key. A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures B. Stop at the info screen with the temperatures
that need to be monitored. that need to be monitored are on.
4. Place the declutch switch in the OFF position. 4. Hold the bucket control lever in the ROLLBACK
position while raising and lowering the lift arms
5. Place the automatic switch in the manual mode
from ground level to full height.
position. Push down and hold the brake pedal for
the remainder of this procedure. 5. Continue this procedure until the temperature of
the hydraulic oil is 54° to 57°C (129° to 134°F).
6. Release the parking brake.
7. Move the transmission control lever to Forward
and turn the transmission control lever to 3rd
gear.
8. Increase the engine speed to full throttle and run
the engine at this speed for 30 seconds.
9. Decrease the engine speed to low idle and move
the transmission control lever to the Neutral
position for 15 seconds.
10. Repeat steps 7, 8, and 9 until the temperature of
the torque converter oil is 82° to 104°C (180° to
220°F).
2002-8
POWER MODE SELECTION

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

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

1. Sit in the seat. No. 3
1. If the engine speed was as specified, the engine
and hydraulic system are good.
3. Increase the engine speed to full throttle.
2. If the engine speed was more or less than
4. Hold the bucket control lever in the ROLLBACK specified the main relieef setting may be too low
position and raise the lift arms. or too high. See Section 8002 for troubleshooting
information.
NOTE: The stall speed must be read while the lift
arms are in motion. 3. If the engine speed was less than specified in all
tests, the engine is probably the cause.
5. Check the engine speed.
6. Release the bucket control lever.
8. Lower the bucket to the ground.
9. Stop the engine.
Section
2003
2003
AFTER COOLER
2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2003-3
TROUBLESHOOTING AFTER COOLER

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

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

BD03A115
leaks
Inspect the after cooler inlet flex hose for leaks or
holes and insure that the clamps are tight. NOTE: If the leak source has not been located,
remove and test the after cooler.
2003-4
AFTERCOOLER REMOVAL
Removal STEP 4
STEP 1
BD03A118
Loosen clamps and remove air cooler outlet hose.

BD03A116
Loosen clamps and remove turbocharger outlet STEP 5

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

with appropriate lifting device. Remove cover support
BD03A115 latch.
Loosen clamps and remove air cooler inlet hose.
STEP 6
STEP 3
BD03A111
BD03A119 Remove three cover mounting bolts and lift cover off.
Loosen clamps and remove Intake hose.
2003-5
STEP 7 STEP 10
BD03A109 BD03A113
Unlatch air conditioning condenser clamp. Remove two bolts, one from each side of the after
cooler mounting frame.
STEP 8
STEP 11
L i f t a i r c o o l e r a n d f ra m e f r o m m a c h i n e w i t h
appropriate lifting devise.
STEP 12
BD03A107
Rotate air conditioning condenser up and remove the

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

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

mounting frame.
2003-6
Leak Test Installation

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

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

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

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

engine intake.
BD03A111
Install three cover mounting bolts.

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

Section
2010
ENGINE INTAKE AIR FILTRATION
2010
2010-2
TABLE OF CONTENTS
Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pre-cleaner Disassembly & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2010-3
AIR FILTRATION
Pre-cleaner Disassembly & STEP 3

Reassembly
STEP 1
IMG_1682.AI.TIF
Disassemble and remove precleaner from machine.

721F-8469.PNG
Access pre-cleaner located on top of engine

STEP 4
compartment hood.
STEP 2
IMG_1680.AI.TIF
Empty debris and clean wipe precleaner with a damp

clean cloth. Reassemble/install unit on machine.
IMG_1683.AI.TIF
Loosen wing nut.

2010-4
Primary/Secondary Fillter Element STEP 3

Disassembly
STEP 1
1 2
IMG_0115.PNGD
Release all clips securing air filter element housing

cover.
721F-8469.PNG
STEP 4
Raise engine compartment hood using controls
located behind access cover (1). Air filter
housing/element (2) is located in main engine
compartment on left hand side of engine.
STEP 2
IMG_0142.PNG
Remove cover from air filter element housing.
STEP 5
IMG_0099.PNG
Turn master electric switch “off”.
IMG_0143A.PNG
Remove primary filter element by lifting up on handle

2010-5
STEP 6 STEP 2
IMG_0144A.PNG IMG_0143A.PNG
Remove secondary filter element from right side of Install new primary filter element by sliding it down
housing. Remove debris from inside filter element into housing.
housing before installing new filter elements.
NOTE: Make sure primary and secondary filter
NOTE: Do not clean the seconday filter element. It elements form an effective seal.
must be replaced if damaged or clogged.
STEP 3
Primary/Secondary Element
Reassembly
STEP 1
IMG_0142.PNG
Install housing cover.
STEP 4
IMG_0144A.PNG
Install new secondary filter element by inserting it

into positioning slot.
NOTE: Make sure filter element is firmly seated into
housing.
721F-8508.PNG
Lock clips to secure filter housing cover.

NOTE: If cover does not fit properly, recheck filter
element installation. Cover will be difficult to install if
filter elements are not properly installed.
2010-6
STEP 5
IMG_0099.PNG
Turn master electric power switch “on”. Clear any

fault codes. Start machine and confirm problem has
been corrected.
Section
2020
SCR SYSTEM SENSORS
2020
2020-2
TABLE OF CONTENTS
SCR System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
NOx Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2020-3
SCR SYSTEM SENSORS
Upstream Exhaust Temperature STEP 3

Sensor Removal
2
NOTE: Do not use impact wrenches on the exhaust 1
system unless the sensors are removed.”
STEP 1
IMG_0912.TIF
Locate exhaust temperature sensor (1) on exhaust

system before the catalyst (2).
721F-8469.PNG STEP 4
Raise the hood using controls located behind the
access cover.
STEP 2
IMG_1507.TIF
Loosen hex nut on sensor.

IMG_0099.PNG
Turn master electric switch to the “off” position.

2020-4
STEP 5 Upstream Exhaust Temperature
Sensor Reinstall
NOTE: Do not use impact wrenches on the exhaust
STEP 1
IMG_1510.JPG
Remove temperature sensor from exhaust system.
STEP 6
IMG_1510.TIF
Install temperature sensor into exhaust pipe.
STEP 2
IMG_1514.TIF
Remove wire ties securing wire harness to support

brackets. Unplug sensor from machine wiring
harness and remove it.
IMG_1507.TIF
Secure sensor into exhaust pipe. Sensor torque 40 to

50 Nm (30 to 36 lb ft.). Reconnect sensor to wire
harness and secure harness to support brackets
using new wire ties.
2020-5
STEP 3 STEP 2
IMG_0099.PNG IMG_0099.PNG
Turn master electric switch to “on” position. Clear any Turn master electric switch to the “off” position.
fault code. Start engine and check to see if problem
has been corrected. STEP 3
Downstream Exhaust Temperature 1 2

Sensor Removal
STEP 1
IMG_1465.TIF
Locate the exhaust temperature sensor (1) on

exhaust system after catalyst (2).
STEP 4
721F-8469.PNG

access panel.
GRAPHIC_ID
Loosen hex nut and remove sensor from exhaust

system.
2020-6
STEP 5 Downstream Exhaust Temperature
Sensor Reinstall
STEP 1
IMG_1524.TIF
Loosen hex nut and remove P-clamp securing

sensor wiring harness to catalyst mounting support
bracket. Remove any wire ties securing wiring
harness to machine.
STEP 6 IMG_1518.TIF
Install temperature sensor into exhaust system.

Secure sensor by tightening hex nut. Sensor torque
40 to 50 Nm (30 to 36 lb ft.).
STEP 2
1528.TIF
Disconnect sensor from wiring harness.
STEP 7
IMG_1524.TIF
Install hex nut and P-clamp holding sensor wiring

harness to catalyst mounting support bracket.
GRAPHIC_ID
R e m o ve s e n s o r a n d w i r i n g h a r n e s s a s o n e
component from machine.
2020-7
STEP 3 NOx Sensor Removal
STEP 1
IMG_1528.TIF
Reconnect sensor to machine wiring harness.
STEP 4 721F-8469.PNG

access cover.
STEP 2
IMG_0099.PNG
Turn master electric switch to “on” position. Clear any

fault code. Start engine and check to see if problem
has been corrected.
IMG_0099.PNG

2020-8
STEP 3 STEP 5
1
2
IMG_1465.TIF IMG_1535.TIF
Locate NOx sensor (1) on exhaust system down Loosen hex nut on NOx sensor.
stream of catalyst (2).
STEP 6
STEP 4
2
1
IMG_1536.TIF
IMG_1524.TIF Remove NOx sensor from exhaust system.

Loosen hex nut and remove P-clamp (1) holding
sensor wiring harness to catalyst mounting support STEP 7
bracket (2).
1 2
IMG_1539.TIF
Locate NOx sensor module (1) on the backside of the

SCR catalyst mounting support bracket (2).
2020-9
STEP 8 NOx Sensor Reinstall
STEP 1
IMG_1585.TIF
Disconnect NOx sensor module from machine wiring

harness.
STEP 9
IMG_1536.TIF
Install NOx sensor into exhaust system.
STEP 2
IMG_1584.TIF
Remove hex bolts securing NOx sensor module to

mounting support bracket and remove module.
STEP 10 IMG_1535.TIF
Secure NOx sensor with hex nut. Sensor torque 40 to

60 Nm (30 to 44 lb ft.)
IMG_1544.TIF
Remove wire ties securing NOx sensor wiring

harness to machine and remove sensor.
2020-10
STEP 3 STEP 5
1 2
Install NOx sensor module and secure it to mounting Secure NOx sensor wire harness with P-clip (1) to
support bracket using hex bolts. NOx sensor module catalyst mounting support bracket (2) using hex
torque 10.5 to 14.5 Nm (8 to 10.5 lb ft.). bolts. Secure wire harness with wire ties where
appropriate.
STEP 4
STEP 6
IMG_0099.PNG
IMG_1585.TIF Turn master electric switch to “on” position. Clear any

Reconnect machine wiring harness to NOx sensor fault code. Start engine and check to see if problem
module. has been corrected.
Section
2030
SCR CATALYST
2030
2030-2
TABLE OF CONTENTS
SCR Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2030-3
SCR CATALYST
Removal STEP 3
NOTE: Do not use impact wrenches on the exhaust 2
system unless sensors are removed. 1
STEP 1
IMG_0912.TIF
Locate the SCR catalyst (1) and the upstream

exhaust gas temperature sensor (2).
721F-8469.PNG
Raise the hood using controls located behind the STEP 4

access cover.
STEP 2
IMG_1507.TIF
IMG_0099.PNG Loosen hex nut on sensor.
Turn the master electric switch to the “off” position.
2030-4
STEP 5 STEP 7
Remove upstream exhaust gas temperature sensor. Loosen hex nut and remove downstream exhaust
temperature sensor.
STEP 6
STEP 8
1 2
IMG_1465.TIF
Locate the downstream NOx sensor (1) and exhaust IMG_1535.TIF
gas temperature sensor (2) after the SCR catalyst. Loosen hex nut on NOx sensor.
STEP 9
IMG_1536.TIF
Remove NOX sensor from exhaust system.

2030-5
STEP 10 STEP 12
Attach a suitable lifting device and lift strap to the Remove hex bolts from mounting support brackets at
SCR catalyst. front of SCR catalyst.
STEP 11 STEP 13
Remove clamp, gasket and gasket alignment sleeve Remove hex bolts that secure mounting support
at SCR catalyst and mixing pipe connection. Discard bracket to the rear of the SCR catalyst.
clamp and gasket.
NOTE: Gasket alignment sleeve may be attached to
mixing pipe. Gasket and clamp should be replaced
every time the connection is disassembled.
2030-6
STEP 14 Installation
system unless sensors are removed.
STEP 1
IMG_1560.TIF
Lift SCR catalyst from machine.
STEP 15
IMG_1571.TIF
Attach mounting support bracket to front of SCR

catalyst.
STEP 2
IMG_1571.TIF
Remove mounting support bracket from front of SCR

catalyst.
IMG_1567.TIF
Attach a suitable lifting device and lift strap to the

SCR catalyst. Move SCR catalyst into position within
the wheel loader.
2030-7
STEP 3 STEP 5
Install hex bolts into SCR catalyst through rear Install new gasket and clamp on connection between
mounting support bracket. SCR catalyst and mixing pipe. Clamp torque 6 Nm
(53 lb in.). Tighten all hex bolts to secure SCR
NOTE: Leave hex bolts loose until final positioning of
catalyst to mounting support brackets.
SCR catalyst is completed.
NOTE: Gasket and clamp should be replaced every
STEP 4 time connection is disassembled. The gasket
alignment sleeve press fits into mixing pipe or
muffler, whichever fits better.
NOTE: It might be necessary to loosen the turbo
clamp, brackets and U-bolts to gain proper alignment
of components.
STEP 6
IMG_1552.TIF
Install hex bolts into front mounting support brackets.

NOTE: Leave hex bolts loose until final positioning of
SCR catalyst is obtained.
IMG_1536.TIF
Install NOx sensor into exhaust pipe downstream of

SCR catalyst. Sensor torque 40 to 60 Nm (30 to 44 lb
ft.).
2030-8
STEP 7 STEP 9
IMG_0099.PNG
Turn the master electric switch to the “on” position.

IMG_1518.TIF Clear any fault code. Start machine and check for
Install downstream exhaust gas temperature sensor exhaust leaks. Confirm problem has been corrected.
into exhaust pipe after SCR catalyst. Sensor torque
40 to 50 Nm (30 to 36 lb ft.).
STEP 8
IMG_1507.TIF
Install upstream exhaust gas temperature sensor into

mixing pipe upstream of SCR catalyst. Sensor torque
40 to 50 Nm (30 to 36 lb ft.).
Section
2040
ENGINE INTAKE TEMPERATURE/HUMIDITY SENSOR
2040
2000-2
TABLE OF CONTENTS
Intake Temperature/Humidity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2040-3
INTAKE TEMPERATURE/HUMIDITY SENSOR
Removal STEP 3
STEP 1
IMG_1643.TIF
721F-8469.PNG
Raise the engine compartment hood using controls Locate the intake temperature/humidity sensor on air
located behind the access cover. intake pipe between the air filter housing and
turbocharger.
STEP 2
STEP 4
IMG_0099.PNG

IMG_1645.TIF
Disconnect wiring harness plug.

2040-4
STEP 5 Installation
STEP 1
IMG_1646.TIF
Remove hex bolts.

IMG_1648.TIF
STEP 6 Remove plug covering hole in intake pipe. Insert
sensor.
STEP 2
IMG_1648.TIF
Remove sensor.
NOTE: Cover hole in the intake pipe to prevent
debris from entering the system. IMG_1646.TIF
Secure sensor with hex bolts.

2040-5
STEP 3
IMG_1645.TIF
Reconnect wiring harness plug.
STEP 4
IMG_0099.PNG
Turn master electric switch “on”. Clear any fault code.

Start machine and confirm that problem has been
corrected.
2040-6
Section
2050
DEF/ADBLUE HEATER CONTROL VALVE
2050
2050-2
TABLE OF CONTENTS
DEF/ADBLUE Heater Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2050-3
DEF/ADBLUE HEATER CONTROL VALVE
Removal STEP 3
STEP 1
IMG_1693.TIF
721F-8469.PNG
Raise the hood using controls located behind the Place a suitable container below radiator drain
access cover. located behind access cover. Remove radiator cap.
Remove drain cap and drain engine coolant. Install
tank drain plug and radiator cap after coolant has
STEP 2
drained.
NOTE: Use compressed air and water to clean
debris from around drain plug area prior to draining
the system.
STEP 4
IMG_0099.PNG
IMG_0945.TIF
Locate DEF/AdBlue Heater Control valve next to the

DNOx Supply Module on the right hand side of the
engine.
2050-4
STEP 5 STEP 7
Disconnect the machine wiring harness from the Remove hex bolts securing heater control valve to
DEF/AdBlue heater control valve. mounting support bracket.
STEP 6 STEP 8
IMG_1479.TIF 1486.TIF
Using a small flat blade screw driver, pull up on the Remove heater control valve from machine.
fitting retaining clip and disconnect the coolant
inlet/outlet lines from the heater control valve.
2050-5
Installation STEP 3
STEP 1
IMG_0099.PNG
Turn master electric switch to the “on” position. Clear

any fault code. Start the machine and check for
engine coolant leaks. Confirm that problem has been
IMG_1484.TIF
corrected.
Position DEF/AdBlue heater control valve on the
mounting support bracket and secure it with hex
bolts.
STEP 2
IMG_1477.TIF
Reconnect coolant inlet/outlet lines and wiring

harness. Refill engine cooling system.
2050-6
Section
2060
DEF/ADBLUE DNOx SUPPLY MODULE
2060
2060-2
TABLE OF CONTENTS
DEF/ADBLUE DNOx Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2060-3
DEF/ADBLUE DNOX SUPPLY MODULE
Removal STEP 3
STEP 1
721F-8490.PNG
Open the grill located above the radiator/charge air

721F-8469.PNG
cooler/oil cooler/hydraulic cooler package located
Raise the hood using controls located behind the just behind the cab.
access cover.
STEP 4
STEP 2
IMG_0099.PNG
IMG_1592.TIF
Raise the right hand side engine compartment side
panel of the machine.
2060-4
STEP 5 STEP 7
Remove thumb screw securing the right hand side Mark supply and return line connection locations for
inner fender panel. reference during reassembly.
STEP 6 STEP 8
IMG_1598.TIF GRAPHIC_ID
Remove right hand side inner fender panel. Disconnect DEF/AdBlue supply and return lines from
underneath DNOx supply module.
NOTE: To disconnect fittings, squirt water into the
fitting connection to lubricate the O-ring. Squeeze the
locking tabs together while slightly pushing the fitting
ends together and then pulling them apart. If the
fitting will not release, but is free to rotate, the O-ring
is likely stuck and additional water should be used.
debris from supply and return line connections.
2060-5
STEP 9 STEP 11
Remove hex bolts securing the DNOx supply module Remove DNOx supply module from the machine.
to the mounting support bracket.
Installation
STEP 10
STEP 1
1 2
1 2
IMG_1634.TIF
Par tially remove DNOx supply module from its GRAPHIC_ID

mounting support bracket to gain access to the wiring Position the DNOx supply module on its mounting
harness (1). Open the lever (2) and disconnect wiring support bracket. Connect wiring harness to back of
harness from DNOx supply module. supply module. Be sure the lever (1) is fully engaged
and the plug (2) is fully seated.
2060-6
STEP 2 STEP 4
Fit the DNOx supply module into mounting support Check wire harness and supply lines for proper
bracket and secure with hex bolts. positioning.
NOTE: Make sure wire harness and supply lines do
STEP 3 not contact anything that would cause damage.
STEP 5
IMG_1640.TIF
IMG_0099.PNG
Reconnect supply and return lines underneath DNOx Turn master switch to “on” position. Clear any fault
control module. To connect, push the two fitting ends codes. Start engine. Check for fluid leaks at
together until an audible snap is heard. connections. Confirm problem has been corrected.
NOTE: Test fitting connections to be sure they are
secure. Match supply and return markings to ensure
correct connections are made.
2060-7
STEP 6
IMG_1598.TIF
Reinstall inner fender panel and secure using

thumbscrew.
STEP 7
IMG_1592.TIF
Lower right hand side engine compartment side

panel of machine. Lowe r gr ill located above
radiator/charge air cooler/oil cooler/hydraulic cooler
package located just behind cab. Close engine
compartment hood.
2060-8
Section
2070
DEF/ADBLUE DOSING INJECTOR
2070
2070-2
TABLE OF CONTENTS
DEF/Adblue Dosing Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2070-3
DEF/ADBLUE DOSING INJECTOR
Removal STEP 3
system unless the sensors are removed.
STEP 1
WHL011MM.PNG
Clean dirt and debris from around engine air intake

pipe connections and DEF/AdBlue dosing injector.
NOTE: The dosing injector is located in the exhaust
721F-8469.PNG
system upstream from the SCR catalyst and
Raise the hood using controls located behind the downstream of the turbocharger.
access cover.
STEP 4
STEP 2
1 2
WHL010MM.PNG
IMG_0099.PNG
Remove intake pipe (1) connecting turbocharger and
Turn master electric switch “off”. charge air cooler. Remove intake pipe (2) connecting
air filter housing inlet and support bracket.
NOTE: Cover openings to prevent debris entering
system.
2070-4
STEP 5 STEP 7
1 2
WHL026MM.PNG WHL021MM.PNG
Remove engine coolant line hold down bracket (1) for Mark location of DEF/AdBlue supply and return lines
easier access to dosing injector (2). fo r r e fe r e n c e d u r i n g r e a s s e m b l y. R e m o ve
DEF/AdBlue supply and return lines. Cap lines to
NOTE: Mark location and routing of coolant lines for
prevent debris from entering the system
reference during reassembly.
NOTE: To separate connections, squirt water into
STEP 6 fittings to lubricate O-rings. Squeeze fitting locking
tabs slightly and push fitting together then pull it
apart. If fitting will not release, but is free to rotate,
the O-ring is likely stuck and additional water should
be applied.
STEP 8
WHL001MM.PNG
Disconnect dosing injector wiring harness.
WHL023MM.PNG
Remove bolts securing dosing injector into mixing

pipe.
2070-5
STEP 9 Installation
system unless the sensors are removed.
STEP 1
WHL025MM.PNG
Remove dosing injector. Cover opening to prevent

debris from entering exhaust system.
STEP 10
WHL025MM.PNG
Remove cover from exhaust system and install

dosing injector.
NOTE: Use markings made during disassembly to
determined proper positioning.
STEP 2
WHL027MM.PNG
Inspect dosing injector and service or replace as

recommended.
WHL023MM.PNG
Secure dosing injector to exhaust pipe. Torque

screws to 7 +/- 0.5 Nm (62 +/- 4 lb in.).
2070-6
STEP 3 STEP 5
1 2
Connect DEF/AdBlue supply and return lines and Remove covers from air intake pipe openings. Install
wiring harness to dosing injector. air intake pipe (1) connecting air filter housing inlet
and suppor t bracket. Install air intake pipe (2)
NOTE: Use marks made during disassembly to
connecting turbocharger inlet side and charge air
determine proper positioning.
cooler.
STEP 4 STEP 6
WHL026MM.PNG
IMG_0099.PNG
Secure engine coolant line hold down bracket.
Turn master electric switch to “on”. Clear any fault
code. Start machine. Check for leaks at DEF/AdBlue,
exhaust and intake system connections. Confirm
problem has been corrected.
Section
2080
DEF/ADBLUE SUPPLY TANK
2080
2080-2
TABLE OF CONTENTS
DEF/AdBlue Supply Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2080-3
DEF/ADBLUE SUPPLY TANK
Removal STEP 3
STEP 1
IMG_1693.TIF
721F-8469.PNG
Raise the hood using controls located behind the Place a suitable container below radiator drain
access cover. located beneath the access cover at rear left hand
side of machine. Remove radiator cap. Remove drain
cap. Drain coolant. Install tank drain plug and radiator
STEP 2
cap after coolant has drained.
debris from around drain plug area.
STEP 4
IMG_0099.PNG
Turn master electric switch “off”.
WHL024MM.PNG
Loosen hex bolts and remove access cover below

supply tank to gain access to the drain.
NOTE: Use compressed air and water, to clean
debris from around drain plug area.
2080-4
STEP 5 STEP 7
WHL029MM.PNG
Place a suitable container below DEF/AdBlue supply

tank drain plug. Remove filler neck cap from supply PICT109.TIF
tank. Loosen drain plug and drain DEF/AdBlue. Remove filler neck/screen assembly and O-ring from
Install drain plug and access cover after DEF/AdBlue supply ta nk by pullin g upwa rd while twisting
has drained. assembly left and right.
STEP 6 STEP 8
PICT106.TIF WHL002MM.PNG
Remove bolts securing filler neck screen assembly. Remove hex bolts and panel to access supply tank.
NOTE: Place a plug in filler neck hole to prevent
loose screws from entering the supply tank.
2080-5
STEP 9 STEP 11
Remove rubber boot cover from liquid level/temp Pull wire and hose harness up and off to the side out
sensor sending unit wires, DEF/AdBlue and engine of the way.
coolant supply lines. Mark wire and hose connection
NOTE: Plug all lines to prevent debris from entering
positions.
the system.
debris from top of DEF/AdBlue supply tank around STEP 12
liquid level/temp sensor sending unit area.
STEP 10
WHL008MM.PNG
Mark location of pickup unit within tank before

removal. Twist DEF/AdBlue level temperature sensor
WHL006MM.PNG unit counter clockwise to loosen it from tank.
Unplug wiring harness. Disconnect engine coolant
lines and DEF/AdBlue lines by pushing coupling
together, squeezing tabs and then pulling connection
apart.
2080-6
STEP 1
WHL009MM.PNG
Lift DEF/AdBlue level/temp sensor unit out of tank.

NOTE: Cover tank opening to prevent debris from IMG_0910.TIF
entering it. Install DEF/AdBlue supply tank into the machine

frame cradle and secure it using hex bolts and upper
STEP 14 support mounting bracket.
STEP 2
WHL012MM.JPG
Remove hex bolts from mounting support bracket

above tank and from bottom of tank. Lift tank up and
out of its cradle in the wheel loader frame.
WHL009MM.PNG
Lower DEF/AdBlue level temp sensor and pick-up

unit into tank.
2080-7
STEP 3 STEP 6
Use reference marks from disassembly procedure to Replace access panel and secure using hex bolts.
position DEF/AdBlue level temp sensor and pick-up
unit. Secure by turning it clockwise. STEP 7
STEP 4
WHL006MM.PNG PICT119.TIF
Remove plugs from all lines. Reconnect DEF/AdBlue Reinstall the O-ring onto the DEF/AdBlue supply tank
supply/return and purge lines, engine coolant supply/ with the radius surface facing upward.
return lines and liquid level gage sensor wiring
NOTE: Lubricate O-ring with petroleum jelly.
harness. To connect, push connections together all
the way, and then pull back to lock.
STEP 8
STEP 5
WHL005MM.PNG
PICT109.TIF
Replace rubber boot protective cover.
Reinstall filler neck assembly onto supply tank.
2080-8
STEP 9
PICT106.TIF
Secure filler neck assembly using Torx bolts. Refill

DEF/AdBlue storage tank and engine cooling
system.
STEP 10
IMG_0099.PNG
Turn master electric power switch to “on” position.

Clear any fault codes. Start machine and check for
DEF/AdBlue and coolant leaks. Confirm that the
problem has been corrected.
Section
2090
DEF/ADBLUE SUPPLY TANK LEVEL AND

TEMPERATURE SENSOR/PICK-UP AND HEATER
2090
2090-2
TABLE OF CONTENTS
DEF ADBLUE SUPPLY TANK LEVEL AND TEMPERATURE SENSOR PICKUP AND HEATER . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2090-3
DEF ADBLUE SUPPLY TANK LEVEL AND TEMPERATURE SENSOR PICKUP

AND HEATER
Removal STEP 3
STEP 1
IMG_1693.TIF
721F-8469.PNG
Raise the hood using controls located behind the Place a suitable container below the radiator drain
access cover. under the access cover at the left rear of the
machine. Remove radiator cap. Remove drain cap
and drain engine coolant. Install tank drain plug and
STEP 2
radiator cap after coolant has drained.
debris from around drain plug area before draining
system.
STEP 4
IMG_0099.PNG
Turn master electric switch to “off” position.
WHL002MM.PNG
Loosen hex bolts and remove cover on right rear of

machine to access DEF/AdBLue supply tank.
2090-4
STEP 5 STEP 7
Use compressed air or water to clean dirt and debris Unplug wiring harness. Disconnect engine coolant
from DEF/AdBlue supply tank around filler cap/neck lines and DEF/AdBlue lines. Disconnect the lines by
(1) and level/temp sensor pickup heater element (2). pushing coupling together all the way to unlock.
Squeeze tabs and pull coupling apar t to break
STEP 6 connections.
STEP 8
WHL005MM.PNG
Remove rubber cover from DEF/AdBlue level/temp

sensor pickup heater wires and supply/return lines. WHL007MM.PNG
Mark hose and wire connection positioning. Move wiring harness, engine coolant/DEF/AdBlue
supply/return and purge line harness off to the side.
Plug all lines to prevent debris from entering the
system.
2090-5
STEP 9 Installation
STEP 1
WHL008MM.PNG
Mark positioning of the DEF/AdBlue level temp

sensor pickup heater unit within thank. Turn unit
counter clockwise to loosen it from tank.
WHL009MM.PNG
STEP 10 Insert the DEF/AdBlue tank level/temp sensor pickup
heater unit into the supply tank.
STEP 2
WHL009MM.PNG
Lift the DEF/AdBlue level/temp sensor pickup heater WHL008MM.PNG

unit out of tank. Cover the tank opening to prevent Twist DEF/AdBlue tank level/temp sensor pick up
debris from entering. heater unit clockwise to secure it to the tank.
NOTE: Use markings made during disassembly to
position unit correctly in the tank.
2090-6
STEP 3 STEP 5
WHL006MM.PNG IMG_0099.PNG
Remove plugs from all lines. Reconnect DEF/AdBlue Turn master electric switch to the “on” position. Clear
purge and supply/return lines. Reconnect engine any fault codes. Start the machine and check for
coolant supply/return lines. Reconnect liquid level engine coolant and DEF/AdBlue leaks. Confirm that
and temperature sensor wiring har ness. Push problem has been corrected.
connections together all the way and then pull back
to lock. STEP 6
STEP 4
721F-8490.PNG
Replace tank access cover and secure with hex

WHL003MM.PNG bolts.
Replace protective rubber boot cover. Refill engine
cooling system. Turn master electric switch “on”.
Erase fault code. Star t machine and check for
coolant or DEF/AdBlue leaks. Confirm problem has
been corrected.
Section
2100
DEF/ADBLUE SUPPLY FILTERS
2100
2100-2
TABLE OF CONTENTS
DEF/adblue supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2100-3
DEF/ADBLUE SUPPLY FILTERS
Removal Supply Tank Filler Neck STEP 3

Screen
STEP 1
IMG_0099.PNG
Turn off master electric switch to the “off” position.
STEP 4
721F-8490.PNG
Locate the DEF/AdBlue supply tank on the right hand

side of the machine beneath an access cover.
STEP 2
PICT101.TIF
Open access cover and remove filler cap from filler

neck of supply tank.
721F-8469.PNG
Raise the hood using controls located behind the NOTE: Use compressed air and water, to clean
access cover. debris from around filler cap/neck area.
2100-4
STEP 5 STEP 7
PICT106.TIF WHL018MM.PNG
Remove bolts securing filler cap/neck screen Remove plug from filler neck. Rinse screen with
assembly. water to remove accumulated debris. Reinstall plug
into filler hole.
NOTE: Place a stopper into filler neck hole to
prevent loose screws and debris from entering NOTE: If the screen is damaged replace it. To
supply tank. replace, remove bolts and separate filler neck from
screen. Attach new screen to filler neck and secure
STEP 6 with bolts.
Installation Supply Tank Filler Neck

Screen
STEP 1
PICT109.TIF
Remove filler cap/neck screen assembly and O-ring.

Pull upwards while twisting assembly left and right.
NOTE: Cap opening of supply tank to prevent debris
from entering tank.
PICT119.TIF
Reinstall O-ring (1) onto supply tank (2) with radius

surface facing upward.
2100-5
STEP 2 Removal Supply Line Screen
STEP 1
1
PICT122.TIF
721F-8490.PNG
Reinstall filler cap/neck screen assembly (1) into DEF/AdBlue supply line screen is located under the
supply tank (2). engine hood on the right side of engine at rear of
machine.
STEP 3
STEP 2
PICT106.TIF
Secure assembly with bolts and remove stopper from 721F-8469.PNG

filler neck hole. Reinstall supply tank filler neck cap. Raise the hood using controls located behind the
access cover.
STEP 4
STEP 3
IMG_0099.PNG
Close side cover concealing supply tank. Turn master IMG_0099.PNG

electr ic switch to “on” position. Lower engine Turn master electric switch to “off” position.
compartment hood.
2100-6
STEP 4 STEP 6
2
1
921F-9194.PNG IMG_2007.PNG
Locate supply line filter screen housing within supply Remove filter screen from housing with needle nose
line between supply tank (1) and DNOx supply pliers. Rinse filter screen with water to remove
module (2) mounted on right hand side of engine. accumulated debris.
NOTE: Use compressed air and water to clean NOTE: If filter screen is damaged, replace it.
debris from around screen assembly.
Installation Supply Line Screen
STEP 5
STEP 1
WHL013MM.PNG
To open fitting, push fitting together, squeeze locking IMG_2007.PNG

tabs slightly, and then pull apart. Install filter screen into supply line filter housing.
NOTE: Squirt water into fitting connection to
lubricate O-ring. If fitting will not release, but is free to STEP 2
rotate, O-ring is likely stuck and additional water
should be used to free connection.
NOTE: Use a suitable container to catch any fluid
discharged during hose and filter disassembly.
WHL013MM.PNG
Reconnect supply line coupling.

2100-7
STEP 3 STEP 2
IMG_0099.PNG 721F-8469.PNG
Turn master electric switch to “on” position. Clear any Raise the hood using controls located behind the
fault codes. Start engine and check connections for access cover.
leaks. Confirm problem has been corrected.
STEP 3
Removal DNOx Supply Module
Filter
STEP 1
IMG_0099.PNG
STEP 4
721F-8490.PNG
The DEF/AdBlue Supply filter is located inside the

DNOx supply module under the hood on the right
side of the engine at the rear of the machine.
1
2
921F-9194.PNG
Locate the DNOx supply module (1). The filter

element assembly (2) is located on the underside of
the module.
NOTE: Clean dirt and debris from filter element
housing using compressed air and water.
2100-8
STEP 5 STEP 7
Squirt water into fitting connections to lubricate Remove filter element (1) from housing (2) by turing it
O-r ings. Disconnect fittings by pushing them counter clockwise. Discard filter element following
together. Then squeeze locking tabs and pull fitting local environmental and waste regulations.
down and off.
NOTE: If the fitting will not release, but is free to Installation DNOx Supply Module
rotate, the O-ring is likely stuck and lubrication of the Filter
O-ring should be repeated.
STEP 1
STEP 6
2
1
WHL014MM.PNG
IMG_2001.PNG Lubricate filter element O-ring (1) on housing side.
Remove the DEF/AdBlue filter element assembly Lubricate housing O-ring (2). Install filter element on
from DNOx supply module by turning it counter housing by turing it clockwise.
clockwise. Pull straight down and away from module.
NOTE: Use a suitable container to catch any fluid
discharged during disassembly. NOTE: Hand tighten filter only.
2100-9
STEP 2 STEP 5
IMG_2023.PNG IMG-0099.PNG
Lubricate filter element O-ring on control module Turn master electric switch to “on” position. Clear any
side. fault codes. Start engine and check connections for
leaks. Confirm problem has been corrected.
STEP 3
IMG_2003.PNG
Insert filter housing assembly into DNOx supply

module and turn clockwise to tighten.
NOTE: Hand tighten filter only.
STEP 4
WHL015MM.PNG
Reinstall DEF/AdBlue supply line. Push connection

together and then pull back to make sure it is secure.
2100-10
4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND

ALTERNATOR
4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
With Out Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
With Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4001-3
STARTER
Removal STEP 4
STEP 1
Park machine on a level surface and lower bucket to
ground.
STEP 2
BD06F135
Remove the ground strap from the starter, remove

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

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

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

ground cable to the bottom mounting stud (2) and
install the nut, attach the ground strap and wire to the
outer stud (1) and install the nut, install the lower nut.
Torque the three nuts to 40 to 50 Nm
(29 to 37 pound-feet).
4001-5
ALTERNATOR
Removal STEP 4
STEP 1
ground.
STEP 2
BD06F137
BD06F133
Raise the engine compartment with lifting motor.

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

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

the tension on the belt. Remove the belt.
4001-6
STEP 6 Installation
STEP 7
BD06F140
Remove mounting bolts for alternator, remove

alternator. BD06F140
Place alternator onto engine, install mounting bolts

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

belt.
NOTE: Belt routing instructions are on belt cover.
4001-7
STEP 9 STEP 10
BD06F137 BD06F136
Connect wires to the alternator, place rubber boot

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

and tighten.
BD06F133

position. Lower the engine compartment with lifting
motor.
4001-8
BELT INSTALLATION
BC05G045
WITH OUT AIR CONDITIONING
BC05G046
WITH AIR CONDITIONING
4002
Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING
4002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
..................................................................................... 50
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
..................................................................................... 52
POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Power Relay Module A, Power converter F1, Secondary steering F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Power Relay Module B, ACC Power F1, DNOX F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Power Relay Module C, Ignition Power F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power Relay Module D, Fuel Filter Heater F1, Engine ECM F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
..................................................................................... 55
Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fan Control Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fan Reverse Relay (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4002-3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for
Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Warning (AIC) Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4002-4
Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4002-5
Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
HOOD RAISE AND LOWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
STARTING / ignition SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
...................................................................................... 135
Ignition Power Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Ignition Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Start Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
SCR SYSTEM/ joystick steering/ misc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
NOX Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Humidity and ambient temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
NOX Sensor (NOXS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Tank heater control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
DEF Level and tank temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Downstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Doser metering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
DNOX Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Rear View Camera / Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Differential Lock Switch (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Differential Lock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Pilot Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
JSS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Load Sense Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Pilot Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Lockup Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Joystick PVRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Transmission Kick Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
ARM POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
FNR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
FNR Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
JSS Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Joystick STR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
JSS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4002-6
4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage................................................................................................................................................24 volts
Batteries
Group Size ..........................................................................................................................................................31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17° C (0° F) for 60 Seconds At 6.0 Volts................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Alternator ..................................................................................................................................... 24 volt, 65 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20° C (68° F) (Nominal)................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20° C (68° F) (Nominal) ........... 305 ohms
Fuel Level Sender............................................................................................................................... 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20° C (68° F) ......................................... 3521 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Set point ............................................................................................................................ 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig)
A/C High Pressure Switch
Closed With Pressure .................................................................................. Above 27.6 ± 0.7 bar (400.3 ± 10.1 psi)
Opens With Pressure ..................................................................................Below 20.7 ± 0.7 bar (300.22 ± 10.1 psi)
A/C Low Pressure Switch
Closed With Pressure .......................................................................................Below 0.3 ± 0.1 bar (4.35 ± 1.45 psi)
Opens With Pressure ......................................................................................... Above 1.4 ± 0.2 bar (20.3 ± 2.9 psi)
Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi)
Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi)
Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Set point.....................................................4.13 bar (60 psi)
Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi)
Fuel Filters Heater Resistance At 20° C (68° F) (Nominal) .......................................................................... 1.9 ohms
Water Separator Heater At 20° C (68° F) (Nominal)..................................................................................... 1.9 ohms
Parking Brake Solenoid DC Resistance At 20° C (68° F) (Nominal) .......................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20° C (68° F) (Nominal) .......................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20° C (68° F) (Nominal) ..................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20° C (68° F) (Nominal)............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20° C (68° F) (Nominal) .............................................................. 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20° C (68° F) (Nominal).......................................................... 39.3 ohms
Fan PWM Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................................. 29.3 ohms
Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi)
Fuel Temperature Sensor At 20° C (68° F) (Nominal) ............................................................................... 2500 ohms
Grid Heater .................................................................................................................................................. 500 ohms
Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)
Analog Throttle ..................................................................................Idle Validation Switch Closes At 0.775V ± 0.1V
Throttle Position Potentiometer.................................................................................................. 5V Reference ± 0.2V
Low Idle Position .............................................................................................................................. 0.4V ± 0.025V
High Idle Position ................................................................................................................................. 4.0V ± 0.1V
4002-8
ELECTRICAL WIRE IDENTIFICATION
Wire Identification Codes

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

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

Color, Size,
Wire Circuit Connector Cav Connector Cav
and Material
W 0.8 GXL
1 JMP1, JSS Load Sense A JMP2, JSS Load Sense C
Twist
Bk 0.8 GXL
2 JMP1, JSS Load Sense B JMP2, JSS Load Sense A
Twist
14 Alternator D+ Lg 1.0 SXL AD, Alternator D+ 1 ENG, Engine Cab1 26
30 Battery Sensing R 1.0 SXL Alt_5 Alternator D+ 2 AB_5 Alternator B+ 1
31 EDC Relay Control OR 0.8 GXL EDC7, Engine Controller 13 SPL_EDC4, Ultrasonic A
38 Doser Valve B+ R 0.8 GXL DNOX2, NOX Controller 12 DEFDM, Doser Metering VLV 1
42 Work Lights Switched Fused Pwr R 2.0 GXL SPL-WL, Ultrasonic A ECC, Elect Center C A2
44 Brake Lt Control Power T 1.0 SXL BTM_C, Cab bottom bulkhd J PBL, Brake Light Press Switch 2
49 Back Lt Power DU1.0 GXL D-OR, Diode OR C SPL-BCK-LGT, Spl Back Lgt Pwr A
52 Fan Reverse LSD W 0.8 TXL AIC-1, Adv Instr Clust 1 23 ECB, Electrical Center B B8
56 Fan Control PWM W 0.8 TXL CAB-E, Cab Engine 23 AIC-1, Adv Instr Clust 1 26
57 Pin Engage Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 17 YPE, Pin Engage Jumper A
58 Ride Control Sol Pwr W 1.0 SXL PRBF, Rollback Press Sw A YRC, Ride Control Option 1
64 Horn Power Or 1.0 SXL FRONT, Cab Front Chassis 13 HN1, Horn Power 1
460 Fan Speed Sensor Signal Y 1.0 SXL Eng, Engine-Cab1 16 FSS, Fan Speed Sens 1
016B Pedal Sensor Grnd DU 0.8 GXL BTM_C, Cab Bottom Bulkhd D BPP, Pedal Position 6
GND_ENG7, Tranny, Cool

017A Fan Speed Sensor GND BK 1.0 SXL 1 FSS, Fan Speed Sens 2
Temp
GND_CAB_SPL, Cab Grnd
0D_C DIAG2 GRND BK 0.8 GXL DIA_2, Diagnostic A D
Splice
0E_A EXHT Temp Up GND BK 0.8 GXL UTS, Upstream Temp Sense 2 DNOX2, Nox Controller 17
SPL_BCK_LT_GD2, SPL_BACK
0_29 RTT/Float GND BK 0.8 GXL SFL, Return to Travel SW 4 K
LGT GRND
SPL-BCK-LT-GD2, Spl Back Lgt
0 29 RTT/Float Ground Bk 0.8 GXL SFL, Return To Travel Sw 4 K
Gnd
0 AA Proximity Switch Grnd Bk 1.0 SXL PXH, Height Control RTT B SPL-A2, Ultrasonic A
0 AB Proximity Switch Grnd Bk 1.0 SXL SPL-A2, Ultrasonic A GND-FC, Ground A 1
0 AC Proximity Switch Grnd Bk 1.0 SXL PXF, RTD B SPL-A2, Ultrasonic A
0 AD Ride Control Ground Bk 1.0 SXL YRC, Ride Control Option 2 SPL-A1, Ultrasonic A
0 AE Pin Engage Ground Bk 1.0 SXL SPL-A1, Ultrasonic A YPE, Pin Engage Jumper B
4002-9

21C Bk - 1.0


Color, Size,
and Material
0 AF Horn Ground Bk 1.0 SXL HN2, Horn Ground 1 SPL-A1, Ultrasonic A
0 AG Front Chassis Ground Bk 2.0 SXL SPL-A1, Ultrasonic A GND-FC, Ground A 1
0 AH RH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LRF, Lights RH 1
0 AJ LH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LLF, Lights LH 1
0 AK Park Brake/Warning Ground Bk 1.0 SXL SPL-A4, Ultrasonic A BTM_E, CAB BTTOM 2
0 AL Brake Warning Press Sw Gnd Bk 1.0 SXL PBW, Brake Warn Press Sw 2 SPL-A4, Ultrasonic A
0 AM RTD Grnd Bk 1.0 SXL PXM, RTD B PXT, RTD B
0 AN Park Brake Solenoid Ground Bk 1.0 SXL YPB, Park Brake Solenoid 2 SPL-A4, Ultrasonic A
0 AP Front To Rear Chassis Ground Bk 5.0 SXL GND-S1, Ground A 1 GND-S2, Ground A 1
JSS_FRM, JSS Frame to

0 AS GRND, JOYSTICK Bk 1.0 GXL G SPL_JSS_17, Ultrasonic A
CAB
0 AT GRND, JSS VLV Bk 1.0 GXL JSS_Valve, JSS HYD Valve 3 SPL_JSS_17, Ultrasonic A
0 AU GRND, Pilot Dump Bk 1.0 GXL SPL_JSS_17, Ultrasonic A JSS_PIL_DUMP, JSS Pilot Dump 2
0 AV GRND Bk 1.0 GXL SPL_JSS_17, Ultrasonic A GND_JSS, Ground_A 1
0 AW Pin Engage GND Bk 1.0 SXL YPE1, Pin Engage Jumper B YPE2, Pin_Engage_OPT B
0B Front Washer Ground Bk 1.0 SXL FWW, Front Washer 2 SPL-ENG-GRD, Gnd Spl 6 Pck E
SPL-PED-BL-GD, Spl Bk Lgt

0 B1 Back Light Ground Bk 0.8 GXL SPC, Pilot Control Switch 7 B
Grnd 6 Pck
SPL-BCK-LT-GD2, Spl Bk Lt
0 B2 Back Light Ground Bk 0.8 GXL SFL, Return To Travel Switch 7 B
Grnd
0 B3 Back Light Ground Bk 0.8 GXL SHC, Height Control Switch 7 C
Grnd
0 B4 Back Light Ground Bk 0.8 GXL SRTD, Detent Switch 7 D
Grnd
0 B5 Back Light Ground Bk 0.8 GXL SPE, Pin Engage Switch 9 E
Grnd
SPL_BCK_LT_GD, SPL Back SPL-BCK-LT-GD2, Spl Bk Lt
0 B6 Cab2 Ground Bk 1.0 GXL D F
Lght GRND Grnd
0 B7 Back Light Ground Bk 0.8 GXL SFC, Fan Control Switch 7 M
Grnd
0 B8 Front Wiper Motor Ground Bk 0.8 GXL GND_CAB2, Ground_A 1 FWMG, Wiper Ground A
SPL-HOOD-GRND, Hood
0 B10 Hood Ground Bk 1.0 GXL E GND-CAB2, Ground A 1
Grnd 6 Pck
4002-10

21C Bk - 1.0


Color, Size,
and Material
SPL-BCK-LT-GD2, Spl Bk Lt SPL-PED-BL-GD, Spl Bk Lt Grnd
0 B11 Back Light Ground Bk 0.8 GXL L F
Grnd 6 Pck
SPL-HOOD-GRND, Hood
0 B12 Hood Down Relay Ground Bk 1.0 GXL A ECC, Elect Center C C4
Grnd 6 Pck
SPL-BCK-LT-GD, Spl Bk Lt
0 B13 Back Light Ground Bk 1.0 GXL A SPL_WL1, Ultrasonic A
Grnd
0 B14 Back Light Ground Bk 0.8 GXL SWL, Work Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd B
0 B15 Back Light Ground Bk 0.8 GXL SBE, Beacon Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd C
SPL-HOOD-GRND, Hood
0 B16 Hood Down Control Ground Bk 1.0 GXL B ECC, Elect CNTR C B4
Grnd 6 Pck
0 B17 Back Light Ground Bk 0.8 GXL STA, Trans Auto Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd E
0 B18 Back Light Ground Bk 0.8 GXL SDC, Declutch Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd F
0 B19 Back Light Ground Bk 0.8 GXL SDR, Driving Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd G
0 B20 Back Light Ground Bk 0.8 GXL SRC, Ride Control Switch 7 J
Grnd
0 B21 Back Light Ground Bk 0.8 GXL SBU, Backup Alarm Disc Sw 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd J
SPL-HOOD-GRND, Hood
0 B22 Hood Up Relay Ground Bk 1.0 GXL C ECC, Elect CNTR C C2
Gnd 6 Pck
0 B23 Back Light Ground Bk 0.8 GXL SRWP, Rear Wiper Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd L
SPL-PED-BL-GD, Spl Bk Lt Grnd
0 B24 Back Light Ground Bk 0.8 GXL SHZ, Hazard Switch 7 C
6 Pck
SPL-HOOD-GRND, Hood
0 B25 Hood Up Control Ground Bk 1.0 GXL D ECC, Elect CNTR C B2
Gnd 6 Pck
0 B26 Buzzer/Switch Pad Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A GND_CAB2, Ground A 1
0 B27 Buzzer Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A BUZ, AIC Buzzer 2
0 B28 Switch Pad Ground Bk 0.8 TXL SW-PD, Switch Pad 10 SPL-BUZ, Ultrasonic A
SPL-PED-BL-GD, Spl Bk Lt Grnd

0 B29 RTT/Float Ground Bk 0.8 GXL SPB, Parking Brake Switch 7 E
6 Pck
SPL_BCK_LT_GD2,
0 B31 SDA GND Bk 0.8 GXL A SDA, Diff Lock Switch 7
SPL_BACK LGT GRND
SPL_BCK_LT_GD, SPL Back
0 B32 Back Light GND Bk 0.8 GXL SRP, Work Lights SW 7 M
Lght GD
0 BA Pedestal Gnd Strap Bk 5.0 SXL. GND-PDST, Ground A 1 GND-PDST2, Ground A 1
0 BAC EDC7 Ground Bk 2.0 SXL SPL-EDC1, Ultrasonic A GND-ENG2, WIF, EDC 1
0 BAE EDC7 Sender Ground Bk 1.0 SXL RECT, Engine Coolant Temp B GND-ENG7, Tranny, Cool Temp 1
4002-11

21C Bk - 1.0


Color, Size,
and Material
0 BAG Hood Grounds (EURO) Bk 1.0 SXL GND-ENG4, Rear Lighting 1 E-HD, Trans Hood c
0 BAG
Hood Grounds (NA) Bk 1.0 SXL ENG-H, Engine to Hood 1 GND-ENG4, Rear Lighting 1
N
GND-WIF, Gnd WIF Ring

0 BAR WIF Body Ground Bk 1.0 SXL 1 GND-ENG6, Dedicated 1
Term
0 BAT Crank Request FGND Bk 1.0 SXL Eng, Engine-CAB1 6 GND_ENG2, WIF, EDC 1
0 BAU EVGT_2 GND Bk 1.0 SXL Turbo, Eng Dash_Turbo 5 GND_ENG2, WIF, EDC 1
0 BB Fan Reverse Solenoid Ground Bk 1.0 SXL YFR, Fan Reverse Sol Opt 2 SPL-FAN, Ultrasonic A
0 BBA JOYSTICK GROUND Bk 0.8 GXL SPL_JSS_1, Ultrasonic A SJS, Joystick_Control_SW 4
0 BBB JOYSTICK GROUND Bk 0.8 GXL SJS, Joystick_Control_SW 7 SPL_JSS_1, Ultrasonic A
GND_CAB_SPL2, SPL Back

0 BBC JOYSTICK GROUND Bk 0.8 GXL F SPL_JSS_1, Ultrasonic A
LGHT GD
0 BBD JOYSTICK GROUND Bk 0.8 GXL JSS_CAB, JSS CAB 8 SPL_JSS_1, Ultrasonic A
0 BBE JOYSTICK GROUND Bk 0.8 GXL SJS_Joystick_Control_SW 9 SPL_JSS_1, Ultrasonic A
0 BBF DNOX2 Module GND Bk 2.0 SXL SPL_DCUG, Ultrasonic A DC2_A, Disconnect-Battery 1
GND_ENG3, SPLC_PK, WSHR

0 BBR Ground Bk 1.0 SXL ENG_B, CAB BTTOM 2 1
MTR
0 BC EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 11
0 BD EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 10
0 BE EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 5
0 BF EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 6
0 BG AIC Power Ground Bk 0.8 GXL ENG, Engine Cab1 19 GND-ENG6, Dedicated 1
0 BH AIC Power Ground Red Bk 0.8 GXL ENG, Engine Cab1 20 GND-ENG6, Dedicated 1
0 BJ AIC Sensor Ground Bk 0.8 GXL ENG, Engine Cab1 17 GND-ENG6, Dedicated 1
0 BL Rear Washer Ground Bk 1.0 SXL RWW, Rear Washer 2 SPL-ENG, Ultrasonic A
GND-ENG3, SPLC-PK, Washer

0 BM Engine Splice Grounds Bk 1.0 SXL SPL_ENG, Ultrasonic A 1
Motor
0 BP WIF Sensor Ground Bk 1.0 SXL GND-ENG2, WIF, EDC 1 WIF, Water In Fuel Sensor 2
0 BQ Fan Speed PWM Sol Grd Bk 1.0 SXL YFN, Fan PWM Solenoid B SPL-FAN, Ultrasonic A
0 BR RH Rear Light Ground (EURO) Bk 1.0 SXL LRR-E, RH Rear Comb Lamp 5 GND-ENG4, Rear Lighting 1
0 BR N LH Rear Light Ground (NA) Bk 1.0 SXL LLR, LH Rear Comb Lamp 1 SPL-J1, Ultrasonic A
0 BS Fan Control Ground Bk 1.0 SXL SPL-FAN, Ultrasonic A SPL-ENG, Ultrasonic A
4002-12

21C Bk - 1.0


Color, Size,
and Material
0 BT LH Rear Light Ground (EURO) Bk 1.0 SXL LLR-E, LH Rear Comb Lamp 5 GND-ENG4, Rear Lighting 1
0 BT N RH Rear Light Ground (NA) Bk 1.0 SXL LRR, RH Rear Comb Lamp 1 SPL-J1, Ultrasonic A
0 BU Fuel Level Sender Ground Bk 1.0 SXL RFLG, Fuel Send Ground 1 GND-ENG7, Tranny, Cool Temp 1
0 BV Grid Heater Control Grnd Bk 0.8 TXL GHC, Grid Heater Relay 2 EDC7, Engine Controller 75
GND-ENG1, Start, FFH,

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

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

0 DAP Back Light Ground Bk 0.8 GXL STE, Trans Enable Switch 7 K
Light Ground
0 DAV TECM Diagnostic Ground Bk 0.8 GXL 108F, Diagnostic connector 3 GND-CAB3D, Ground A 1
0 DB AIC Power Ground Red Bk 0.8 TXL CAB-E, Cab Engine 20 AIC-2, ADV Instr Cluster 2 15
0 DD Work Lights Grnd Bk 2.0 GXL SPL_WL1, Ultrasonic A GND_CAB1, Ground A 1

0 DE Neutral Start Relay Control Grd Bk 0.8 GXL G ECB, Elect Center B B4
Light GD
Crank Request Relay Control
0 DF Bk 0.8 GXL CAB_E, CAB-Engine 6 ECB, Elect Center B B6
Ground
0 DG Cab Splice Grounds Bk 1.0 GXL GND-CAB-SPL, Cab Grd Spl F GND-CAB3, Ground C 1
0 DH Diagnostic Connector Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl M DIA, Diagnostic A
0 DJ AC Relay Control Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl K ECD, Elect Center D B10
0 DK Seat Compressor Motor Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl J SC, Seat Comp Motor B
4002-13

21C Bk - 1.0


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

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

0 EE DIODE Suppression Grounds Bk 0.8 GXL A 140M, DIODE Module C
Spl
GND-CAB-SPL2, Spl Back
0 EF Brake Lights Relay Ctrl Grnd Bk 0.8 GXL M ECC, Elec CNTR D A1
Light Ground
GND-CAB-SPL2, Spl Back Light
0 EG Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 4 L
Ground
GND-CAB-SPL2, Spl Back Light
0 EH Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 3 K
Ground
CNV, 24V to 12V Pwr
0 EJ Power Converter Ground Bk 1.0 GXL 3 GND-CAB4, Ground C 1
Convert
0 EK AUX Power Outlet 1 Grnd Bk 1.0 GXL PO1, Power Outlet C GND-CAB5, Ground C 1
0 EL AUX Power Outlet 2 Grnd Bk 1.0 GXL PO2, Power Outlet C GND-CAB5, Ground C 1
0 EM Radio Ground Bk 0.8 GXL CAB-RF, Cab to Roof Conn. M GND-CAB-SPL, Cab Grnd Spl B
0 EN Radio Ground Bk 0.8 GXL ROOF, Roof to Cab Conn. M RAD, Radio Power 8
4002-14

21C Bk - 1.0


Color, Size,
and Material
0 EP Horn Switch Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl C SRHSTLK, RH Stalk Switch 31
Splice Pack GND-CAB-SPL2 GND-CAB-SPL2, Spl Back GND-CAB6, Start, FFH, Water
0 EQ Bk 0.8 GXL H 1
Grnd Light Ground Sep Htr
0 ER Power Converter Grnd Bk 1.0 GXL CNV, 24V to 12V Pwr Conv 6 GND-CAB4, Ground C 1
GND-GH1, STRT, FFH, Water

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

0 EW Power Relay GND Bk 0.8 GXL ECB, Elect CNTR B B1 E
LGHT GD
0 EY Power Relay GND Bk 0.8 GXL ECD, Elec CNTR D A4 SPl_SD1, Ultrasonic A
0 EZ Power Relay Control W 0.8 GXL ECD, Elec CNTR D A3 AIC_1, ADV Instr Cluster 1 22
GND_CB, Ground, On
0G Bk 2.0 SXL 1 GND_GL, Ground, Rear Grill 1
Cooling Box
GND-ENG1, STRT, FFH, Water
0 GB Starter Relay Control Ground Bk 1.0 SXL SRC-1, Relay 2 1
Sep Htr
0 HD Speed Sensor Grounds Bk 1.0 SXL TRANS, Cab Transmission 11 SPL-H2, Ultrasonic A
0 HE Output Speed Sensor Grnd Bk 1.0 SXL TRANS, Cab Transmission 28 OSS, Out Speed Sensor 1
Bk 0.8 GXL
0 HF Engine Speed Sensor Grnd ESS, Engine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
Bk 0.8 GXL
0 HG Inter Speed Sensor Grnd ISS, Inter Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
Bk 0.8 GXL
0 HH Turbine Speed Sensor Grnd TSS, Turbine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
0 HL Redundant Brake Switch Grnd Bk 1.0 SXL PRB2, Redundant Brake Sw B GND_TRANS, Ground_Trans 1
0 HM Redundant Brake Switch Grnd Bk 1.0 SXL PRB1, Redundant Brake Sw B GND_TRANS, Ground_Trans 1
0 HR HYD FLTR SW Grnd Bk 1.0 SXL PHF9, HYD_FLTR_RES_SW 1 GND_TRANS, Ground_Trans 1
HOT, Hydraulic Oil Temp

0 HW Hot Ground Bk 1.0 SXL B GND_TRANS, Ground_Trans 1
Send
0J Start Lockout RLY GND Bk 0.8 GXL ECC, Elect CNTR C B10 A
LGHT GD
0 JA Hood Grounds (EURO) Bk 1.0 SXL HD-E, Hood Trans C SPL-J1, Ultrasonic A
0 JA N Hood Grounds (NA) Bk 1.0 SXL HD-N, Hood to Engine 1 SPL-J1, Ultrasonic A
4002-15

21C Bk - 1.0


Color, Size,
and Material
0 JB Backup Alarm Grnd Bk 1.0 SXL BU1, Backup Alarm Grnd 1 SPL-J1, Ultrasonic A
0 JC License Plate Light Grnd Bk 1.0 SXL LPL, Lic Plate Light B SPL-J1, Ultrasonic A

0K Camera GND BK 0.8 GXL C Mon, Camera/Monitor 2
LGHT GD
0 KA IGN PWR Control GND Bk 0.8 GXL ECD, Elec CNTR D AA3 B
LGHT GD
0L Telematics GRND BK 2.0 GXL TEL, Telematics H CABE2, CAB to ENG2 Bulkhd G
0 LA DNOX2 Module GND Bk 2.0 GXL ENG2, ENG Bulkhd 2 G SPL_DCUG, Ultrasonic A
0 LB DNOX2 Module GND Bk 1.0 GXL DNOX2, NOX Controller 14 SPL_DCUG, Ultrasonic A
0 LC DNOX2 Module GND Bk 1.0 GXL SPL_DCUG, Ultrasonic A DNOX2, Nox Controller 15
0 LD DNOX2 Module GND Bk 2.0 GXL ENG2, ENG Bulkhd 2 G DC2_A, Disconnect-Battery 1
0 MA Rear Wiper Motor Grnd Bk 1.0 GXL SPL-ROOF, Spl Rood Grnd C RWMG, Rear Wiper Motor Grnd 1
0 MB Dome Light Grnd Bk 0.8 GXL LDM3, Dome Light Grnd 1 SPL-ROOF, Spl Rood Grnd B
0 MC Beacon Light Grnd Bk 1.0 GXL LBEGRD, Light Beacon Grnd 1 SPL-ROOF, Spl Rood Grnd A
0 ME LH Rear Work Light Grnd Bk 1.0 GXL LLRW, LH Rear Work Light 2 SPL_WR, Ultrasonic A
0 MF RH Rear Work Light Grnd Bk 1.0 GXL LRRW, RH Rear Work Light 2 SPL_WR, Ultrasonic A
0 MG RH Front Work Light Grnd Bk 1.0 GXL LRFS, Front_WK_LT_OPT 2 SPL_WRK2, Ultrasonic A
Roof, Roof to CAB

0 MH Rear Work Light Grnd Bk 1.0 GXL B SPL_WR, Ultrasonic A
Connection
0 MJ RH Front Work Light Grnd Bk 1.0 GXL LRFW, RH Front Work Light 2 SPL_WK, Ultrasonic A
0 MK Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. G SPL-ROOF, Spl Rood Grnd E
0 ML RH Front Work Light Grnd Bk 1.0 GXL SPL_WRK2, Ultrasonic A LRFR, Front_EWK_LT_OPT 2
0 MN Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. F SPL-ROOF, Spl Rood Grnd D
0 MP RH Front Work Light Grnd Bk 1.0 GXL SPL_WRK2, Ultrasonic A LRFO, Front_WK_LT_OPT 2
0 MU LH Front Work Light Grnd Bk 1.0 GXL LLFW, LH Front Work Light 2 SPL_WK, Ultrasonic A
Roof, Roof to CAB

0 MV RH Front Work Light Grnd Bk 2.0 SXL A SPL_WK, Ultrasonic A
Connection
0 NA Hood Grounds (EU) Bk 1.0 SXL HD_9, Hood to ENG 1 SPL_B1 A
0 NB Master Disconnect Grnd Bk 62.0 SGR DC2, Discon Black Grnd 1 STTR-GRN, Grid Heater Fuse 1
0 NC Battery Disconnect Bk 62.0 SGR BT4, Discon Black Grnd 1 DC1, Disconnect Battery 1
242F, Chassis Grnd Sec. GND-SSCHAS, SSM Ground

0 ND SSM Ground Bk 62.0 SGR 1 1
Strg Motor Cable
4002-16

21C Bk - 1.0


Color, Size,
and Material
0 NE Hood Grounds (EU) Bk 1.0 SXL SPL_B1 A LLR_9, LH_Rear_Comb_LT 5
0 NF Hood Grounds (EU) Bk 1.0 SXL SPL_B1 A LLR_9, RH_Rear_Comb_LT 5
0 NG Hood Grounds (EU) Bk 1.0 SXL SPL_B1 A SPL_J1, Ultrasonic A
0 PA Left Speaker Grnd Bk 0.8 GXL LSPK, Left Speaker B SPK, Speaker 8
0 PB Right Speaker Grnd Bk 0.8 GXL RSPK, Right Speaker B SPK, Speaker 2
YRC_J, Ride
0 RD Ride Control Grnd Bk 1.0 SXL 2 YRC_J2, Ride_Control_OPT 2
CNTRL_Jumper
JSS_ARM, JSS Armrest to
0 SC GRND, Joystick Bk 0.8 GXL 7 PVRES, JSS Joystick V
CAB
0 SD GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A CAB_ARM, CAB to Armrest 7
0 SE GRND Bk 0.8 TXL SPL_JSS_10, Ultrasonic A CAN_MOD_2, JSS can mod 10
0 SF GRND Bk 0.8 GXL SPL_JSS_14, Ultrasonic A Cab to JSS Frame G
0 SG Common Bk 0.8 GXL SPL_JSS_10, Ultrasonic A Arm_Pos, Arm position 1

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

0 SK GRND, CAN MOD Bk 0.8 GXL 8 SPL_JSS_9, Ultrasonic A
to Frm
0 SL Ground Bk 0.8 GXL JSS_RLY, Relay K2 87A SPL_JSS_9, Ultrasonic A
0 SM GRND, Joystick Bk 0.8 GXL JSS_CNT, JSS Controller 10 SPL_JSS_20, Ultrasonic A
0 SN GRND, Joystick Bk 0.8 GXL SPL_JSS_20, Ultrasonic A JSS_CNT, JSS Controller 11
0 SP GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A R1, Resistor CS0
0 SR GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A JSS_CNT, JSS Controller 15
0 SS GRND, Joystick Bk 0.8 GXL JSS_197F, Main_CAB_FNR 1 FNR_RLY, Relay K2 87A
0 ST GRND, Joystick Bk 0.8 GXL FNR_RLY, Relay K2 85 SPL_JSS_9, Ultrasonic A
0 SU GRND, Joystick Bk 0.8 GXL SPL_JSS_20, Ultrasonic A SPL_JSS_9, Ultrasonic A
0T DEF Sensor GND Bk 0.8 GXL UBJ, DEF Level Temp 2 Dnox2, NOX Controller 19
DTLTS,
0 TA DEF Sensor GND LU 0.8 GXL UBJM, DEF Level Temp 2 2
DEF_Tank_Level_Temp_Sensor
0U EXHT Temp DWN GND Bk 0.8 SXL DNOX2, NOX Controller 25 DTS, Downstream Temp SENS 2
12ACC Ignition Switch ACC Power W 0.8 GXL S-KEY, Ignition Switch 4 SPL-ACC, Ultrasonic A
12ACC
ACC PRM Control Power W 0.8 GXL SPL-ACC, Ultrasonic A PRM-B1, PRM Signal A
B
4002-17

21C Bk - 1.0


Color, Size,
and Material
12ACC Power Converter PRM Control
W 0.8 GXL SPL-ACC, Ultrasonic A PRM-A2, PRM Signal A
C Power
12V 12V Pwr To Outlet 1 Or 1.0 GXL PO1, Power Outlet A ECB, Elect Center B AA1
12V A 12V Pwr To Outlet 2 Or 1.0 GXL PO2, Power Outlet A ECB, Elect Center B AA2
12V B 12V Fused Pwr to Radio Or 1.0 GXL CAB-RF, Cab to Roof Conn. N ECB, Elect Center B AA9
12V C 12V Switched Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 5 SPL-12V, Ultrasonic A
12V D Plug 1 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A1
12V E Plug 2 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A2
12V F Radio 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A9
12V G 2 Way Radio 12V Switched Pwr Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A10
12V H 12V Fused Power to Radio Or 0.8 GXL ROOF, Roof to Cab Conn. N SPL-RAD, Ultrasonic A
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 7
HA
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 4
HB
13A EVGT Relay Or 0.8 TXL Evgt_4, EVGT C EDC7, Engine Controller 51
13B EVGT Relay PWR Or 1.0 GXL Turbo, ENG Dash_Turbo 6 EVGT_4, EVGT A
13C Fuel Shutoff Fused Power Or 1.0 SXL DC3, Fuel Solenoid Disc 1 DISC, Disconnect Engine A
13C A Fuel Shutoff Fused Power Or 1.0 SXL ENG-D, Disc Harness A ENG, Engine Cab1 21
13C B Fuel Shutoff Fused Power Or 1.0 SXL CAB-E, Cab Engine 21 ECA, Elect Center A A9
13K Ignition Switch Pwr Or 1.0 GXL S-KEY, Ignition Switch 3 SPL-PK1, Slice 3-4 Way E
13K A Ignition Switch Pwr Or 1.0 GXL TDM, Time Delay Module 5 SPL-PK1, Slice 3-4 Way G
13K B Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way F PRM-A1, PRM Signal A
13K C Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way H ECB, Elect Center B D1
13M Fuel Shutoff Fused Power Or 1.0 SXL DC4, Fuel Sol Disconnect 1 DISC, Disconnect Engine B
13M A Fuel Shutoff Fused Power Or 0.8 TXL ENG-D, Disconnect Harness B EDC7, Engine Controller 40
14 5 Alternator D+ LG 1.0 SXL ENG, Engine-CAB1 26 ALT_5, Alternator D+ 3
14 A Alternator D+ LG 0.8 GXL SPL_ALT, Ultrasonic A 215F, Alternator Resistor 1
14 AB Alternator D+ LG 0.8 GXL SPL_ALT, Ultrasonic A CAB_E, CAB-Engine 26
14 AC Alternator Running LG 0.8 GXL SPL_ALT, Ultrasonic A TEL, Telematics D
16R C FNR Reverse Signal LU 0.8 GXL JSS_197M, FNR-Main_CAB 4 RVS_DIODE, Diode ASSY C
17P A Switch Pad Power From AIC Pwr Or 0.8 TXL SW-PD, Switch Pad 9 SPL_SW_PD, Ultrasonic A
4002-18

21C Bk - 1.0


Color, Size,
and Material
17P B SW Pad PWR from AIC PWR Or 0.8 TXL SPL_SW_PD, Ultrasonic A AIC_1, ADV Instr Cluster 1 25
17P C B+ CAN MOD Or 0.8 GXL SPL_SW_PD,Ultrasonic A JSS_CAB, JSS CAB 2
17P D B+ CAN MOD Or 0.8 GXL SPL_JSS_18, Ultrasonic A CAB_ARM, Cab to Armrest 4

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

17P G B+ Joystick Or 0.8 GXL SPL_JSS_18, Ultrasonic A 2
Frm
18B LH High Beam Fused Power Or 2.0 SXL FRONT, Cab Front Chassis 6 LLF, Lights LH 3
18B A LH High Beam Fused Power Or 2.0 GXL CAB-F, Cab Front Chassis 6 ECB, Elect Center B AA3
18C RH High Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 16 LRF, Lights RH 3
18C A RH High Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 16 ECB, Elect Center B AA4
18D LH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 14 LLF, Lights LH 2
18D A LH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 14 ECB, Elect Center B AA6
18E RH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 15 LRF, Lights RH 2
18E A RH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 15 ECB, Elect Center B AA5
18F LH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 10 LLF, Lights LH 4
18F A LH Position/Tail Fused Power Or 0.8 GXL CABE2, CAB to ENG2 Bulkhd M SPL-POS-L, Ultrasonic A
18F
LH Position/Tail Fused Power Or 1.0 SXL ENG2, ENG Bulkhd 2 M ENG-H, Engine to Hood 6
AN
18F B LH Position/Tail Fused Power Or 1.0 SXL ENG2, ENG Bulkhd 2 M LLR-E, LH Rear Comb Light 3
18F LLR-N LH Rear Combination
LH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 6 3
BN Light
18F C LH Position/Tail Fused Power Or 1.0 GXL SPL-POS-L, Ultrasonic A ECB, Electric Center B AA7
18F E LH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 10 SPL-POS-L, Ultrasonic A
18F F LH Position/Tail Fused Power Or 1.0 SXL HD-9, Hood to Engine 6 LLR-9, LH Rear Comb Light 3
18G RH Position/Tail Fused Power Or 1.0 GXL SPL-POS-R, Ultrasonic A ECB, Elect Center B AA8
18G A RH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 5 LRF, Lights RH 4
18G
RH Position/Tail Fused Power Or 1.0 SXL SPL-POS-NA, Ultrasonic A LRR, RH Rear Combination Light 3
CN
18G D Licence Plate Light Fused Pwr Or 1.0 SXL SPL-POS, Ultrasonic A E-HD, Trans Hood A
18G E Licence Plate Light Fused Pwr Or 0.8 GXL HD-E, Hood Trans A LPL, Licence Plate Light A
4002-19

21C Bk - 1.0


Color, Size,
and Material
18G
Licence Plate Light Fused Pwr Or 1.0 SXL LPL, Licence Plate Light A SPL-POS-NA, Ultrasonic A
EN
18G F RH Position/Tail Fused Power Or 0.8 GXL CABE2, CAB to ENG2 Bulkhd N SPL-POS-R, Ultrasonic A
18G G RH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 5 SPL-POS-R, Ultrasonic A
18G H RH Position/Tail Fused Power Or 1.0 SXL ENG2, Engine Bulkhd 2 N SPL-POS, Ultrasonic A
18G
RH Position/Tail Fused Power Or 1.0 SXL ENG2, Engine Bulkhd 2 N ENG-H, Engine to Hood 5
HN
LRR-E, RH Rear
18G J RH Position/Tail Fused Power Or 1.0 SXL 3 SPL-POS, Ultrasonic A
Combination Light
18G
RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-POS-NA, Ultrasonic A
JN
18G K RH Position/Tail Fused Power Or 1.0 SXL HD-9, Hood to Engine 5 SPL-P9, A
18G L LIC Plate Fused Power Or 1.0 SXL SPL-P9, A LPL, LIC_PLATE_LIGHT A
LRR-9, RH Rear Combination

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

18S D B+, JSS Fused Or 0.8 GXL J 11
Frame FRM
4002-20

21C Bk - 1.0


Color, Size,
and Material
JSS_PIL_PR, JSS Pilot
18S E B+, JSS Fused Or 1.0 SXL A JSS_FRM, JSS Frame to Cab J
Pressure
18T DNOX SW B+ Or 0.8 GXL ECA, Elect CNTR A A10 CABE2, Cab to ENG2 Bulkhd H
18T A DNOX2 SW B+ Or 1.0 SXL ENG2, ENG Bulkhd 2 H DNOX2, NOX Controller 24
18U A DNOX2 Module B+ Or 3.0 GXL PRMB_L2, B+ Power 1 CABE2, Cab to ENG2 Bulkhd E
18U B DNOX2 BATT Or 3.0 GXL ENG2, ENG Bulkhd 2 E DNOX2, NOX Controller 4
18U C DNOX2 BATT Or 3.0 GXL PRMB_L2, B+ Power 1 CABE2, Cab to ENG2 Bulkhd B
18U D DNOX2 BATT Or 3.0 GXL ENG2, ENG Bulkhd 2 B DNOX2, NOX Controller 3
19A Output Speed Sensor Fused Pwr Or 1.0 SXL TRANS, Transmisson-CAB 29 OSS, Out Speed Sensor 3
19A A Brake Declutch Sw Fused Pwr Or 1.0 SXL TRANS, Transmisson-CAB 24 PBD, Dec. Pressure Switch A
19A B FNR Switched Fused Power Or 0.8 GXL 197M, FNR Main Cab 1 SPL-FNR, Ultrasonic A
19A C FNR Switched Fused Power Or 0.8 GXL 197F, Main Cab FNR 1 SPL-TRNS-PWR, Trans Pwr F
19A D Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 2 SPL-D15, Ultrasonic A
19A E AIC Fused Power Or 0.8 GXL STE, Trans Enable Switch 10 SPL-D15, Ultrasonic A
19A F Trans Enable Switch Fused Pwr Or 0.8 GXL SPL-TRNS-PWR, Trans Pwr B SPL-D15, Ultrasonic A
19A G FNR Sw Fused Power Or 0.8 GXL SPL-FNR, Ultrasonic A SFNR, FNR Switch 8
19A H Trans Shifter Fused Power Or 0.8 GXL TS1, Transmission Shifter A SPL-TRNS-PWR, Trans Pwr M
SPL-TRANS-PWR, Trans
19A K TECM Fused Power Or 0.8 TXL J TECM, Trans 45
Pwr
19A L Park Brake Switched Fused Pwr Or 0.8 GXL SPB, Parking Brake Switch 2 SPL-PBS, Ultrasonic A
19A M Output Speed Sensor Fused Pwr Or 0.8 TXL CAB-T, Cab Transmission 29 SPL-TRNS-PWR, Trans Power K
SPL-TRANS-PWR, Trans
19A N Trans Fused Power Or 1.0 GXL A ECA, Elect Center A A1
Pwr
19A P Backup Alarm Relay Control SPL-TRANS-PWR, Trans

Or 1.0 GXL G ECD, Elect Center D AA10
Fused Power Pwr
19A Q Trans/Auto Switch Fused Power Or 0.8 GXL STA, Trans Auto Switch 2 SPL-TRANS-PWR, Trans Pwr C
19A R Declutch Switch Fused Power Or 0.8 GXL SDC, Declutch Switch 2 SPL-TRANS-PWR, Trans Pwr H
19A T Brake Declutch Switch Fused Or 0.8 GXL CAB-T, Cab-Transmission 24 SPL-TRANS-PWR, Trans Pwr D
Power
19A U Trans Kick Down Switch Fused Or 0.8 GXL SPL-FNR, Ultrasonic A 20M, Trans Kick Down 1
Power
19A V FNR Switch Fused Power Or 0.8 GXL SFNR, FNR Switch 5 SPL-FNR, Ultrasonic A
19A W Diagnostic Conn. Fused Power Or 0.8 GXL 108F, Diagnostic Connector 1 SPL-TRANS-PWR, Trans Pwr E
4002-21

21C Bk - 1.0


Color, Size,
and Material
19B Turn Signal Fused Power Or 0.8 GXL SRHSTLK, RH Stalk Switch 49a ECA, Elect Center A A8
19B A FNR SW Fused PWR W 0.8 GXL FNR_RLY, Relay K2 30 JSS_197M, FNR-MAIN_CAB 1
19B B FNR SW Fused PWR Or 0.8 GXL CAB_FNR, MAIN_CAB_FNR 1 FNR_RLY, Relay K2 87
19B C FNR SW Fused PWR Or 0.8 GXL ARM_FNR, FNR-MAIN_CAB 1 SPL_AJ, Ultrasonic A
19B D FNR SW Fused PWR Or 0.8 GXL 21M, Trans_KICK-DOWN 1 SPL_AJ, Ultrasonic A
19B E FNR SW Fused PWR Or 0.8 GXL SAJ, FNR_SWITCH 5 SPL_AJ, Ultrasonic A
19B F FNR SW Fused PWR Or 0.8 GXL SAJ, FNR_SWITCH 8 SPL_AJ, Ultrasonic A
19C A Pilot Ctrl Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A ECA, Elect Center A A5
19C B Pilot Ctrl Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A ECD, Elect Center D B5
19C C Pilot Ctrl Fused Pwr Or 0.8 GXL SPL-D24, Ultrasonic A ECD, Elect Center D D5
19C D Ride Control SW Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A SRC, Ride Control Switch 2
19C E Pilot Control SW FSD Pwr Or 0.8 GXL SPL-D24, Ultrasonic A TEL, Telematics C
19C F Pilot Control SW Fused Pwr Or 0.8 GXL SPL-D24, Ultrasonic A SPC, Pilot_Control_Switch 2
19D A Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECA, Elect Center A A6
19D B Parking Brake Relay Fused Pwr Or 0.8 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B D9
19D C Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B B9
19E A AIC Wake Up Ignition Or 0.8 TXL SPL_AP, Ultrasonic A ECA, Elect Center A A3
19H Backup Alarm B+ Or 1.0 GXL ECA, Elect Center A C4 ECD, Elect Center D A10
19J Front Wiper Fused Pwr Or 0.8 GXL SPL-PK3, Splice 3-4 Way K ECA, Elect Center A C2
19J A Front Wiper Motor Fused Pwr Or 0.8 GXL SPL-PK3, Splice 3-4 Way M FWM, Front Wiper Motor C
19J B Front Wip Wash Sw Fused Pwr Or 0.8 GXL SFWW, Front Wiper/Washer 5 SPL-PK3, Splice 3-4 Way J
19J C Front Wiper Relay Fused Power Or 0.8 GXL SPL-PK3, Splice 3-4 Way L SPL-FW, Ultrasonic A
19J D Front Wiper Relay Fused Power Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D D1
19J E Front Wiper Relay Fused Power Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D B1
Front Wiper Relay LS Control

19J F Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D D3
Fused Power
19J G Wiper Cutout Relay Fused Pwr Or 0.8 GXL SPL-FW, Ultrasonic A K-WCO, Wiper Cutout 86
19K Rear Wiper Fused Pwr Or 1.0 GXL SPL-RWW, Ultrasonic A ECA, Elect Center A C3
19K A Rear Wiper Sw Fused Pwr Or 1.0 GXL SRWP, Rear Wiper Sw 3 SPL-RWW, Ultrasonic A
19K B Rear Wip Wash Fused Pwr Or 0.8 GXL SRWP, Rear Wiper Sw 5 SPL-RWW, Ultrasonic A
4002-22

21C Bk - 1.0


Color, Size,
and Material
CAB-RF, Cab to Roof
19K C Rear Wiper Motor Fused Pwr Or 1.0 GXL J SPL-RWW, Ultrasonic A
Connect
19K D Rear Wiper Motor Fused Pwr Or 1.0 SXL ROOF, Roof to Cab Connect J RWM, rear Wiper Motor C
19L Pwr Converter Fused Power Or 3.0 GXL PRM-E1, PRM Output C SPL-CNV, Ultrasonic A
19L A Pwr Converter Fused Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 1 SPL-CNV, Ultrasonic A
19L B Pwr Converter Fused Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 2 SPL-CNV, Ultrasonic A
Sec. Steering Accessory Fused

19M Or 0.8 GXL CAB-T, Cab Transmission 3 ECA, Elect Center A C7
Pwr
19M A Sec. Steering Accessory Fused Or 1.0 SXL TRANS, Cab Transmission 3 TR-SS, Sec. Steering Module Opt A
Pwr
19M C Sec. Steering Accessory Fused Or 1.0 SXL SSM, Sec. Steering Module 7 SS-TR, Sec. Steering Mod Trans A
Pwr
19N Seat Compressor Fused Pwr Or 1.0 GXL SC, Seat Compressor Motor A ECA, Elect Center A C6
19P Pin Engage/Fan Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr B ECA, Elect Center A A7
19P A Pin Engage Sw Fused Pwr Or 0.8 GXL SPE, Pin Engage Sw 2 SPL-PIN, Spl Back Lgt Pwr A
19P C Fan Rev Sw Fused Pwr Or 0.8 GXL SFC, Fan Control Switch 5 SPL-PIN, Spl Back Lgt Pwr C
19P D Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr E ECB, Elect Center B D7
19P E Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr F ECB, Elect Center B B7
19R Sec. Steering Ign Fused Pwr Or 0.8 GXL DM, Diode OR C SPL-2 Ultrasonic A
19RR Sec. Steering Ign Fused Pwr Or 0.8 GXL DM, Diode OR A ECA, Elect Center A A4
19R A Sec. Steering Ign Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 4 TR-SS, Sec. Steering Module Opt B
19R C Sec. Steering Ign Fused Pwr Or 1.0 SXL SSM, Sec. Steering Module 1 SS-TR, Sec. Steering Mod Trans B
19R D Alternator Resistor Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A 216F, Alternator Resistor 1
19R E Sec. Steering Ign Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A CAB-T, Cab Transmission 4
19S1 Sec. Steering Fused Pwr Or 3.0 GXL PRM_A1, PRM Output A SPL_19S, Ultrasonic A
19S2 Sec. Steering Fused Pw Or 1.0 GXL SPL_19S, Ultrasonic A CAB_T, Cab-Transmission 26
19S1 E Sec. Steering Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 26 TR-SS, Sec. Steering Module Opt E
SS-TR, Sec. Steering Module

19S1 X Sec. Steering Fused Pwr Or 1.0 SXL SSM, Sec. Steering Module 3 E
Trans
19S B AIC Delay Fused Power Or 0.8 GXL SPL-DKY3, Ultrasonic A ECC, Elect Center C A8
19S C AIC Delay Fused Power Or 0.8 TXL SPL-DKY3, Ultrasonic A AIC-2, Advanced Instr Cluster 2 20
19S D AIC Delay Fused Power Or 0.8 TXL SPL-DKY3, Ultrasonic A AIC-2, Advanced Instr Cluster 2 14
4002-23

21C Bk - 1.0


Color, Size,
and Material
19S E AIC BATT B+ Or 1.0 GXL SPL_AP, Ultrasonic A AIC_1, ADV Instr Cluster 1 1
19S F AIC BATT B+ Or 1.0 GXL SPL_AP, Ultrasonic A AIC_2, ADV Instr Cluster 2 21
19T A Fused_Batt_Pwr Or 0.8 TXL TECM, Trans 23 SPL_D17, Ultrasonic A
19T B Fused_Batt_Pwr Or 0.8 TXL TECM, Trans 68 SPL_D17, Ultrasonic A
19T C Fused_Batt_Pwr Or 0.8 TXL ECC, Elect CNTR C A10 SPL_D17, Ultrasonic A
19U Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Elect CNTR C A6
19U A Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Elect CNTR C B7
19U B Beacon Dome Lt Fused Pwr Or 1.0 GXL SPL-LT, Ultrasonic A ECC, Elect CNTR C A1
ROOF, Roof to Cab

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

19U F Door Sw Fused Power Or 0.8 GXL P DS, Door Switch A
Connection
CAB-RF, Cab to Roof
19U G Door Sw Fused Power Or 0.8 GXL P SPL-LT, Ultrasonic A
Connection
19U H Beacon Switch Fused Power Or 1.0 GXL SBE, Beacon Switch 2 SPL-LT, Ultrasonic A
19W Cigar Lighter Pwr Or 3.0 GXL CL, Cigar Lighter 1 ECC, Elect CNTR A C8
19Y Hood control Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect CNTR C A7
19Y A Hood Up Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect CNTR C D2
19Y B Hood Down Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect CNTR C D4
19Y C Hood Switch Fused Power Or 1.0 GXL CABE2, Cab to Eng2 Bulkhd T SPL-HOOD, Ultrasonic A
19Y D Hood Switch Fused Power Or 1.0 GXL ENG2, Engine Bulkhd 2 T HD, Hood Switch B
19Z Driving Lights Sw Fused Power Or 1.0 GXL SPL_DR, Ultrasonic A ECC, Elect CNTR C A3
19Z A Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 2 SPL_DR, Ultrasonic A
19Z B Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 5 SPL_DR, Ultrasonic A
19Z C High Beam Flash Fused Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56d SPL_DR, Ultrasonic A
1CB Cab CB Protected Power R 19.0 SXL P_C3, B+ Pwr FRM PRMD 1 CBPW, Cab Power 1
1CB A Cab CB Protected Power R 19.0 SXL P-A3, B+ Power 1 CAB-PW, Cab Power 1
1DM Time Delay/Ign Sw Fused Pwr R 1.0 GXL ECC, Elect CNTR C A5 S_Key, Ignition_Switch 1
1 AA Brake Lt Sw Pwr R 1.0 SXL BTM_C, Cab Bottom Bulkhd K PBL, Brake Light Press Switch 1
4002-24

21C Bk - 1.0


Color, Size,
and Material
1B EVGT Relay PWR R 1.0 GXL EVGT_3, EVGT_Fuse B EVGT_4, EVGT D
1 BA Alternator B+ R 13.0 SXL AB+, Alternator B+ 1 B2 Starter Power 1
1 BB Starter Solenoid Pwr R 8.0 SXL 193 Starter Relay 1 194 Starter Signal 1
1 BE Grid Htr Pwr R 19.0 SXL 115 Grid Htr Pwr 1 GH, Grid Htr 1
1 BF Alternator B+ R 13.0 SXL AB_5, Alternator B+ 1 B6, Starter Power 1
1 BG B+ PWR PRMC R 19.0 SXL B5, Starter PWR Stud 1 P_C1, B+ PWR FRM PRMD 1
1C ECC Bat Power R 8.0 GXL P-A1, B+ Power 1 L1-ECC, ECC Battery Power 1
1 DR Brake Light Switch Power R 1.0 GXL CAB-B, Cab Front Chassis K SPL-FLSHR-PWR, Ultrasonic A
1 DU Flasher Module Pwr R 1.0 GXL FLSHR, Flasher Module 1 SPL-FLSHR-PWR, Ultrasonic A
SPL-FLSHR-PWR,
1 DV Brake Lights/Flasher Bat Pwr R 2.0 GXL A ECC, Elec CNTR C A4
Ultrasonic
SPL-FLSHR-PWR,
1 DW Brake Lt Relay Bat Pwr R 1.0 GXL A ECD, Elec CNTR D A2
Ultrasonic
1E Grid heater Fuse Bat Power R 19.0 SXL P-C2, B+ Power from PRMD 1 GHF1, Grid Heater Fuse 1
1 GA Filter Htr Pwr R 3.0 SXL PRM-D1, PRM Output C SPL-HTR, Ultrasonic A
1 GB Fuel Filter Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A FFH, Fuel Filter Heater A
1 GC Water Sep Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A WSH, Water Separator Heater B
1 KA Hazard Switch Pwr R 1.0 GXL SHZ, Hazard Switch 2 SPL-FLSHR-PWR, Ultrasonic A
1 NA Battery Crossover R 62.0 SGR BT3, Starter Battery 1 BT2, Disconnect Battery 1
1 NB Battery Starter R 62.0 SGR BT1, Battery Starter 1 B3, Starter Battery 1
1 NC B+ Power PRMC R 19.0 SXL B1, Starter Power Stud 1 P-C1, B+ Power From PRMC 1
1 ND SSM Power R 62.0 SGR 244F Starter Sec. Strg Mtr 1 B4, Starter Power 1
1 NE Battery STRTR R 62.0 SGR B7, Starter-Battery 1 BT1, Battery_Starter 1
1 NF SSM PWR R 62.0 SGR B8, Starter_Power 1 244F, Starter-sec_STRG_MTR 1
1T EVGT_3 PWR R 1.0 SXL P_C6, B+ PWR FRM PRMD 1 EVGT_3, EVGT_FUSE A
1Y Grid Heater Fused Power R 19.0 SXL GHF3, Grid heater Fuse 1 GHF4, Grid Heater 1
1Z Starter Relay Battery Power R 8.0 SXL P-C4, B+, Power From PRMC 1 195, Starter Relay Power 1
20G A EDC7 ESO-K Interface W 0.8 TXL ENG, Engine Cab1 31 EDC7, Engine Controller 89
20G B EDC7 ESO-K Interface W 0.8 GXL CAB-E, Cab Engine 31 DIA, Diagnostic E
21C Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D4
21C A Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D5
4002-25

21C Bk - 1.0


Color, Size,
and Material
21C B Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECD, Elect Center D A6
21D Starter Relay Signal W 1.0 SXL SRC-1, Relay 1 ENG, Engine Cab1 15
21D A Starter Relay Signal W 0.8 GXL CAB_E, Cab-Engine 15 ECD, Elect Center D AA5
21E Key Switch Crank W 0.8 GXL ECB, Elect CNTR B D6 ECC, Elect Center C B9
21E A Key Switch Crank W 0.8 TXL ENG, Engine Cab1 27 EDC7, Engine Controller 32
21E B Key Switch Crank W 0.8 GXL ECC, Elect CNTR C C10 CAB_E, Cab-Engine 27
21F EDC7 Digital Ground W 0.8 GXL CAB-E, Cab Engine 11 ECB, Elect Center B B5
21F A EDC7 Digital Ground W 0.8 GXL ENG, Engine Cab 11 SPL-EDC3, Ultrasonic A
21F B EDC7 Digital Ground W 0.8 TXL SPL-EDC3, Ultrasonic A EDC7, Engine Controller 29
21F C EDC7 Digital Ground W 0.8 TXL ENG_B, CAB BTTOM 1 SPL-EDC3, Ultrasonic A
21F D EDC7 Digital Ground W 0.8 TXL RTHP, Throttle Pedal 1 BTM_E, CAB BTTOM 1
21G EDC7 Crank Control relay W 0.8 GXL CAB-E, Cab Engine 3 ECD, Elect Center D AA6
21G A EDC7 Crank Control relay W 0.8 TXL ENG, Engine Cab1 3 EDC7, Engine Controller 37
21H Crank control relay LSD W 0.8 GXL CAB-E, Cab Engine 4 ECD, Elect Center D A5
21H A Crank control relay LSD W 0.8 TXL ENG, Engine Cab1 4 EDC7, Engine Controller 17
21J Restart Prevent W 0.8 GXL ECC, Elect CNTR C D9 TEL, Telematics S
21K Ign Sw Start Signal W 0.8 GXL S-KEY, Ignition Switch 2 SPL-CRK, Ultrasonic A
21K A Ign Sw Start Signal W 0.8 TXL SPL-CRK, Ultrasonic A AIC-2, Adv Instrument Cluster 2 17
21K B Ign Sw Start Signal W 0.8 GXL SPL-CRK, Ultrasonic A ECB, Elect Center B B3
22A Declutch SW DU 0.8 TXL SDC, Declutch_Switch 3 TECM, Trans 21
22B Pedal Sensor +5V K 0.8 TXL TECM, Trans 37 CAB_B, Cab BTM Bulkhd B
22C Pedal POS Signal Y 0.8 TXL TECM, Trans 38 CAB_B, Cab BTM Bulkhd C
22D Pedal Sensor Grnd LU 0.8 TXL TECM, Trans 24 CAB_B, Cab BTM Bulkhd A
22E Pedal Sensor +5V K 0.8 TXL BTM_C, Cab Bottom Bulkhd B BPP, Pedal Position 2
22F Pedal POS Signal Y 0.8 GXL BTM_C, Cab Bottom Bulkhd C BPP, Pedal Position 3
22G Pedal Sensor Grnd LU 0.8 GXL BTM_C, Cab Bottom Bulkhd A BPP, Pedal Position 1
23A A DNOX2 Module B+ N 0.8 TXL ENG2, Eng Bulkhd C NOXS, NOX Sensor 1
23B A NOX Sensor B+ Or 0.8 GXL ECD, Elec CNTR D A8 CABE2, Cab to Eng2 Bulkhd F
23B B NOX Sensor B+ N 0.8 GXL ECD, Elec CNTR D AA7 CABE2, Cab to Eng2 Bulkhd C
GND_CAB_SPL, Cab Grnd

23B C NOX Relay GND Bk 0.8 GXL ECD, Elec CNTR D A7 E
Splice
4002-26

21C Bk - 1.0


Color, Size,
and Material
23B D NOX Relay B+ Or 0.8 GXL ECD, Elec CNTR D AA8 CABE2, Cab to Eng2 Bulkhd A
23B E NOX Sensor B+ Or 1.0 GXL ENG2, Eng Bulkhd 2 F SPL_EDC2, Ultrasonic A
23B F NOX Relay B+ Or 1.0 SXL ENG2, Eng Bulkhd 2 A SPL_EDC4, Ultrasonic A
23D D NOX Sensor GND Bk 0.8 TXL NOXS, NOX Sensor 2 GND_ENG2, WIF, EDC 1
23J B DNOX2 K-Line W 0.8 GXL DIA_2, Diagnostic E CAB_Em Cab-Engine 18
23K A Temp/Humd B+ K 0.8 TXL HTS, HMDTY and AMB Temp 1 EDC7, Engine Controller 68
23K B Temp/Humd Temp Y 0.8 GXL HTS, HMDTY and AMB Temp 2 EDC7, Engine Controller 26
23K C Temp/Humd Humd Y 0.8 GXL HTS, HMDTY and AMB Temp 4 EDC7, Engine Controller 27
23K E Temp/Humd GND LU 0.8 GXL EDC7, Engine Controller 28 HTS, HMDTY and AMB Temp 3
24B Throttle Signal W 0.8 TXL ENG_B, Cab BTTOM 3 EDC7, Engine Controller 79
24B A Throttle Signal W 0.8 TXL RTHP, Throttle Pedal 3 BTM+E, Cab BTTOM 3
24L Low Idle Sw W 0.8 TXL ENG_B, Cab BTTOM 6 EDC7, Engine Controller 48
24L A Low Idle Sw W 0.8 TXL RTHP, Throttle Pedal 6 BTM_E, Cab BTTOM 6
24R Throttle Grnd W 0.8 TXL ENG_B, Cab BTTOM 4 EDC7, Engine Controller 78
24R A Throttle Grnd W 0.8 TXL RTHP, Throttle Pedal 4 BTM_E, Cab BTTOM 4
24S Throttle Supply W 0.8 TXL ENG_B, Cab BTTOM 5 EDC7, Engine Controller 77
24S A Throttle Supply W 0.8 TXL RTHP, Throttle Pedal 5 BTM_E, Cab BTTOM 5
24T B TC Lockup SOL GND LU 1.0 SXL TRANS, Cab Transmission 25 YLS, TC_Lockup_Valve 2
255E Pedal Sensor +5V K 0.8 TXL BTM_C, Cab Bottom Bulkhd E BPP, Pedal Position 5
LU 0.8 GXL
25A Eng Speed Sig TRANS, Cab Transmission 7 ESS, Engine speed Sensor 1
Twist
25A A Eng Speed Sig LU 0.8 TXL TECM, Trans 19 Cab+T, Cab-Transmission 7
LU 0.8 GXL
25B Int Speed Sig TRANS, Cab Transmission 9 ISS, Int Speed Sensor 1
Twist
25B A Int Speed Sig LU 0.8 TXL TECM, Trans 42 Cab+T, Cab-Transmission 9
LU 0.8 GXL
25C Turbine Speed Sig TRANS, Cab Transmission 8 TSS, Turbine Speed Sensor 1
Twist
25C A Turbine Speed Sig LU 0.8 TXL TECM, Trans 41 Cab+T, Cab-Transmission 8
25D Output Speed Sig LU 1.0 SXL TRANS, Cab Transmission 10 OSS, Output Speed Sensor 2
25D A Output Speed Sig LU 0.8 TXL TECM, Trans 62 Cab+T, Cab-Transmission 10
25F Forward Signal LU 0.8 TXL TS1, Transmission Shifter B TECM, Trans 43
25G Brake Declutch Switch LU 1.0 SXL Trans, Transmission-Cab 14 PBD, Declutch Pressure Switch B
4002-27

21C Bk - 1.0


Color, Size,
and Material
25G A Brake Declutch Switch CTRL LU 0.8 GXL CAB-T, Cab Transmission 14 SPL-DC, Ultrasonic A
25G B Brake Declutch Switch CTRL LU 0.8 GXL SDC, Declutch Switch 1 SPL-DC, Ultrasonic A
25G C Brake Declutch Switch CTRL LU 0.8 TXL SPL-DC, Ultrasonic A TECM, Trans 66
25H Trans Auto Signal LU 0.8 TXL STA, Trans Auto Switch 3 TECM, Trans 29
25J Trans Sol Valve Y6 LU 0.8 TXL TRANS, Cab Transmission 21 TRC, Trans Control 6
25J A Trans Sol Valve Y6 LU 0.8 TXL CAB-T, Cab Transmission 21 TECM, Trans 51
25K Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 1
25K 9 Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 2
25K A Trans Sol Valve Y1 LU 0.8 TXL CAB-T, Cab Transmission 16 TECM, Trans 56
25L Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 2
25L 9 Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 1
25L A Trans Sol Valve Y2 LU 0.8 TXL CAB-T, Cab Transmission 17 TECM, Trans 10
25M Trans Sol Valve Y3 LU 0.8 TXL TRANS, Cab Transmission 18 TRC, Trans Control 3
25M A Trans Sol Valve Y3 LU 0.8 TXL CAB-T, Cab Transmission 18 TECM, Trans 32
25N Trans Sol Valve Y4 LU 0.8 TXL TRANS, Cab Transmission 19 TRC, Trans Control 4
25N A Trans Sol Valve Y4 LU 0.8 TXL CAB-T, Cab Transmission 19 TECM, Trans 55
25P Trans Sol Valve Y5 LU 0.8 TXL TRANS, Cab Transmission 20 TRC, Trans Control 5
25P A Trans Sol Valve Y5 LU 0.8 TXL CAB-T, Cab Transmission 20 TECM, Trans 9
25R Reverse Signal LU 0.8 TXL TS1, Transmission Shifter C TECM, Trans 64
25R A TC Lockup SOL Power LU 0.8 TXL TECM, Trans 50 CAB_T, Cab-Transmission 15
25R B TC Lockup SOL Power LU 1.0 SXL Trans, Transmission-CAB 15 YLS, TC_Lockup_Valve 1
25S Output Sw Power VPS1 LU 0.8 TXL TRANS, Cab Transmission 22 TRC, Transmission Control 7
25S A Output Sw Power VPS1 LU 0.8 TXL CAB-T, Cab Transmission 22 SPL D12, Ultrasonic A
25S B Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 12
25S C Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 13
25T Neutral Signal LU 0.8 GXL SPL-NEU, Ultrasonic A ECB, Elect Center B D3
25T A TC Lockup SOL GND W 0.8 TXL SPL_D19, Ultrasonic A CAB_T, Cab-Transmission 25
25T B Neutral Signal LU 0.8 GXL TS1, Transmission Shifter D SPL-NEU, Ultrasonic A
25T C Neutral Signal LU 0.8 TXL SPL-NEU, Ultrasonic A TECM, Trans 67
25W 3rd And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter B TECM, Trans 65
25Y Trans Kick Down Signal LU 0.8 GXL TS2, Transmission Shifter D SPL D11, Ultrasonic A
4002-28

21C Bk - 1.0


Color, Size,
and Material
25Y A Trans Kick Down Signal LU 0.8 TXL SPL D11, Ultrasonic A TECM, Trans 22
25Y B Trans Kick Down Signal LU 0.8 GXL 197F, Main Cab FNR 6 SPL D11, Ultrasonic A
25Y C Trans Kick Down Signal LU 0.8 GXL 20M, Trans Kick Down 2 197M, FNR Main Cab 6
25Y D Trans Kick Down Signal LU 0.8 GXL KD_Diode, Diode ASSY C JSS_197M, FNR-Main_Cab 6
25Y E Trans Kick Down Signal LU 0.8 GXL CAB_FNR, Main_Cab_Fnr 6 KD_Diode, Diode ASSY B
25Y F Trans Kick Down Signal LU 0.8 GXL KD_Diode, Diode ASSY A JSS_197F, Main_Cab_Fnr 6
25Y G Trans Kick Down Signal LU 0.8 SXL 21M, Trans_Kick-Down 2 ARM_FNR, Fnr-Main_Cab 6
25Z 1st And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter C TECM, Trans 63
26E A Trans Enable Signal LU 0.8 TXL STE, Trans Enable Switch 3 TECM, Trans 31
26F A FNR Forward Signal LU 0.8 GXL 197M, FNR Main Cab 2 SFNR, FNR Switch 6
26F B FNR Forward Signal LU 0.8 TXL 197F, Main Cab FNR 2 TECM, Trans 20
26F C FNR Forward Signal LU 0.8 GXL FWD_DIODE, Diode ASSY C JSS_197M, FNR-Main_Cab 2
26F D FNR Forward Signal LU 0.8 GXL JSS_197F, Main_Cab_Fnr 2 FWD_DIODE, Diode ASSY A
26F E FNR Forward Signal LU 0.8 GXL CAB_FNR, Main_Cab_Fnr 2 FWD_DIODE, Diode ASSY B
26F F FNR Forward Signal LU 0.8 GXL SAJ, FNR_Switch 6 ARM_FNR, FNR-Main_Cab 2
26J FNR Switch Jumper LU 0.8 GXL SFNR, FNR Switch 2 SFNR, FNR Switch 4
26K FNR Switch Jumper LU 0.8 GXL SAJ, FNR_Switch 2 SAJ, FNR_Switch 4
26N A FNR Neutral Signal LU 0.8 GXL SFNR, FNR Switch 3 197M, FNR Main Cab 3
26N B FNR Neutral Signal LU 0.8 TXL 197F, Main Cab FNR 3 TECM, Trans 44
26N C FNR Neutral Signal LU 0.8 GXL JSS_197M, FNR-Main_Cab 3 NTRL_DIODE, Diode ASSY C
26N D FNR Neutral Signal LU 0.8 GXL JSS_197F, Main_Cab_Fnr 3 NTRL_DIODE, Diode ASSY A
26N E FNR Neutral Signal LU 0.8 GXL NTRL_DIODE, Diode Assy B CAB_FNR, Main_Cab_Fnr 3
26N F FNR Neutral Signal LU 0.8 GXL SAJ, FNR_Switch 3 ARM_FNR, FNR-Main_Cab 3
26R A FNR Reverse Signal LU 0.8 GXL SFNR, FNR Switch 1 197M, FNR Main Cab 4
26R B FNR Reverse Signal LU 0.8 TXL 197F, Main Cab FNR 4 TECM, Trans 30
26R D FNR Reverse Signal LU 0.8 GXL JSS_197F, Main_Cab_Fnr 4 RVS_DIODE, Diode ASSY A
26R E FNR Reverse Signal LU 0.8 GXL CAB_FNR, Main_Cab_Fnr 4 RVS_DIODE, Diode ASSY B
26R F FNR Reverse Signal LU 0.8 GXL SAJ, FNR_Switch 1 ARM_FNR, Fnr-Main_Cab 4
28F Fuel FLTR HTR RLY CTRL W 0.8 TXL PRM-D2,PRM Signal A EDC7, Engine Controller 36
28G Grid Heater Source Dr. W 1.0 GXL GHC, Grid Htr Relay 1 EDC7, Engine Controller 12
31A EVGT Relay B+ Or 0.8 GXL EVGT_4, EVGT B SPL_EDC4, Ultrasonic A
4002-29

21C Bk - 1.0


Color, Size,
and Material
31B Filter Heater Control Or 0.8 GXL PRM_D2, PRM Signal B SPL_EDC4, Ultrasonic A
31F Air Filter Rest Sw Signal Y 1.0 SXL ENG, Engine Cab1 28 PAF, Air Filter Rest Sw 1
31F A Air Filter Rest Sw Signal Y 0.8 TXL CAB-E, Cab Engine 28 SW-PD, Switch Pad 5
31H Hyd Filter Rest Sw Signal Y 1.0 SXL TRANS, Cab Transmission 23 PHF, Hyd Oil Filter Rest Sw 1
31H9 HYD FLTR RST SW 9 Y 1.0 SXL TRANS, Cab Transmission 23 PHF9, HYD_FLTR_RES_SW 2
31H A Hyd Filter Rest Sw Signal Y 0.8 TXL SW-PD, Switch Pad 4 CAB-T, Cab Transmission 23
31L Pilot Control Switch High Y 0.8 TXL SPC, Pilot Control Switch 3 AIC-2, Advance Instr Cluster 2 18
32F Trans Filter Maint Sw Y 1.0 SXL TRANS, Cab Transmission 31 FM, Filter Maint Sw 1
32F A Trans Filter Maint Sw Y 0.8 TXL CAB-T, Cab Transmission 31 TECM, Trans 17
32J A Trans Enable Indiction Y 0.8 GXL SFNR, FNR Switch 7 197M FNR Main Cab 5
32J C Trans Enable Indiction Y 0.8 GXL STE, Trans Enable Switch 9 SPL-D16, Ultrasonic A
32J D Trans Enable Indiction Y 0.8 TXL SPL-D16, Ultrasonic A TECM, Trans 5
32J E Trans Enable Indiction Y 0.8 GXL 197F, Main Cab FNR 5 SPL-D16, Ultrasonic A
32J F Trans Enable Indiction Y 0.8 GXL SPL_JSS_21, Ultrasonic A JSS_197M, FNR-Main_Cab 5
32J G Trans Enable Indiction Y 0.8 GXL JSS_197F, Main_Cab_Fnr 5 SPL_JSS_21, Ultrasonic A
32J H Trans Enable Indiction Y 0.8 GXL CAB_FNR, Main_Cab_Fnr 5 SPL_JSS_21, Ultrasonic A
32J J Trans Enable Indiction Y 0.8 GXL SAJ, FNR_Switch 7 ARM_FNR, Fnr-Main_Cab 5
33P Brake Warning Press Low Y 1.0 SXL BTM_C, Cab Bottom Bulkhd L PBW, Brake Warning Press Sw 1
33P A Brake Warning Press Low Y 0.8 TXL CAB_B, Cab BTM Bulkhd L AIC-2, Advance Instr Cluster 2 5
Redundant Brake Accumulator

33R Y 0.8 TXL CAB-T, Cab Transmission 1 AIC-2, Advance Instr Cluster 2 4
Pressure Low
33R A Redundant Brake Accumulator Y 1.0 SXL TRANS, Cab Transmission 1 SPL-RD, Ultrasonic A
Pressure Low
33R B Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB2, Redundant Brake Switch A
Pressure Low
33R C Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB1, Redundant Brake Switch A
Pressure Low
33U Parking Brake Switch Y 0.8 TXL SPB, Parking Brake Switch 3 AIC-2, Advance Instr Cluster 2 6
34A A Diff Lock SW B+ Or 0.8 GXL SDA, Diff Lock Switch 2 SPL_PBS, Ultrasonic A
34A B Diff Lock SW SIG B+ Or 0.8 GXL SDA, Diff Lock Switch 2 SPL_PBS, Ultrasonic A
34A C Diff Lock SOL B+ W 0.8 TXL SPL_D19, Ultrasonic A CAB_T, Cab-Transmission 2
34A D Diff Lock SOL B+ Or 1.0 SXL TRANS, Transmission-Cab 27 YDL, Diff Lock Solenoid 1
4002-30

21C Bk - 1.0


Color, Size,
and Material
34A E Diff Lock SOL B+ Or 1.0 SXL YDL_1, Diff Lock Solenoid 1 YDL_2, Diff Lock Solenoid 1
34B Diff Lock SW SIG LU 0.8 TXL SDA, Diff Lock Switch 3 TECM, Trans 35
34C Diff Lock SOL GND LU 0.8 TXL TECM, Trans 11 CAB_T, Cab-Transmission 27
34C A Diff Lock SOL GND LU 1.0 SXL TRANS, Transmission-Cab 2 YDL, Diff Lock Solenoid 2
34C D Diff Lock SOL GND LU 1.0 SXL YDL_1, Diff Lock Solenoid 2 YDL_2, Diff Lock Solenoid 2
34D Diff Lock SW SIG LU 0.8 TXL TECM, Trans 59 SDM, Diff Lock Switch 1
35A 9 Backup Alarm RLY OUT Bk 1.0 SXL HD-9, Hood to Engine 7 BU2, Backup_Alarm 1
35A A Backup Alarm Y 0.8 GXL SPL_35A, Ultrasonic A ECD, Elect Control D AA9
35A B Backup Alarm Disable Switch Y 0.8 GXL SBU, Backup Alarm Dis Sw 2 SPL_35A, Ultrasonic A
35A C Backup Alarm Relay Out Y 0.8 GXL SPL_35A, Ultrasonic A CABE2, Cab to Eng2 Bulkhd L
209M, Backup Alarm Dis

35A D Backup Alarm Relay Out Y 0.8 GXL A SPL_35A, Ultrasonic A
Jump
209F, Backup Alarm Dis
35A E Backup Alarm Relay Out Y 0.8 SXL 1 SPL-D8-C1, Ultrasonic A
Jump
35A F Backup Alarm Relay Out Y 0.8 SXL CABE2, Cab to Eng2 Bulkhd K SPL-D8-C1, Ultrasonic A
35A G Backup Alarm Relay Out Y 0.8 SXL ENG2, Eng Bulkhd 2 K E-HD, Trans Hood B
35A
Backup Alarm Relay Out Y 1.0 SXL ENG2, Eng Bulkhd 2 K ENG-H, Engine to Hood 7
GN
35A H Backup Alarm Relay Out Y 1.0 SXL HD-E, Hood Trans B BU2, Backup Alarm 1
35A
Backup Alarm Relay Out Y 1.0 SXL HD-N, Hood to Engine 7 BU2, Backup Alarm 1
HN
35A J Reverse Light K 1.0 SXL ENG2, Eng Bulkhd 2 L SPL-A1A, Ultrasonic A
35A K Reverse Light K 1.0 SXL SPL-A1A, Ultrasonic A LRR-E, RH rear Comb Light 4
35A L Reverse Light K 1.0 SXL SPL-A1A, Ultrasonic A LLR-E, LH rear Comb Light 4
35A M Reverse Signal K 1.0 SXL SPL-35A, Ultrasonic A MON, Camera/Monitor 3
35A N Reverse Light K 1.0 SXL SPL-REV A LLR-9, LH Rear Comb Light 4
35A O Reverse Light K 1.0 SXL HD_9, Hood to Eng 8 SPL_REV A
35A P Reverse Light K 1.0 SXL LRR-9, RH rear Comb Light 4 SPL-REV A
35A R Backup Alarm Relay Out Y 1.0 SXL ENG2, Eng Bulkhd 2 L ENG-H, Engine to Hood 8
35B AIC Buzzer HSD W 0.8 TXL BUZ, AIC Buzzer 1 AIC-1, Advance Instr Cluster 1 13
35C Backup Alarm Relay Control Y 0.8 TXL TECM, Trans 7 ECD, Elect Center D A9
35R C Backup Alarm Sw Y 0.8 GXL SBU, Backup Alarm Dis Sw 1 SPL-D8-C1, Ultrasonic A
4002-31

21C Bk - 1.0


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

36G P 1.0 SXL TRANS, Cab Transmission 13 TCOT, TCO Sender 1
Signal
36G A Torque Conv Output Temp P 0.8 TXL CAB-T, Cab Transmission 13 TECM, Trans 49
Signal
36H Hydraulic Oil Temp P 1.0 SXL TRANS, Cab Transmission 30 HOT, Hydraulic Oil Temp Sender A
36H A Hydraulic Oil Temp P 0.8 TXL CAB-T, Cab Transmission 30 AIC-1, Advance Instr Cluster 1 9
36J Fuel Level Analog P 1.0 SXL ENG, Engine-Cab1 1 RFL_23, Fuel_Level_Send A
36R A Trans Temps/Filter Return P 1.0 SXL TRANS, Cab Transmission 12 SPL H1, Ultrasonic A
36R B Trans Filter Maint Sw Return P 1.0 SXL SPL H1, Ultrasonic A FM, Filter Maint Switch 2
36R C Valve Body Temp Return P 0.8 TXL SPL H1, Ultrasonic A TRC, Trans Control 9
36R D TCO Temp Return P 1.0 SXL SPL H1, Ultrasonic A TCOT, TCO Sender 2
36R E Trans Temps/Filter Return P 0.8 TXL CAB-T, Cab Transmission 12 TECM, Trans 46
36T Valve Body Temp Sig P 0.8 TXL TRANS, Cab Transmission 5 TRC, Trans Control 8
36T A Valve Body Temp Sig P 0.8 TXL CAB-T, Cab Transmission 5 TECM, Trans 39
37D A Diagnostic Signal P 0.8 TXL 108F, Diagnostic Connector 2 TECM, Trans 15
37E Diagnostic Signal Switched P 0.8 TXL 108F, Diagnostic Connector 4 TECM, Trans 18
38A Doser Valve GND LU 0.8 GXL DNOX2, NOX Controller 11 DEFDM, Doser Metering VLV 2
38B DEF Level SIG Y 0.8 GXL UBJ, DEF Level Temp 1 DNOX2, Nox Controller 18
DTLTS,
38B A DEF Level SIG Y 0.8 GXL UBJM, DEF Level Temp 1 1
DEF_Tank_Level_Temp_Sensor
38C Tank Heat GND LU 0.8 TXL DNOX2, NOX Controller 23 THV, Tank Heater Control Valve 1
38D Tank Heat B+ Or 0.8 TXL DNOX2, NOX Controller 1 THV, Tank Heater Control Valve 2
4002-32

21C Bk - 1.0


Color, Size,
and Material
38E EXHT Temp DWN B+ Y 0.8 GXL DNOX2, NOX Controller 26 DTS, Downstream Temp Sens 1
38F EXHT Up Signal Y 0.8 GXL UTS, Upstream Temp Sense 1 DNOX2, NOX Controller 28
38G DEF Temp SIG Y 0.8 GXL UBJ, DEF Level Temp 3 DNOX2, NOX Controller 29
DTLTS,
38G A DEF Temp SIG Y 0.8 GXL UBJM, Def Level Temp 3 3
Def_Tank_Level_Temp_Sensor
38H DNOX2 K-Line W 0.8 TXL ENG, Engine-Cab1 18 DNOX2, NOX Controller 31
401B Pedal POS Signal Y 0.8 GXL BTM_C, Cab Bottom Bulkhd F BPP, Pedal Position 4
41H A High Beam Pwr Or 1.0 GXL SRHSTLK, RH Stalk Switch 56a SPL_HB, Ultrasonic A
41H B High Beam LH Pwr Or 0.8 GXL SPL_HB, Ultrasonic A ECB, Elect Center B A3
41H C High Beam RH Pwr Or 0.8 GXL SPL_HB, Ultrasonic A ECB, Elect Center B A4
41H D High Beam Pwr Or 0.8 TXL SW-PD, Switch Pad 1 SPL_HB, Ultrasonic A
41J Driving Light Power Or 1.0 GXL SDR, Driving Lights Switch 6 SRHSTLK, RH Stalk Switch 56
41L A Low Beam Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56b SPL-LB, Ultrasonic A
41L B Low Beam LH Power Or 0.8 GXL SPL-LB, Ultrasonic A ECB, Elect Center B A6
41L C Low Beam RH Power Or 0.8 GXL SPL-LB, Ultrasonic A ECB, Elect Center B A5
41T Position Lights Switched Pwr K 1.0 GXL SDR, Driving Lights Switch 3 SPL_PR, Ultrasonic A
41T A Position Lights RH Switched Pwr K 1.0 GXL SPL_PR, Ultrasonic A ECB, Elect Center B A8
41T B Position Lights LH Switched Pwr K 1.0 GXL SPL_PR, Ultrasonic A ECB, Elect Center B A7
41T C Position Lights Switched Pwr K 1.0 GXL D-OR, Diode OR B SPL_PR, Ultrasonic A
42C A Front Work Lights Fused Pwr DU 2.0 GXL CAB-RF, Cab to Roof Conn. H SPL_42C, Ultrasonic A
42C C Front Work Lights Fused Pwr DU 2.0 GXL SPL_42C, Ultrasonic A SWL, Work Lights SW 3
42C D Front Work Lights Fused Pwr DU 1.0 GXL SPL_42C, Ultrasonic A D-OR, Diode OR A
42C F Front Work Lights Fused Pwr DU 2.0 GXL ROOF, Roof to Cab Conn. H SPL-WRKF, Ultrasonic A
42C G RH Front Work Lights Fused Pwr DU 1.0 GXL SPL-WRKF, Ultrasonic A LRFW, RH Front Work Light 1
42C H LH Front Work Lights Fused Pwr DU 1.0 GXL SPL-WRKF, Ultrasonic A LLFW, LH Front Work Light 1
42R A RH Front Work Lights Fuse Pwr DU 1.0 GXL LRFS, Front_WK_LT_OPT 1 SPL_WRK1, Ultrasonic A
42R B RH Front Work Lights Fuse Pwr DU 1.0 GXL SPL_WRK1, Ultrasonic A LRFR, Front_WK_LT_OPT 1
42R C Rear Work Lights Fused Pwr DU 2.0 GXL CAB-RF, Cab to Roof Conn. S SWL, Work Lights SW 6
42R F Rear Work Lights Fused Pwr DU 2.0 GXL ROOF, Roof to Cab Conn. S SPL-WRKR, Ultrasonic A
42R G RH Rear Work Lt Fused Pwr DU 1.0 GXL SPL-WRKR, Ultrasonic A LRRW, RH Rear Work Light 1
42R H LH Rear Work Lt Fused Pwr DU 1.0 GXL SPL-WRKR, Ultrasonic A LLRW, LH Rear Work Light 1
4002-33

21C Bk - 1.0


Color, Size,
and Material
42R K RH Front Work Lights Fuse Pwr DU 1.0 GXL SPL_WRK1, Ultrasonic A LRFO, Front_WK_LT_OPT 1
42 A Work Lights Fused Power R 2.0 GXL SWL, Work Lights Switch 2 SPL-WL, Ultrasonic A
42 B Work Lights Fused Power R 1.0 GXL SWL, Work Lights Switch 5 SPL-WL, Ultrasonic A
43S A Door Open Signal W 0.8 GXL CAB-RF, Cab to Roof Conn. R AIC_2, ADV Instr Cluster 2 2
43S B Door Open Signal W 0.8 GXL ROOF, Roof to Cab Conn. R DS, Door Switch B
43 A Dome Light Auto Mode DU 0.8 TXL CAB-RF, Cab to Roof Conn. C AIC-1, Adv Instrument Cluster 1 7
43 B Dome Light Auto Mode DU 0.8 GXL ROOF, Roof to Cab Conn. C LDM2, Dome Light Auto 1
44A A Brake Light Relay Out T 0.8 GXL CABE2, Cab to Eng2 Bulkhd S ECD, Elect CNTR D AA1
44A D Brake Light Relay Out T 1.0 SXL ENG2, Eng Bulkhd2 S SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL ENG2, Eng Bulkhd2 S ENG-H, Engine to Hood 2
DN
44A E Brake Light Relay Out T 1.0 SXL LLR-E, LH Rear Comb Light 1 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL HD-N, Hood to Engine 2 SPL-J2-N, Ultrasonic A
EN
44A F Brake Light Relay Out T 1.0 SXL LRR-E, RH Rear Comb Light 1 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL LLR-N, LH Rear Comb Light 2 SPL-J2-N, Ultrasonic A
FN
44A
Brake Light Relay Out T 1.0 SXL LRR-N, RH Rear Comb Light 2 SPL-J2-N, Ultrasonic A
GN
44A J Brake Light Relay Out T 1.0 SXL SPL-L1 A HD-9, Hood to Engine 2
44A K Brake Light Relay Out T 1.0 SXL SPL-L1 A LRR-9, RH Rear Comb Light 1
44A L Brake Light Relay Out T 1.0 SXL LLR-9, LH Rear Comb Light 1 SPL-L1 A
44 A Brake Light Control Power T 0.8 GXL CAB-B, Cab BTM Bulkhd J ECD, Elec CNTR D AA2
45A A Left Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 9 SRHSTLK, RH Stalk Switch L
45B A Right Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 10 SRHSTLK, RH Stalk Switch R
45H Hazard Switch Power N 0.8 GXL FLSHR, Flasher Module 11 SHZ, Hazard Switch 3
45L Left Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 2 LLF, Lights LH 5
45L A Left Turn Signal N 1.0 SXL ENG2, Eng Bulkhd 2 R LLR-E, LH Rear Comb Light 2
45L AN Left Turn Signal N 1.0 SXL ENG2, Eng Bulkhd 2 R ENG-H, Engine to Hood 3
45L B Left Turn Signal N 0.8 GXL CABE2, Cab to Eng2 Bulkhd R SPL-PK3, Splice 3-4 Way D
45L BN Left Turn Signal N 1.0 SXL HD-N, Hood to Engine 3 LLR, LH Rear Comb Light 4
45L C Left Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 2 SPL-PK3, Splice 3-4 Way C
4002-34

21C Bk - 1.0


Color, Size,
and Material
45L D Left Turn Signal N 0.8 GXL FLSHR, Flasher Module 8 SPL-PK3, Splice 3-4 Way B
45L E Left Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way A AIC-2, Adv Instrument Cluster 2 9
45L N Left Turn Signal N 1.0 SXL HD_9, Hood to Eng 3 LLR_9, LH_Rear_Comb_LT 2
45N A Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 2 64F, Flasher Connector 1
45N B Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 12 64M, Flasher Connector 1
45R Right Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 3 LRF, Lights RH 5
45R 9 Right Turn Signal N 1.0 SXL HD-9, Hood to Engine 4 LRR-9, RH Rear Comb Light 2
45R A Right Turn Signal N 1.0 SXL ENG2, Eng Bulkhd 2 P LRR-E, RH Rear Comb Light 2
45R
Right Turn Signal N 1.0 SXL ENG2, Eng Bulkhd 2 P ENG-H, Engine to Hood 4
AN
45R B Right Turn Signal N 0.8 GXL CABE2, Cab to Eng2 Bulkhd P SPL-PK3, Splice 3-4 Way H
45R
Right Turn Signal N 1.0 SXL HD-N, Hood to Engine 4 LRR, RH Rear Comb Light C
BN
45R C Right Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way E AIC-2, Adv Instrument Cluster 2 10
45R D Right Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 3 SPL-PK3, Splice 3-4 Way G
45R E Right Turn Signal N 0.8 GXL FLSHR, Flasher Module 7 SPL-PK3, Splice 3-4 Way F
46 C Beacon Switched Power K 1.0 GXL CAB-RF, Cab to Roof Conn. E SBE, Beacon Switch 3
46 D Beacon Switched Power K 1.0 GXL ROOF, Roof to Cab Conn. E LBEPWR, Light Beacon power 1
49A Back Light Power S 0.8 GXL HVAC1, HVAC1 3 SPL-BCK-LGT, Spl Back Lgt Pwr F
49S Back Light Power S 0.8 GXL STA, Trans Auto Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr J
49 A Back Light Power S 0.8 GXL SWL, Work Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr M
49 B Back Light Power S 0.8 GXL SBE, Beacon Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr L
49 C Back Light Power S 0.8 GXL SRWP, Rear Wiper Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr C
SPL-PED-BL, Spl Back Lgt Pwr 6
49 D Back Light Power S 0.8 GXL SHZ, Hazard SWitch 8 C
Pck
SPL-BCK-LGT2, Spl Back
49 E Back Light Power S 0.8 GXL A SPL-BCK-LGT, Spl Back Lgt Pwr K
Lgt Pwr
SPL-BCK-LGT2, Spl Back Lgt
49 F Back Light Power S 0.8 GXL SPE, Pin Engage Switch 10 F
Pwr
49 G Back Light Power S 0.8 GXL SRC, Ride control Switch 8 K
Pwr
49 H Back Light Power S 0.8 GXL STE, Trans Enable Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr D
4002-35

21C Bk - 1.0


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

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

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

49 S Back Light Power S 0.8 GXL F M
Pwr 6 Pck Pwr
49 T Back Light Power S 0.8 GXL SFWW, Front Wiper/Washer 8 H
Pwr
49 V Back Light Power S 0.8 GXL SPB, Parking Brake Switch 8 E
Pck
49 W JSS Backlight S 0.8 GXL SJS, Joystick_Control_SW 8 Pck A

49 X Back Light AIC S 0.8 TXL SW_PD, Switch Pad 3 Pck D
SPL_BCK_LGT2, Spl_Back
49 Z Back Light Power S 0.8 GXL J SDA, Diff Lock Switch 8
Lgt Pwr
51B A JSS ACT SW W 0.8 GXL SPL_JSS_2, Ultrasonic A SJS, Joystick_Control_SW 3
51B B JSS ACT SW W 0.8 GXL SJS, Joystick_Control_SW 6 SPL_JSS_2, Ultrasonic A
51B C JSS ACT SW W 0.8 GXL JSS_CAB, JSS Cab 5 SPL_JSS_2, Ultrasonic A
51B D JSS ACT SW W 1.0 SXL 5 SPL_JSS_7, Ultrasonic A
to Frm
51B E B+, JSS W 0.8 GXL JSS_RLY, Relay K2 86 SPL_JSS_7, Ultrasonic A
51B G B+, JSS W 0.8 GXL SPL_JSS_7, Ultrasonic A JSS_RLY, Relay K2 87
51B H JSS ACT SW W 0.8 GXL SPL_JSS_7, Ultrasonic A CAB_ARM, Cab to Armrest 6
4002-36

21C Bk - 1.0


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

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

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

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

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

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

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

51NO NO Neutral SW Y 0.8 GXL 11 PVRES, JSS Joystick U
Cab
51NO
NO Neutral SW P 0.8 GXL CAB_ARM, Cab to Armrest 11 JSS_CNT, JSS Controller 14
A
51PW
JSS Power W 1.0 SXL SPL_JSS_16, Ultrasonic A JSS_FRM, JSS Frame to Cab H
H
4002-37

21C Bk - 1.0


Color, Size,
and Material
51PW
JSS Power W 1.0 SXL JSS_LS, JSS Load Sense A SPL_JSS_16, Ultrasonic A
J
51PW
JSS Power W 1.0 SXL SPL_JSS_16, Ultrasonic A JSS_PIL_DUMP, JSS Pilot Dump 1
K
51PW CAB_ARM_FRM, Cab to Arm to
JSS Power W 0.8 GXL SPL_JSS_6, Ultrasonic A 9
M Frm
51PW
JSS Power W 0.8 GXL JSS_CAB, JSS Cab 9 SJS, Joystick_Control_SW 10
N
51PW
JSS Power W 0.8 GXL JSS_RLY, Relay K2 30 SPL_JSS_4, Ultrasonic A
P
51PW
JSS Power W 0.8 GXL JSS_CNT, JSS Controller 9 SPL_JSS_4, Ultrasonic A
Q
51PW
JSS Power W 0.8 GXL SPL_JSS_6, Ultrasonic A CAB_ARM, Cab to Armrest 8
R
51PW
JSS Power W 0.8 GXL SPL_JSS_13, Ultrasonic A JSS_ARM, JSS Armrest to Cab 8
S
51PW
JSS Power W 0.8 GXL SPL_JSS_6, Ultrasonic A CAB_FRM, Cab to JSS Frame H
T
51PW
JSS Power Bk 0.8 TXL SPL_JSS_13, Ultrasonic A CAN_MOD_2, JSS Can Mod 2
U
51PW
JSS Power W 0.8 GXL SPL_JSS_13, Ultrasonic A PVRES, JSS Joystick S
V
51PW
JSS Power W 0.8 GXL SPL_JSS_6, Ultrasonic A SPL_JSS_4, Ultrasonic A
W
51P A SEC STR High Press W 1.0 SXL SSM, SEC STR MOD 9 PSS, Sec Str Press Switch A
51R Armrest Raise Bk 0.8 TXL ARM_POS, Arm Position 2 CAN_MOD_2, JSS Can Mod 5
51S A JSS Okay PWR W 0.8 GXL JSS_CNT, JSS Controller 5 SPL_JSS_5, Ultrasonic A
51S B JSS Okay PWR W 0.8 GXL CAB_ARM, Cab to Armrest 9 SPL_JSS_5, Ultrasonic A
51S C JSS Okay PWR W 0.8 GXL SPL_JSS_15, Ultrasonic A JSS_ARM, JSS Armrest to Cab 9
51S D JSS Okay PWR Bk 0.8 TXL CAN_MOD_2, JSS Can Mod 4 SPL_JSS_15, Ultrasonic A
51S E JSS Okay PWR W 0.8 GXL PVRES, JSS Joystick R SPL_JSS_15, Ultrasonic A
CAB_FRM, Cab to JSS

51S F JSS Okay PWR W 0.8 GXL F SPL_JSS_5, Ultrasonic A
Frame
51S J JSS Okay PWR W 1.0 SXL JSS_VALVE, JSS HYD Valve 4 JSS_FRM, JSS Frame to Cab F
51 A Sec. Str Motor Control W 1.0 SXL SSM, Sec. Steer Module 2 SPL-SS, Ultrasonic A
4002-38

21C Bk - 1.0


Color, Size,
and Material
51 B Sec. Str Motor Control W 1.0 SXL SPL-SS, Ultrasonic A SSS, SS Mag Switch 1
51 C Sec. Str Sol Control W 1.0 SXL SPL-SS, Ultrasonic A YSS, Sec. Steering Solenoid 1
51 D Sec. Str Flyback W 1.0 SXL SSS, SS Mag Switch 1 SSD, SEC_STR_Diode C
52AU Fan Reverse Auto W 0.8 TXL SFC, Fan Control Switch 3 AIC-2, Adv Instrument Cluster 2 8
52A A Fan Reverse Relay Out W 1.0 GXL CAB-E, Cab Engine 22 ECB, Elect Center B D8
52A B Fan Reverse Relay Out W 1.0 SXL ENG, Engine Cab1 22 YFR, Fan Rev Solenoid Option 1
AIC-1, Adv Instrument

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

53C A Pilot Control Solenoid LSD W 0.8 TXL 20 ECD, Elect Center D B6
Cluster 1
53P A Pilot Control Relay Out W 0.8 GXL SPL-D25, Ultrasonic A YPP, Pilot Pressure Solenoid A
53P B Pilot Control Relay Out W 0.8 GXL SFL, Return to Travel Switch 2 SPL-D25, Ultrasonic A
53P C Pilot Control Relay Out W 1.0 GXL SPL-D25, Ultrasonic A ECD, Elect Center D D6
53P D Pilot Control Relay Out W 0.8 GXL SHC, Height Control Switch 2 SPL-D25, Ultrasonic A
53P E Pilot Control Relay Out W 0.8 GXL SRTD, Detent Switch 2 SPL-D25, Ultrasonic A
53P F Pilot Control Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 9 SPL-D25, Ultrasonic A
53P G Pilot Control Relay Out W 1.0 SXL FRONT, Cab Front Chassis 9 SPL-A3, Ultrasonic A
53P H Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXF, RTD C
53P I Pilot Control Relay Out W 1.0 SXL PXM, RTD C PXT, RTD C
53P J Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXH, Height Control RTT C
54A Height Control Switch Power W 0.8 GXL SHC, Height Control Switch 6 EM, RTD Height Control RTT 2
54B HC RTT Control Signal W 1.0 SXL FRONT, Cab Front Chassis 11 PXH, Height Control RTT A
4002-39

21C Bk - 1.0


Color, Size,
and Material
54B A HC RTT Control Signal W 0.8 GXL CAB-F, Cab Front Chassis 11 SPL-D1, Ultrasonic A
54B B HC RTT Control Signal W 0.8 GXL EM, RTD Height Control RTT 5 SPL-D1, Ultrasonic A
54B C HC RTT Control Signal W 0.8 GXL SFL, Return to Travel Switch 6 SPL-D1, Ultrasonic A
55A A RTT Float Sw Power W 0.8 GXL EM, RTD Height Control RTT 1 SPL-RTT, Ultrasonic A
55A B RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 1 SPL-RTT, Ultrasonic A
55A C RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 3 SPL-RTT, Ultrasonic A
55B RTT Float Switch Control W 0.8 GXL SFL, Return to Travel Switch 5 EM, RTD Height Control RTT 6
56 A Fan Control PWM W 1.0 SXL ENG, Engine Cab1 23 YFN, Fan PWM Solenoid A
57 A Pin Engage Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 17 SPL-PINE, Ultrasonic A
57 B Pin Engage Sol Pwr W 0.8 GXL SPE, Pin Engage Switch 1 SPL-PINE, Ultrasonic A
57 C Pin Engage Sol Pwr W 0.8 TXL SPL-PINE, Ultrasonic A AIC-2, Adv Instrument Cluster 2 16
57 D Pin Engage Sol Pwr W 1.0 SXL YPE1, PIN Engage Jumper A YPE2, Pin_Engage_OPT A
58C Ride Control Switch Jumper W 0.8 GXL SRC, Ride Control Switch 5 SRC, Ride Control Switch 3
58H A Power VPS2 W 0.8 TXL TECM, Trans 8 SPL_D19, Ultrasonic A
58H B Power VPSL W 0.8 TXL SPL_D19, Ultrasonic A TECM, Trans 53
58H C Power W 0.8 GXL ECD,Elec CNTR D D7 SPL_D19, Ultrasonic A
58L Ride Control Relay LSD Bk 0.8 TXL TECM, Trans 57 ECD, Elect Center D B8
58T Ride Control Relay Sw Pwr W 0.8 GXL SRC, Ride Control Switch 4 ECD, Elect Center D B7
58 A Ride Control Sol Pwr W 1.0 SXL 202M, Rollback Jumper A 202M, Rollback Jumper B
58 B Ride Control Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 18 PRBF, Rollback Pressure Switch B
58 C Ride Control Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 18 SPL-D26, Ultrasonic A
58 D Ride Control Sol Pwr W 0.8 GXL 140M, Diode Module D SPL-D26, Ultrasonic A
58 E Ride Control Sol Pwr W 0.8 GXL SPL-D26, Ultrasonic A ECD, Elect Center D D8
58 F Ride Control Sol Pwr W 0.8 GXL SRC, Ride Control Switch 6 SPL-D26, Ultrasonic A
58 G Ride Control Sol Pwr W 1.0 SXL Front, FRNT_CHAS_CAB 18 YRC, Ride_Control_OPT 1
58 H Ride Control Signal W 1.0 SXL YRC_J, Ride CNTR_Jumper 1 YRC_J2, Ride_Control_OPT 1
59D Hood Relay Control Down W 1.0 GXL CABE2, Cab to Eng2 Bulkhd V ECC, Elect CNTR C D3
59D A Hood Relay Control Down W 1.0 SXL ENG2, Eng Bulkhd 2 V HD, Hood Switch A
59U Hood Relay Control Up W 1.0 GXL CABE2, Cab to Eng2 Bulkhd X ECC, Elect CNTR C D1
59U A Hood Relay Control Up W 1.0 SXL ENG2, Eng Bulkhd 2 X HD, Hood Switch C
60D Hood Down Relay Out W 1.0 GXL CABE2, Cab to Eng2 Bulkhd U ECC, Elect CNTR C B3
4002-40

21C Bk - 1.0


Color, Size,
and Material
60D A Hood Down Relay Out W 1.0 SXL ENG2, Eng Bulkhd 2 U HDM, Hood Lift Motor 2
60U Hood Up Relay Out W 1.0 GXL CABE2, Cab to Eng2 Bulkhd W ECC, Elect CNTR C B1
60U A Hood Up Relay Out W 1.0 SXL ENG2, Eng Bulkhd 2 W HDM, Hood Lift Motor 1
61A AC Press SW input W 1.0 SXL ENG, Engine Cab1 30 SPL_ACP, Ultrasonic A
61A B Trinary Press Sw Input W 0.8 GXL SPL_AC, Ultrasonic A CAB_E, Cab-Engine 30
61A C AC Switch Input W 1.0 SXL SPL_ACP, Ultrasonic A ENG_B, Cab Bttom 8
61A D AC Switch Input W 1.0 SXL SPL_ACP, Ultrasonic A PRH, AC High Press SW A
61A E AC Switch Input W 1.0 SXL PRL, AC Low Press SW A BTM_E, Cab Bttom 8
61A F Trinary Press Sw Input W 0.8 GXL HVAC1, HVAC1 1 SPL_AC Ultrasonic A
61A G Trinary Press Sw Input W 0.8 GXL ECD, Elec CNTR D B9 SPL_AC Ultrasonic A
61B A AC Signal W 0.8 GXL HVAC1, HVAC1 4 AIC_2, ADV Instr Cluster2 12
61C AC Relay Out Or 0.8 GXL CAB-E, Cab Engine 2 ECD, Elect Center D C10
61C A AC Relay Out Or 1.0 SXL ENG, Engine Cab1 2 ACT, AC Comp Clutch 1
61R AC Relay Control W 1.0 SXL ENG, Engine Cab1 29 SPL_ACS Ultrasonic A
61R B AC Relay Control W 0.8 GXL CAB-E, Cab Engine 29 ECD, Elect Center D D9
61R C AC Switch Output W 1.0 SXL SPL_ACS, Ultrasonic A ENG_B, Cab Bttom 7
61R D AC Switch Output W 1.0 SXL SPL_ACS, Ultrasonic A PRH, AC High Press SW B
61R E AC Switch Output W 1.0 SXL PRL, AC Low Press SW B BTM_E, Cab Bttom 7
63C Front Wiper Park Control W 0.8 GXL FWM, Front Wiper Motor D ECD, Elect Center D C4
63C2 Front Wiper Park Control W 0.8 GXL ECD, Elect Center D D4 ECD, Elect Center D C2
63C3 Front Wiper Park Control W 0.8 GXL K-WCO, Wiper Cutout 87a ECD, Elect Center D B3
63HC Front Wiper High Speed Rly Ctrl W 0.8 GXL SFWW, Front Wiper/Washer 9 SPL-HC, Ultrasonic A
63HC
Wiper Cutout Relay Control W 0.8 GXL SPL-HC, Ultrasonic A K-WCO, Wiper Cutout 85
A
63HC
Front Wiper Rly High Speed W 0.8 GXL SPL-HC, Ultrasonic A ECD, Elect Center D B2
B
63H A Front Wiper High Speed Rly Out W 0.8 GXL FMW, Front Wiper Motor A SPL-WHS, Ultrasonic A
63H B Front Wiper Rly High Speed W 0.8 GXL SPL-WHS, Ultrasonic A ECD, Elect Center D D2
63H C Front Wiper High Speed Rly Out W 0.8 GXL 140M, Diode Module A SPL-WHS, Ultrasonic A
63LC Front Wiper Low Speed Rly Ctrl W 0.8 GXL SFWW, Front Wiper/Washer 3 ECD, Elect Center D B4
63L A Front Wiper Low Speed Rly Out W 0.8 GXL FMW, Front Wiper Motor B SPL-WLS, Ultrasonic A
4002-41

21C Bk - 1.0


Color, Size,
and Material
63L B Front Wiper Low Speed Rly Out W 0.8 GXL K-WCO, Wiper Cutout 30 SPL-WLS, Ultrasonic A
63L C Front Wiper Low Speed Rly Out W 0.8 GXL 140M, Diode Module B SPL-WLS, Ultrasonic A
63W Front Washer Pump W 0.8 GXL CAB-E, Cab Engine 25 SFWW, Front Wiper/Washer 7
63W A Front Washer Pump W 1.0 SXL ENG, Engine Cab1 25 FWW, Front Washer 1
64C Horn Relay Control Or 0.8 GXL SRHSTLK, RH Stalk Switch 31b ECC, Elect CNTR C B8
64 A Horn Power Or 0.8 GXL CAB-F, Cab Front Chassis 13 ECC, Elect CNTR C D8
65L Left Speaker Or 0.8 GXL LSPK, Left Speaker A SPK, Speaker 7
65R Right Speaker Or 0.8 GXL RSPK, Right Speaker A SPK, Speaker 1
66A RR Camera PWR OR 0.8 GXL ECA, Elect CNTR A C9 MON, Camera/Monitor 1
67A Park Brake Signl OR 0.8 GXL TEL, Telematics E SPL_PTM, Ultrasonic A
67B Start Lockout OR 0.8 GXL ECC, Elect CNTR C D10 SRP, Work Lights SW 8
68C Rear Wiper Park Control Or 1.0 GXL CAB-RF, Cab to Roof Conn. K SRWP, Rear Wiper Switch 1
68C A Rear Wiper Park Control Or 1.0 GXL ROOF, Roof to Cab Conn. K RWM, Rear Wiper Motor D
68L Rear Wiper Switch Power Or 1.0 GXL SRWP, Rear Wiper Switch 2 SPL-3, Ultrasonic A
68L A Rear Wiper Switch Power Or 1.0 GXL ROOF, Roof to Cab Conn. L RWM, Rear Wiper Motor B
68L B Rear Wiper Switch Power Or 1.0 GXL CAB-RF, Cab to Roof Conn. L SPL-3, Ultrasonic A
68L C Rear Wiper Switch Power Or 1.0 GXL 140M, Diode Module F SPL-3, Ultrasonic A
68W Rear Washer Pump W 0.8 GXL CAB-E, Cab Engine 24 SRWP, Rear Wiper Switch 6
68W A Rear Washer Pump W 1.0 SXL ENG, Engine Cab 24 RWW, Rear Washer 1
CAN1 Y 0.8 TXL
CAN HI ENG, Engine-Cab1 14 EDC7, Engine Controller 35
H twist
CAN1
G 0.8 TXL
L CAN LO ENG, Engine-Cab1 13 EDC7, Engine Controller 34
twist
CANS Y 0.8 TXL

JSS_ARM, Jss Armrest to
HA CAN HI, CAN MOD2 twist 1 CAN_MOD_2, JSS Can Mod 7
Cab
CANS Y 0.8 TXL

HB CAN HI, CAN MOD2 twist 12 CAB_ARM, Cab to Armrest 1
to Frm
CANS Y 0.8 TXL CAB_ARM_FRM, Cab to Arm

HD CAN HI, CAN MOD3 twist to Frm 7 JSS_CNT, JSS Controller 1
4002-42

21C Bk - 1.0


Color, Size,
and Material
CANS
G 0.8 TXL JSS_ARM, JSS Armrest to
LA CAN LO, CAN MOD2 12 CAN_MOD_2, Jss Can Mod 8
twist Cab
CANS
G 0.8 TXL CAB_ARM_FRM, Cab to Arm to
LB CAN LO, CAN MOD2 CAB_ARM, Cab to Armrest 12 1
twist Frm
CANS CAB_ARM_FRM, Cab to Arm

G 0.8 TXL
LD CAN LO, CAN MOD3 to Frm 6 JSS_CNT, Jss Controller 2
twist
Y 0.8 TXL
CAN H CAN High ENG, Engine-Cab1 14 SPL_CAN_DH, Ultrasonic A
TWIST
CAN Y 0.8 GXL TERM_CAN_2, Can Bulk
CAN2 HI, Term B SPL_CAN_HV, Ultrasonic A
H2 twist Head
CAN Y 0.8 GXL
CAN2 HI, NOX SPL_CAN_HT, Ultrasonic A EDC7, Engine Controller 53
H3 twist
CAN Y 0.8 TXL
CAN High SPL-CAN-JS_HI, Ultrasonic A SPL_CAN_GH, Ultrasonic A
HA TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-DIAG, Ultrasonic A DIA, Diagnostic C
HB TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A SPL-CAN-DIAG, Ultrasonic A
HC TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A TECM, Trans 25
HD TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A SPL-CAN-TRANS, Ultrasonic A
HE TWIST
CAN Y 0.8 TXL
CAN High SW-PD, Switch Pad 7 SPL-CAN, Ultrasonic A
HF TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A AIC-1, Adv Instrument Cluster 1 3
HG TWIST
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A TEL, Telematics M
HH TWIST
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A SPL_CAN_JS_H2, Ultrasonic A
HJ TWIST
CAN Y 0.8 GXL
CAN HI, EDC SPL-CAN-DH, Ultrasonic A EDC7, Engine Controller 35
HK twist
CAN Y 0.8 TXL
CAN High SPL_CAN_TEL, Ultrasonic A SPL_CAN_DIAG, Ultrasonic A
HL TWIST
4002-43

21C Bk - 1.0


Color, Size,
and Material
CAN Y 0.8 GXL
CAN2 HI, EDC SPL-CAN-GH, Ultrasonic A CAB_E, Cab-Engine 14
HM TWIST
CAN Y 0.8 TXL
CAN High SPL_CAN_JS_HI, Ultrasonic A SPL_CAN_JS_H2, Ultrasonic A
HN TWIST
CAN Y 0.8 GXL
CAN2 HI, Diag2 SPL_CAN_GH, Ultrasonic A DIA_2, Diagnostic C
HO TWIST
CAN Y 0.8 GXL
CAN HI, Can Mod2 SPL_CAN_JS_HI, Ultrasonic A JSS_CAB, JSS Cab 12
HP TWIST
CAN Y 0.8 GXL
CAN HI, DNOX2 SPL_CAN_DH, Ultrasonic A DNOX2, NOX Controller 7
HQ TWIST
CAN Y 0.8 GXL SPL_CAN_JS_H2,
CAN HI, Can Mod3 A JSS_CAB, JSS Cab 7
HR TWIST Ultrasonic
CAN Y 0.8 GXL
CAN2 HI, NOX SPL_CAN_HV, Ultrasonc A EDC7, Engine Controller 53
HS TWIST
CAN Y 0.8 TXL
CAN2 HI, NOX SPL_CAN_HT, Ultrasonic A NOXS, NOX Sensor 4
HU TWIST
CAN Y 0.8 GXL
CAN2 HI, TERM SPL_CAN_HT, Ultrasonic A Term_VAN_2, CAN Bulk Head B
HV TWIST
CAN Y 0.8 TXL
CAN2 HI, EVGT SPL_CAN_HV, Ultrasonic A Turbo, ENG Dash_Turbo 7
HW TWIST
CAN Y 0.8 GXL
CAN2 HI SPL_CAN_HV, Ultrasonic A SPL_CAN_HT, Ultrasonic A
HZ TWIST
G 0.8 TXL
CAN L CAN Low ENG, Engine-CAB1 13 SPL_CAN_DL, Ultrasonic A
TWIST
CAN G 0.8 GXL Term_CAN_2, CAN Bluk
CAN 2 LO, TERM A SPL_CAN_LV, Ultrasonic A
L2 TWIST Head
CAN G 0.8 GXL
CAN2 LO, NOX SPL_CAN_LT, Ultrasonic A EDC7, Engine Controller 52
L3 TWIST
CAN G 0.8 TXL
CAN Low SPL-CAN-JS-L1, Ultrasonic A SPL_CAN_GL, Ultrasonic A
LA TWIST
CAN G 0.8 TXL
CAN Low SPL-CAN-DIAG-L, Ultrasonic A DIA, Diagnostic D
LB TWIST
CAN G 0.8 TXL SPL-CAN-TRANS-L,
CAN Low A SPL-CAN-DIAG-L, Ultrasonic A
LC TWIST Ultrasonic
CAN G 0.8 TXL
CAN Low TECM, Trans 26 SPL-CAN-TRANS-L, Ultrasonic A
LD TWIST
4002-44

21C Bk - 1.0


Color, Size,
and Material
CAN G 0.8 TXL
CAN Low SPL-CAN-L, Ultrasonic A SPL-CAN-TRANS-L, Ultrasonic A
LE TWIST
CAN G 0.8 TXL
CAN Low SW-PD, Switch Pad 8 SPL-CAN-L, Ultrasonic A
LF TWIST
CAN G 0.8 TXL
CAN Low SPL-CAN-L, Ultrasonic A AIC-1, Adv Instrument Cluster 1 4
LG TWIST
CAN G 0.8 TXL
CAN Low SPL_CAN_TEL2, Ultrasonic A SPL_CAN_JS_L2, Ultrasonic A
LH TWIST
CAN G 0.8 GXL
CAN LO, EDC EDC7, Engine Controller 34 SPL_CAN_DL, Ultrasonic A
LJ TWIST
CAN G 0.8 GXL
CAN LO, DNOX2 SPL_CAN_DL, Ultrasonic A DNOX2, NOX Controller 8
LK TWIST
CAN G 0.8 GXL
CAN2 LO, EDC SPL-CAN-GL, Ultrasonic A CAB_E, Cab-Engine 13
LL TWIST
CAN G 0.8 TXL
CAN Low SPL_CAN_TEL2, Ultrasonic A TEL, Telematics N
LM TWIST
CAN G 0.8 GXL
CAN Low, Can Mod3 SPL_CAN_JS_L1, Ultrasonic A JSS_CAB, JSS Cab 1
LP TWIST
CAN G 0.8 TXL
CAN Low SPL_CAN_JS_L1, Ultrasonic A SPL_CAN_JS_L2, Ultrasonic A
LQ TWIST
CAN G 0.8 GXL
CAN Low, Can Mod2 SPL_CAN_JS_L2, Ultrasonic A JSS_CAB, JSS Cab 6
LR TWIST
CAN G 0.8 GXL
CAN2 LO, NOX SPL_CAN_LV, Ultrasonic A EDC7, Engine Controller 52
LS TWIST
CAN G 0.8 TXL
CAN2 LO, NOX NOXS, NOX Sensor 3 SPL_CAN+LT, Ultrasonic A
LU TWIST
CAN G 0.8 GXL TERM_CAN_2, Can Bulk
CAN2 LO, TERM A SPL_CAN_LT, Ultrasonic A
LV TWIST Head
CAN G 0.8 TXL
CAN LO, EVGT SPL_CAN_LV, Ultrasonic A Turbo, Eng Dash_Turbo 1
LW TWIST
CAN G 0.8 GXL
CAN2 LO, Diag2 SPL_CAN_GL, Ultrasonic A DIA_2, Diagnostic D
LX TWIST
CAN G 0.8 TXL
CAN Low SPL_CAN_TEL2, Ultrasonic A SPL_CAN_DIAG_L, Ultrasonic A
LY TWIST
CAN G 0.8 GXL
CAN 2 LO SPL_CAN_LV, Ultrasonic A SPL_CAN_LT, Ultrasonic A
LZ TWIST
4002-45

21C Bk - 1.0


Color, Size,
and Material
ECC
Beacon/Dome Light L1 ECC BUSS L1-ECC, ECC Batt Power 1 ECC, Elect CNTR C L1-1
L1
J1 Trans ECM Power ECA-BUSS ECA-L1, B+ Power cs01 ECA, Elect Center A L1
J2 Trans ECM Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J3 Emergency Steer AIC Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J4 Emergency Steer AIC Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J5 Emergency Steer Plt EM Dtnts ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J6 Pltem Dtnts Park Brk Sol ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J7 Park Brake Solenoid Horn ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J8 Fan Reverse Turn Signal ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J9 Turn Signal Engine Shut Down ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J10 DNOX SW B+ ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J11 Blower Motor Power ECA-BUSS ECA, Elect Center A L2 PRMB_L1, B+ Power cs01
Blower Motor Front Wiper

J12 ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
Washer
J13 Front Wiper Rear Wiper Washer ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J14 Rear Wiper Washer Backup ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J15 Backup AC ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J17 Seat Comp EMG Strtr ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J18 Diagnostic Power ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J19 ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J10
BUSS ECC, Elect Center C L1-9 ECC, Elect Center C L1-10
ECC
J2
Beacon/Dome Lt Work Lights ECC-BUSS ECC, Elect Center C L1-1 ECC, Elect Center C L1-2
ECC
J3
Work Lights Driving Lights ECC-BUSS ECC, Elect Center C L1-2 ECC, Elect Center C L1-3
ECC
J4
Driving Lights Brake Lights ECC-BUSS ECC, Elect Center C L1-3 ECC, Elect Center C L1-4
ECC
J5
Brake Lights Delay Power ECC-BUSS ECC, Elect Center C L1-4 ECC, Elect Center C L1-5
ECC
J6
Delay Power Horn ECC-BUSS ECC, Elect Center C L1-5 ECC, Elect Center C L1-6
ECC
4002-46

21C Bk - 1.0


Color, Size,
and Material
J7
Horn HOD Control ECC-BUSS ECC, Elect Center C L1-6 ECC, Elect Center C L1-7
ECC
J9
ECC-BUSS ECC, Elect Center C L1-8 ECC, Elect Center C L1-9
ECC
RAD1 Radio Ground W 0.8 GXL RAD-J3, Radio Jumper 5 RAD-J1, Radio Power 8
RAD2 12V Fused Power to Radio W 0.8 GXL RAD-J3, Radio Jumper 12 RAD-J1, Radio Power 7
RAD3 12V Fused Power to Radio W 0.8 GXL RAD-J3, Radio Jumper 7 RAD-J1, Radio Power 4
RAD4 Left Speaker Ground W 0.8 GXL RAD-J3, Radio Jumper 3 RAD-J2, Speaker 8
RAD5 Left Speaker W 0.8 GXL RAD-J3, Radio Jumper 10 RAD-J2, Speaker 7
RAD6 Not Used W 0.8 GXL RAD-J3, Radio Jumper 4 RAD-J2, Speaker 6
RAD10 Right Speaker Ground W 0.8 GXL RAD-J3, Radio Jumper 1 RAD-J2, Speaker 2
RAD11 Right Speaker W 0.8 GXL RAD-J3, Radio Jumper 8 RAD-J2, Speaker 1
4002-47
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Alternator 1
Correct
Check Points 2 Possible Cause of Bad Reading
Reading
3 4
Check the 10 ampere fuse at
Good Bad fuse.
location 3 and 4C in the fuse block.
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter. 5
6
1. This title is the number and component name on the Electrical Schematic.
2. This column shows the location of the check point.
3. This column shows the indication of the check.
4. This column shows the possible cause of a bad test indication.
5. The numbers in the parentheses show the number of the component on the Electrical Schematic.
6. This statement assumes that all other problems are solved at this point in the test.
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS

NOTE: For the System Electrical Schematic refer to the Schematic Posters located at the rear of this manual.
Components can be located on the Electr ical
Schematic posters (rear pocket) by item number
using the key at the bottom of the posters.
4002-48
STARTING AND CHARGING SYSTEMS
9
3
8
5
10
2
4 11
1
6
RCPH10WHL094FAH
1. STARTING RELAY 7.
2. RESISTOR 75 OHM 8. MASTER DISCONNECT SWITCH
3. ALTERNATOR 9. STARTER
4. CRANK CONTROL RELAY 10. IGNITION SWITCH
5. BATTERIES 11. NEUTRAL START RELAY
6. CRANK REQUEST RELAY 12.
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
4002-49
1 – Starting Relay
Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading
Terminal for wire 0-GB to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position.
Terminal for wire 1-Z to ground 24 volts Check circuit to batteries.
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Terminal for wire 21D to ground 24 volts Check crank control relay (4), also check circuit 21D.
Terminal for wire 1-BB to ground 24 volts Bad starting relay.
2 – Resistor
Located in the cab access panel for fuses and relays.
NOTE: Turn master disconnect switch off, disconnect terminals from resistor.
Correct
Reading
Between terminals of resistor 75 ohms Bad resistor.
3 – Alternator
Located on left side of engine, open engine compartment to gain access.
Correct
Reading
Between housing of alternator and Continuity Bad ground connection.

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

4002-50
4 – Crank Control Relay

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

Correct
Reading
Terminal for wire 0-DF to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Have another person hold the ignition switch in the
START position.
Terminal for wire 21C-A to ground 24 volts Check circuit 21 to neutral start relay (11).
Terminal for wire 21E to ground 24 volts Bad crank request relay.
7 –
4002-51
8 – Master Disconnect Switch

Located on right side battery box cover, remove battery box cover to gain access.
Correct
Reading
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.
Between terminals of master Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
NOTE: Put the master disconnect switch in the OFF position.
Between terminals of master Open Circuit If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
9 – Starter Motor
Located on left side of engine, open engine compartment to gain access.
Correct
Reading
Between housing of starter and Continuity Bad ground connection.

ground
Starter B+ stud to ground 24 volts Check circuit to batteries.
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Bad starting relay (1). Also check wire 1-BB between starter
Terminal S to ground 24 volts
and starting relay (1).
NOTE: If the readings are good, repair or replace the starter.

4002-52
10 – Ignition Switch
Located on steering column.
Correct
Reading
Terminal for wire 1DM to ground 24 volts Check circuit 1DM to ECC-F5 fuse.
NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON.
Between Bat and Ign Continuity Bad ignition switch.
Between Bat and Accessory Continuity Bad ignition switch.
NOTE: Hold the ignition switch in the START position.
Between Bat and Starter Continuity Bad ignition switch.
Between Bat and Ign Continuity Bad ignition switch.
NOTE: Put the switch in the Accessory position.
Between Bat and Accessory Continuity Bad ignition switch.
11 – Neutral Start Relay

Correct
Reading
Terminal for wire 0-DE to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 25T to ground 24 volts Check circuit 25T, check FNR switch (55).
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21K-B to ground 24 volts Check circuit 21K-B and ignition switch (10).
Terminal for wire 21C to ground 24 volts Bad neutral start relay.
12 –
4002-53
POWER RELAY MODULES AND COLD STARTING SYSTEMS
13 14
20
18 15
21 16
17
RCPH10WHL094
13. POWER RLEAY MODULE A 18. POWER RELAY MODULE D

14. POWER RELAY MODULE B 19.
15. POWER RELAY MODULE C 20. WATER SEPARATOR HEATER
16. GRID HEATER RELAY 21. FUEL FILTER HEATER
17. GRID HEATER
4002-54
13 – Power Relay Module A, Power converter F1, Secondary steering F2

Correct
Reading
Check fuse F1, F2 Continuity Bad fuse or circuit.
Terminal for wire 0-EU to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 1CB-A to ground 24 volts Check circuit 1CB.
Terminal for wire 12ACC-C to 24 volts Check circuit 12ACC and check ignition switch (10).
ground
Terminal for wire 19L to ground 24 volts Bad power relay module A.
14 – Power Relay Module B, ACC Power F1, DNOX F2

Correct
Reading
Terminal for wire 0-EC to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire 12ACC-B to 24 volts Check circuit 12ACC, check ignition switch (10).
ground
Terminal for wire 1CB-A to ground 24 volts Check circuit 1CB.
Terminal for wire PRM-B J11 BUSS 24 volts Bad power relay module B
to ground
15 – Power Relay Module C, Ignition Power F1

Correct
Reading
Check fuse F1 Continuity Bad fuse or circuit.
Terminal for wire 0-EB to ground Continuity Bad ground circuit.
NOTE: Put the ignition switch in the ON position.
Terminal for wire 13K-C to ground 24 volts Check 13K and check ignition switch (10).
Terminal for wires J1 BUSS to 24 volts Bad power relay module.

ground
4002-55
16 – Grid Heater Relay

Correct
Reading
Terminal for wire 0-BV to ground Continuity Bad ground circuit or bad EDC7 (24).
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 1-Y to ground 24 volts Bad 150 ampere fuse. Check wires 1-Y and 1-E.
NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make sure
engine temperature is below -0 ° C (32 ° F).
Terminal for wire 28G to ground 24 volts Bad EDC7 (24), also check circuit 28G.
Terminal for wire 1-BE to ground 24 volts Bad grid heater relay.
17 – Grid Heater
Located in the right side of the engine in intake manifold, open engine compartment to gain access.
Correct
Reading
NOTE: Disconnect terminal for wire 1-BE from grid heater.
Terminal for wire 0-ES to ground Continuity Bad ground circuit.
Terminal for wire 1-BE of grid heater Resistance If an open or short circuit is obtained, replace the grid heater.
to ground
18 – Power Relay Module D, Fuel Filter Heater F1, Engine ECM F2

Correct
Reading
NOTE: Make sure engine

temperature is below 0 ° C (32 ° F).
Terminal for wire 31B to ground Continuity Bad ground circuit or bad EDC7 (24).
NOTE: Turn the ignition switch to the ON position.
Terminal for wire 1-NC to ground 24 volts Check circuit 1-NC.
Terminal for wire 28F to ground 24 volts Check EDC7 (24).
Terminal for wire 1-GA to ground 24 volts Bad power relay module
19 –
4002-56
20 – Water Separator Heater

Located in the right side of the engine compartment on water separator housing, open engine compartment to gain
access.
Correct
Reading
Terminal for wire 0-BW to ground Continuity Bad ground circuit.
NOTE: Disconnect connector WSH from water separator heater.
Between terminals A and B of heater 1.9 ohms Bad heater.
NOTE: If the readings are good, check circuit 1-GA between water separator heater connector WSH and power
relay module D connector PRM-D1.
21 – Fuel Filter Heater

Located in the right side of the engine compartment on fuel filter housing, open engine compartment to gain access.
Correct
Reading
Terminal for wire 0-BX to ground Continuity Bad ground circuit.
NOTE: Disconnect connector FFH from fuel filter heater.
Between terminals A and B of heater 1.9 ohms Bad heater.
NOTE: If the readings are good, check circuit 1-G between fuel filter heater connector FFH and power relay
module D connector PRM-D1.
4002-57
ENGINE CONTROLLER
24 22 23
RCPH10WHL094FAH
22. WATER IN FUEL SENSOR

23. THROTTLE POTENTIOMETER
24. ENGINE CONTROLLER
4002-58
22 – Water In Fuel Sensor

Located in the right side of the engine compartment on water separator housing, open engine compartment to gain
access.
Correct
Reading
Terminal for wire 0-BP to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 18J-H to ground 24 volts Check power EDC7, also check circuit 18J.
NOTE: Remove sensor from filter and place probes in water.
Terminal for wire 35W to ground 24 volts Bad water separator sensor.
23 – Throttle Potentiometer
Located below cab under throttle pedal.
Correct
Reading
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 24S to 24R 5 volts Bad EDC7 (24). Also check wire 24S.
Terminal for wire 24R to ground Continuity Bad EDC7 (24). Also check wire 24R.
NOTE: Throttle pedal in low idle position.
0.4 ± 0.025
Terminal for wire 24B to 24R Bad potentiometer.
volts
NOTE: Throttle pedal in high idle position.
Terminal for wire 24B to 24R 4.0 ± 0.1 volts Bad potentiometer.
NOTE: Put the ignition switch in OFF position and the master disconnect switch in the OFF position. Disconnect
connector RTHP. Throttle pedal in low idle position.
Between pin 1 and 6 at pedal Open Bad potentiometer.
NOTE: Throttle pedal in high idle position.
1000 ± 400
Between pin 1 and 6 at pedal ohms at 20° C Bad potentiometer.
(68° F)
NOTE: Throttle pedal in any position.
1200 ± 400
Between pin 4 and 5 at pedal ohms at 20° C Bad potentiometer.
(68° F)
4002-59
24 – Electronic Diesel Control

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

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

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

ground
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position.
Terminal for wire 18J-C pin 2 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
Terminal for wire 18J-B pin 3 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
Terminal for wire 18J-D pin 8 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
Terminal for wire 18J-E pin 9 to 24 volts Bad fuse ECM-F2, bad wire 18J.
ground
NOTE: Use diagnostic service tool for additional tests on EDC7.
4002-60
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE
28
30
25 26 31 32
27
29 33 34
RCPH10WHL094FAH
25. RETURN TO TRAVEL FLOAT SWITCH 30. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH
26. HEIGHT CONTROL SWITCH 31. RETRUN TO DIG SWITCH
27. ELETROMAGNETIC DETENTS 32. PIN ENGAGE SWITCH (OPTION)
28. RETURN TO DIG PROXIMITY SWITCH 33. PILOT PRESSURE SOLENOID
29. PILOT CONTROL RELAY ECD-K3 34. PIN ENGAGE SOLENOID (OPTION)
4002-61
25 – Return-To-Travel/Float Switch
Located on right side console.
Correct
Reading
Terminal for wire 0-B2 to ground Continuity Bad ground circuit.
Terminal for wire 0-29 to ground Continuity Bad ground circuit.
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch. Put the return-to-
travel/float switch in FLOAT position.
Between switch terminals 1 and 2 Continuity Bad return-to-travel/float switch.
NOTE: Put the return-to-travel/float switch in the TRAVEL position.
Between switch terminals 2 and 3 Continuity Bad return-to-travel/float switch.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch. Put
ignition switch in ON position. Put driving lamp switch (95) in position 3.
Bad circuit 49-K. Also check driving lamp switch (95). If

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

Correct
Reading
Terminals for wire 0-B3 to ground Continuity Bad ground circuit.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-D to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
NOTE: Turn the height control switch to the ON position.
Terminal for wire 54A to ground. 24 volts Bad height control switch.
4002-62
27 – Electromagnetic Detents
Located under right side console.
Correct
Reading
NOTE: For joystick controller.
74 ohms @
Between pins 3 and 4 Bad electromagnetic detent
20° C (68° F)
74 ohms @
20° C (68° F)
74 ohms @
20° C (68° F)
NOTE: For single axis controller.
328 ohms @
20° C (68° F)
328 ohms @
20° C (68° F)
328 ohms @
20° C (68° F)
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (39) in OFF
position and return to travel/float switch (25) in ON position.
Wiring harness connector EM, pin 1 24 volts Bad return to travel/float switch (25). Also check wires 55A.
to ground
NOTE: Place the height control switch in the ON position.
Wiring harness connector EM, pin 2 24 volts Bad height control switch (26). Also check wires 54A.
to ground
NOTE: Place the return to dig switch in the ON position.
Wiring harness connector EM, pin 3 24 volts Bad return to dig switch (31). Also check wires 53A.
to ground
28 – Return-To-Dig Proximity Switch

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

Terminal A for wire 53B to ground 24 volts
to dig switch. Also check circuit 53B.
Terminal C for wire 53P-I to ground 24 volts Bad pilot relay (29), also check circuit 53P.
NOTE: If the readings are good, replace the return-to-dig proximity switch.
4002-63
29 – Pilot Control Relay

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

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

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

Correct
Reading
Terminals for wire 0-B4 to ground Continuity Bad ground circuit.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-E to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
NOTE: Turn the height control switch to the ON position.
Terminal for wire 53A to ground. 24 volts Bad return to dig switch.
4002-64
32 – Pin Engage Switch (Option)

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

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

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

Located on.
Correct
Reading
Terminal for wire 0-AW to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(32) in the ON position.
Terminal for wire 57-D to ground 24 volts Bad pin engage switch (32), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid.
4002-65
PILOT CONTROL - RIDE CONTROL - FAN CONTROL
43 44
35 37 39
40
36 41
38 42
RCPH10WHL094FAH
35. RIDE CONTROL SWITCH (OPTION) 40. RIDE CONTROL SOLENOID (OPTION)
36. RIDE CONTROL RELAY (OPTION) 41. ROLLBACK PRESSURE SWITCH (OPTION)
37. FAN CONTROL SWITCH (OPTION) 42. ROLLBACK JUMPER
38. FAN REVERSE RELAY (OPTION) 43. FAN PWM SOLENOID
39. PILOT CONTROL SWITCH 44. FAN REVERSE SOLENOID (OPTION)
4002-66
35 – Ride Control Switch

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

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

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

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

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

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

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

4002-67
37 – Fan Control Switch (Option)

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

Terminal for wire 19P-C to ground 24 volts
19P.
NOTE: Put fan control switch in position 1.
Terminal for wire 52AU to ground 24 volts Bad fan control switch.
NOTE: Put fan control switch in momentary position, hold rocker.
Terminal for wire 52M to ground 24 volts Bad fan control switch.
NOTE: Put driving lamp switch in position 3.
Check driving lamp switch. If LEDs in fan control switch are not
Terminal for wire 49-Q to ground 24 volts
ON with 24 volts at check point, replace fan control switch.
38 – Fan Reverse Relay (Option)

Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position.
Terminal for wire 19P-D and 19P-E 24 volts Check fuse ECA-F7 and circuit 19P.
to ground
NOTE: Put the fan control switch in the manual reverse position.
Bad fan reverse solenoid, bad fan control switch (37), bad
Terminals for wire 52A-A to ground 24 volts
advanced instrument cluster (62).
4002-68
39 – Pilot Control Switch

Located on steering column pedestal.
Correct
Reading
Terminal for wire 0B1 to ground Continuity Bad ground circuit.
Terminal for wire 19C-F to ground 24 volts Bad fuse ECA-F5, also check circuit 19C.
NOTE: Press pilot control switch to turn ON switch LED.
Terminal for wire 31L to ground 24 volts Bad pilot control switch.
NOTE: Put the driving lamp switch (95) in position 3.
Check driving lamp switch (95) and fuse ECC-F3. Also check
Terminal for wire 49-N to ground 24 volts
circuit 49.
NOTE: If the readings are correct replace the pilot control switch.
40 – Ride Control Solenoid

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

control solenoid
41 – Rollback Pressure Switch (Option)

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

switch
Terminal for wire 58 to ground 37 to 43 ohms Bad ride control solenoid (40).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the ride control switch
(35) in the ON position. Accelerate the machine to at least 5 km/hr (3 m.p.h.).
24 volts at
Bad ride control relay (36) or ride control switch (35). Also
Terminal for wire 58-B to ground 5 km/hr
check circuit 58.
(3 m.p.h.)
4002-69
42 – Rollback Jumper (Option)

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

switch
43 – Fan PWM Solenoid (Option)

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

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

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

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

YFR to ground
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ON
position (hold rocker in momentary position).
Pin 1 of wiring harness connector 24 volts Bad fan control switch. Also check wire 52-A.
YFR to ground
4002-70
TRANSMISSION
46 48
52
55 56 57 60
49 50 45 53 54
51 47 61 58
RCPH10WHL094FAH
45. OUTPUT SPEED SENSOR 54. TRANSMISSION ENABLE SWITCH
46. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 55. FNR SWITCH FOR JOYSTICK CONTROLS
47. FILTER MAINTENANCE SWITCH 56. TRANSMISSION KICK-DOWN SWITCH
48. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 57. FNR SWITCH FOR SINGLE AXIS CONTROLS
49. ENGINE SPEED SENSOR 58. TRANSMISSION AUTO SWITCH
50. INTERMEDIATE SPEED SENSOR 59. BRAKE DECLUTCH PRESSURE SWITCH
51. TURBINE SPEED SENSOR 60. DECLUTCH SWITCH
52. TRANSMISSION SHIFTER 61. DIAGNOSTIC CONNECTOR
53. TRANSMISSION ELECTRONIC CONTROL MODULE
4002-71
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 45 through 61.
45 – Output Speed Sensor

46 – Transmission Solenoid Valve and Temperature Sensors
47 – Filter Maintenance Switch
48 – Torque Converter Output Temperature Sender
49 – Engine Speed Sensor
50 – Intermediate Speed Sensor
51 – Turbine Speed Sensor
52 – Transmission Shifter
53 – Transmission Electronic Control Module
54 – Transmission Enable Switch
55 – FNR Switch for Joystick Controls
56 – Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick
Option; Next to Hydraulic Levers for Single Axis Controls)
57 – FNR Switch for Single Axis Controls
58 – Transmission Auto Switch
59 – Brake Declutch Pressure Switch
60 – Declutch Switch
61 – Diagnostic Connector
4002-72
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE
66
62 63
68
67
69
65 64
RCPH10WHL094FAH
62. INSTRUMENT CLUSTER CONNECTOR 1 66. AIR FILTER RESTRICTION SWITCH

63. WARNING BUZZER 67. PARKING BRAKE SOLENOID
64. PARKING BRAKE RELAY 68. RADIATOR COOLANT TEMPERATURE SENDER
65. FUEL LEVEL SENDER 69. BRAKE PRESSURE WARNING SWITCH
4002-73
62 – Instrument Cluster Connector 1

Located on instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-1 from the instrument cluster and SW-PD from the switch pad.
Connector terminal SW-PD 5 to Open Circuit Bad air filter restriction switch (66). Also check circuit 31F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31H-A.
Connector terminal AIC-1 6 and 12 Continuity Bad ground circuit. Check wires 0-DW and 0-DX.
to ground
Connector terminal AIC-1 11 to 130 to 9500 Bad engine coolant temperature sender (68). Also check circuit
ground ohms circuit 36C-A and ground circuit at sender.
Connector terminal AIC-1 2 to Bad fuel level sender (65). Also check circuit 36F-A and ground
33 to 240 ohms
ground circuit at sender.
Connector terminal AIC-1 9 to 130 to 9500 Bad hydraulic oil temperature sender (73). Also check circuit
ground ohms 36H-A and ground circuit at sender.
Connector terminal AIC-1 25 to Continuity Bad wire 17P-A or 17P-B.

connector terminal SW-PD 9
Connector terminal AIC-2 4 to Bad redundant brake switche(s) (75)(76). Also check circuit
Open Circuit
ground 33R.
Connector terminal AIC-1 4 and

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

SW-PD 7 to terminal 25 on the Continuity Bad circuit CAN-H.
transmission electronic control
module (53)
NOTE: Put the parking brake switch in the ON position.
Connector terminal AIC-1 14 to Bad parking brake switch (64). Also check fuse ECA-F6 and
24 volts
ground circuit 19D-B and 52C.
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

Connector terminal 10 to ground 24 volts
pressure switch. Also check circuits 61R, 61A, and 61T.
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1 to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECB-F3 or F4. Also check circuit 41H-D.
Connector terminal AIC-1 14 to Bad parking brake relay or fuse ECA-F6. Also check circuits
24 volts
ground 52C and 19D-B.
Connector terminal AIC-1 20 to Bad pilot control relay or fuse ECA-F5. Also check circuits
24 volts
ground 53C-A and 19C-C.
4002-74
63 – Warning (AIC) Buzzer

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

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

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

Bad fuel level sender.
sender ohms
4002-75
66 – Air Filter Restriction Switch

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

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

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

Replace radiator coolant temperature sender.
coolant temperature sender at 20° C (68° F)
Approximately
Terminal A for wire 36C to ground Check the instrument cluster (62).
5 volts
4002-76
69 – Brake Warning Pressure Switch

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

Between terminals 1 and 2 of the Open Circuit 110.3 bar (1600 psi). Refer to Section 7002 to check brake
switch
pressure.
4002-77
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE
70 71 74
75
76
72
73
RCPH10WHL094FAH
70. SWITCH PAD 74. PARK BRAKE SWITCH

71. INSTRUMENT CLUSTER CONNECTOR 2 75. REDUNDANT BRAKE PRESSURE SWITCH 1
72. HYDRAULIC FILTER RESTRICTION SWITCH 76. REDUNDANT BRAKE PRESSURE SWITCH 2
73. HYDRAULIC OIL TEMPERATURE SENDER 77.
4002-78
70 – Switch Pad
Correct
Reading
NOTE: Disconnect switch pad connector, put master disconnect switch and ignition switch in ON position.
Terminal for wire 17P-A to ground. 24 volts Bad instrument cluster (62).
NOTE: Disconnect instrument cluster connector 1.
Between terminals for wire 17P-A Continuity Bad wire 17P-A.

4002-79
71 – Instrument Cluster Connector 2

Located on instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-2 from the instrument cluster and SW-PD from the switch pad.
Connector terminal AIC-2 5 to Bad brake warning pressure switch (69). Also check circuit
Continuity
ground 33P-A and ground circuit at brake warning pressure switch.
Connector terminal AIC-2 11 to Bad secondary steering pressure switch (118). Also check
Continuity
ground circuit 35X and ground circuit at pressure switch.
Connector terminal SW-PD 5 to Open Circuit Bad air filter restriction switch (66). Also check circuit 31F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31H-A.
Connector terminal AIC-2 15 and 22 Continuity Bad ground circuit. Check wires 0-DB and 0-DA.
to ground.
Connector terminal AIC-2 4 to Bad redundant brake switche(s) (75)(76). Also check circuit
Open Circuit
ground 33R.
Connector terminal AIC-2 14 and 20 24 volts Bad fuse ECD-F8. Also check circuit 19S-C and 19S-D.
to ground
Connector terminal AIC-2 21 to Bad fuse ECA-F3. Also check circuit 19E-A. Also check power
24 volts
ground relay module C (15).
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

Connector terminal 10 to ground 24 volts
pressure switch. Also check circuits 61R, 61A, and 61T.
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1 to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECB-F3 and F4. Also check circuit 41H-D.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and Check fuse ECA-F8, turn signal switch, and flasher module.
Connector terminal AIC-2 9 to off every 1-2 Also check circuit 45A-A to flasher module, and circuit 45L-D
ground seconds from flasher module to instrument cluster.
NOTE: Put the turn signal switch in the RIGHT TURN position.
24 volts on and Check fuse ECA-F8, turn signal switch, and flasher module.
Connector terminal AIC-2 10 to off every 1-2 Also check circuit 45B-A to flasher module, and circuit 45R-E
ground seconds from flasher module to instrument cluster.
Connector terminal AIC-2 18 to Bad pilot control switch or fuse ECA-F5. Also check wire 31L
24 volts
ground and circuit 19A.
4002-80
]
72 – Hydraulic Filter Restriction Switch

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

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

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

Replace hydraulic oil temperature sender.
temperature sender at 20° C (68° F)
Approximately
Terminal A for wire 36H to ground Check the instrument cluster (62).
5 volts
4002-81
74 – Parking Brake Switch

Correct
Reading
Terminal for wire 19A-L to ground 24 volts Check fuse ECA-F6, also check circuit 19A.
NOTE: Apply parking brake switch.
Terminal for wire 33U to ground 24 volts Bad parking brake switch.
NOTE: Put the driving lamp switch (95) in position 3, 4, or 5.
Bad driving lamp switch. Also check fuse ECC-F3 and circuits
Terminal for wire 49-V to ground 24 volts
41 and 19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.
75 – Redundant Brake Pressure Switch 1

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

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

Bad instrument cluster (62), also check circuit 33R.
ground 11.5 volts
NOTE: If the readings are good, replace the redundant brake pressure switch(es).
4002-82
77 –
4002-83
BACK UP ALARM CONTROLS
79
78
RCPH10WHL094FAH
BS06H241 / BS06H242
78. BACK UP ALARM RELAY 79. BACK UP ALARM DISABLE SWITCH

4002-84
78 – Back-up Alarm Relay

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

connector TECM
Bad fuse ECA-F1, also check wires 19A-P, power relay module
Terminal for wire 19A-P to ground 24 volts
C, Ignition power (15).
Bad fuse ECA-F14, also check wires 19H, power relay module
Terminal for wire 19H to ground 24 volts
B, accessory power (14).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A-A to ground 24 volts Bad back-up alarm relay.
79 – Back-up Alarm Disable Switch

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
Terminal for wire 35A-B to ground 24 volts Bad back-up alarm relay (78), also check circuit 35A-B.
NOTE: Wires 35A-E and 35A-D are connected together, connectors 209F and 209M, and switch is removed in
North American models. The connectors are disconnected and the switch is installed in TUV road approved
(Germany) models.
Terminal for wire 35R-C to ground 24 volts Bad back-up alarm disable switch.
4002-85
LIGHTS - 01
87
82 85
81
83 86
88
80 84
89
RCPH10WHL094FAH
80. WORK LIGHTS SWITCH 85. LEFT HAND FRONT WORK LAMP
81. DOOR SWITCH 86. RIGHT HAND FRONT WORK LAMP
82. ROTATING BEACON (OPTIONAL) 87. LEFT HAND REAR WORK LAMP
83. DOME LIGHT 88. RIGHT HAND REAR WORK LAMP
84. ROTATING BEACON SWITCH (OPTIONAL) 89. DIODES
4002-86
80 – Work Lamps Switch

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

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

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

4002-87
83 – Dome Lamp
Located in top of cab.
Correct
Reading
Terminal for wire 0-MB to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put dome lamp switch in ON position.
Terminal for wire 19U-C to ground 24 volts Check fuse ECC-F1, also check circuit 19U.
24 volts
Terminal for wire 43-B to ground Check circuit 43, also check advanced instrument cluster (62).
3 to 5 seconds
NOTE: If readings are good, replace dome lamp.
84 – Beacon Switch (Option)

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

Located on left front side of cab.
Correct
Reading
NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector.
Flood lamp connector pin A to pin B Continuity Bad lamp bulb.
NOTE: Connect wiring harness connector LLFW to LH front work lamp connector.
Terminal for wire 0-MU to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
Check driving lamp switch (95). Also check circuit 42C from
Terminal for wire 42C-H to ground 24 volts
flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.
4002-88
86 – Right Hand Front Work Lamp

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

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

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

4002-90
LIGHTS - 02
93 94
95
90
92 91
RCPH10WHL094FAH
BS06H241 / BS06H242
90. BRAKE LIGHTS SWITCH 93. HAZARD SWITCH

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

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

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

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

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

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

Correct
Reading
HORN SWITCH
Terminal for wire 0-EP to ground Continuity Bad ground circuit.
Check fuse ECC-F6 and horn relay (98). Also check wires 64C
Terminal for wire 64C to ground 24 volts
and circuit 19U.
NOTE: If readings are good, replace the switch.
TURN SIGNAL
Check fuse ECA-F8 and power relay module C(15). Also check
Terminal for wire 19B to ground 24 volts
wire 19B.
NOTE: Move turn signal lever to RIGHT turn position.
Terminal for wire 45B-A to ground 24 volts Bad turn signal switch.
NOTE: Move turn signal lever to LEFT turn position.
Terminal for wire 45A-A to ground 24 volts Bad turn signal switch.
HIGH-LOW BEAM SWITCH
Terminal for wire 0-EP to ground Continuity Bad ground circuit.

4002-94
95 – Driving Lamp Switch

Correct
Reading
Terminal for wire 19Z-a to ground 24 volts Check fuse ECC-F3, also check circuit 19Z.
NOTE: Put the driving lamp switch in position 2.
Terminal for wire 41T to ground 24 volts Bad driving lamp switch.
Terminal for wire 41J to ground 24 volts Bad driving lamp switch.
4002-95
LIGHTS - 03 AND HORN
96 99
97
98
RCPH10WHL094FAH
96. LEFT HAND FRONT COMBINATION LAMPS 98. HORN RELAY

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

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

pin 1
Combination lamp connector pin 2 to Continuity Bad low beam lamp bulb.
pin 1
Combination lamp connector pin 5 to Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector LLF to LH front combination lamp connector.
Terminal for wire 0-AJ to ground Continuity Bad ground circuit.
Check fuse ECB-F7 and driving lamp switch (95). Also check
Terminal for wire 18F to ground 24 volts
circuit 18F.
NOTE: Put high/low beam lever (94) in HIGH beam position.
Check fuse ECB-F3, driving lamp switch (95), and high/low

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

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

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

pin 1
Combination lamp connector pin 2 to Continuity Bad low beam lamp bulb.
pin 1
Combination lamp connector pin 5 to Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector RF to RH front combination lamp connector.
Terminal for wire 0-AH to ground Continuity Bad ground circuit.
Check fuse ECB-F8 and driving lamp switch (95). Also check
Terminal for wire 18G-A to ground 24 volts
circuit 18G and wire 41T-A.
NOTE: Put high/low beam lever (94) in HIGH beam position.

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

Terminal for wire 18E to ground 24 volts
beam switch (94). Also check circuit 18E and wire 41L-C.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R to ground volts check circuit 45R to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp.
4002-98
98 – Horn Relay
Correct
Reading
Terminal for wire 19U-A to ground 24 volts Check fuse ECC-F6, also check wire 19U-A.
Terminal for wire 19U-E to ground 24 volts Check Fuse ECC-F6, also check wire 19U-E.
Terminal for wire 64C to ground 24 volts Bad horn relay.
NOTE: Have another person push and hold the horn switch.
Terminal for wire 64C to ground 0 volt Bad horn switch.
Terminal for wire 64-A to ground 24 volts Bad horn relay.
99 – Horn
Located on the left front of the machine with combination lamps.
Correct
Reading
Terminal for wire 0-AF to ground Continuity Bad ground circuit.
NOTE: Disconnect the wire 64 from the horn. Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground. 24 volts Check the horn relay (98). Also check wires 64 and 64-A.
NOTE: If the readings are good replace the horn.

4002-99
LIGHTS - 04 AND BACK UP ALARM
101
103
100
102
RCPH10WHL094FAH
100.RIGHT HAND REAR COMBINATION LAMPS 102.LICENSE PLATE LAMP

101.LEFT HAND REAR COMBINATION LAMPS 103.BACK UP ALARM
4002-100
100 – Right Hand Rear Combination Lamp (North America Only)

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

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

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

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

Terminal for wire 44A-GN to ground 24 volts
lamps relay (91).
NOTE: Put turn signal lever in RIGHT turn position.
Terminal for wire 45R-BN to ground volts check circuit 45R to flasher module.
NOTE: Put driving lamp switch (95) in position 2 or 3.
Check fuse ECB-F8 and lamp switch (95). Also check circuit
Terminal for wire 18G-CN to ground 24 volts
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.
4002-101
100 – Right Hand Rear Combination Lamp (Europe Only)

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

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

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

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

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

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

Terminal for wire 35A-K to ground 24 volts
backup alarm relay (78).
NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R-A to ground volts check circuit 45R to flasher module.
Terminal for wire 18G-A to ground 24 volts
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.
4002-102
101 – Left Hand Rear Combination Lamp (North America Only)

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

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

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

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

Terminal for wire 44A-FN to ground 24 volts
lamps relay (91).
NOTE: Put turn signal lever in LEFT turn position.
Terminal for wire 45L-BN to ground volts check circuit 45L to flasher module.
Terminal for wire 18F-BN to ground 24 volts
18F.
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp.
4002-103
101 – Left Hand Rear Combination Lamp (Europe Only)

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

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

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

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

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

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

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

Located on the right rear of the machine with combination lamp.
Correct
Reading
Terminal for wire 0-JC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2.
Check fuse ECB-F8 and five driving lamp switch (95). Also
Terminal for wire 18G-E to ground 24 volts
check circuit 18G.
4002-104
102 – License Plate Lamp (Europe Only)

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

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

Terminal for wire 35A-H to ground 24 volts
model, check connector 209F and 209M is connected.
NOTE: If the readings are good, replace the back-up alarm.
103 – Back-up Alarm (Europe Only)

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

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

4002-105
CAB WINDOW WASHER AND WIPER SYSTEM
109 110
111
112
107 108
104 106
113
105
RCPH10WHL094FAH
104.FRONT WIPER HIGH SPEED RELAY 109.FRONT WIPER MOTOR

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

Correct
Reading
Terminal for wire 19J-D and 19J-E to Bad fuse ECA-F12, check circuit 19J, also check power relay
24 volts
ground module B (14).
NOTE: Put the front wiper switch in the HIGH position.
Terminals for wire 63HC-B to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63HC-B to ground 24 volts Bad wiper high speed relay.
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C2 to ground 24 volts Bad wiper high speed relay.
105 – Front Wiper Cut Out Relay

Correct
Reading
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-G to ground 24 volts
module B (14).
Terminal for wire 63L-B to ground 24 volts Bad wiper cut out relay.
Terminals for wire 63HC-A to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63L-B to ground 0 volts Bad wiper cut out relay.
4002-107
106 – Front Wiper Low Speed Relay

Correct
Reading
Bad fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-F to ground 24 volts
module B (14).
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C to ground 24 volts Bad wiper low speed relay.
Terminals for wire 63LC to ground Continuity Bad front wiper and washer switch (108).
Bad wiper low speed relay, also check high speed wiper relay
Terminals for wire 63C3 to ground 24 volts
(104).
107 – Rear Wiper and Washer Switch

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

Terminal for wire 19K-B to ground 24 volts
circuit 19K.
Bad fuse ECA-F13 or power relay module B (14). Also check

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

Correct
Reading
Terminal for wire 0-DT to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch is in the OFF position.
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-B to ground 24 volts
module B (14).
NOTE: Put the front wiper and washer switch in the LOW position.
Bad front wiper and washer switch also check grounding

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

Terminal for wire 63HC to ground Continuity
circuit.
NOTE: Put the front wiper and washer switch in the wash position.
Terminal for wire 63W to ground 24 volts Bad front wiper and washer switch.
4002-109
109 – Front Wiper Motor

Located in front of steering column.
Correct
Reading
NOTE: Make sure the front wiper and washer switch (108) is in the OFF position.
Between terminals B and D for wires Continuity Bad front wiper motor.
63C and 63L
Terminal for wire 19J-A to ground 24 volts Check fuse ECA-F12, also check circuit 19J.
NOTE: Put the front wiper and washer switch (108) in the LOW position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63L-A to ground 24 volts
and washer switch (108), low speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (108)
NOTE: Put the front wiper and washer switch (108) in the HIGH position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63H-A to ground 24 volts
and washer switch (108), high speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (108).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L-A to ground 24 volts pulse Bad front wiper and washer switch (108).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (108).
NOTE: If the readings are good, replace the front wiper motor.
4002-110
110 – Rear Wiper Motor

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

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

Located in left side engine compartment.
Correct
Reading
Terminal for wire 0-B to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (108).
Bad front wiper and washer switch (108), also check circuit
Terminal for wire 63W-A to ground 24 volts
63W.
NOTE: If the readings are good, replace the front washer pump motor.
4002-111
113 – Wiper Diodes

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

4002-112
SECONDARY STEERING
114 116 118

115 117
RCPH10WHL094FAH
114.SECONDARY STEERING DIODES 117.SECONDARY STEERING MOTOR

115.SECONDARY STEERING SOLENOID 118.SECONDARY STEERING PRESSURE SWITCH
116.SECONDARY STEERING MODULE
4002-113
114 – Secondary Steering Diodes

Correct
Reading
NOTE: Disconnect wiring harness connector DM from diode connector.
Multimeter positive on pin A to pin C Continuity Bad diode.
Multimeter positive on pin B to pin C Continuity Bad diode.
Multimeter positive on pin C to pin A None Bad diode.
Multimeter positive on pin C to pin B None Bad diode.
115 – Secondary Steering Solenoid (Option)

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

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

ground
NOTE: Disconnect wire 51-B from secondary steering motor relay; make sure that wire does not touch any metal
part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and
run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN
STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately
to ON position.
Between pin 1 of connector YSS and Check secondary steering module (116) and secondary
24 volts
ground steering pressure switch (118).
4002-114
116 – Secondary Steering Module (Option)

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

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

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

Pin 9 of connector SSM to ground Open Circuit
51P-A.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector SSM to ground 24 volts Bad wire 19S1-X to power relay module A fuse 2 (13).
Pin 7 of connector SSM to ground 24 volts Bad fuse ECA-F17 or ignition switch. Also check circuit 19M.
Check fuse ECA-F4, power relay module C(15), ignition switch,

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

Pin 8 of connector SSM to ground 11 volts
problem is bad instrument cluster.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector SSM to secondary
steering module. Disconnect wire 51-B from secondary steering motor (117) relay terminal. Start and run engine
at idle speed. Disconnect wiring harness connector PSS from secondary steering pressure switch (118). Apply a
ground to pin C of connector PSS.
Terminal for wire 51-B to ground 24 volts Bad secondary steering module.
4002-115
117 – Secondary Steering Motor (Option)

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

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

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

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

Correct
Reading
NOTE: Disconnect wiring harness connector PSS from secondary steering pressure switch.
Pressure switch pin B to pin C Continuity Bad secondary steering pressure switch.
Pressure switch pin B to pin A Open Circuit Bad secondary steering pressure switch.
Pressure switch pin A to pin C Open Circuit Bad secondary steering pressure switch.
NOTE: Start and run engine at idle speed.
Pressure switch pin B to pin A Continuity Bad secondary steering pressure switch.
Pressure switch pin B to pin C Open Circuit Bad secondary steering pressure switch.
4002-116
CAN COMMUNICATION
119
RCPH10WHL094FAH
119.DIAGNOSTIC CONNECTOR
4002-117
119 – CAN Communication Diagnostics Connector

Correct
Reading
Terminal A for wire 0-DH to ground Continuity Bad ground circuit.
Terminal B for wire 18K-D to ground 24 volts Check fuse ECC-F9, check circuit 18K.
4002-118
RADIO AND POWER CONVERTER
125
122 123
124
121
RCPH10WHL094FAH
120. 123.RADIO
121.POWER CONVERTER 24 TO 12 VOLT 124.RIGHT SPEAKER
122.12 VOLT POWER OUTLETS (OPTION) 125.LEFT SPEAKER
4002-119
120 –
121 – Power Converter 24 volts to 12 volts (Option)

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

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

ground
Terminal for wire 12V or 12V-A to Bad power converter (121), check fuse ECB-F1 and F2, also
12 volts
ground check wire 12V-A.
NOTE: If the readings are good replace the power outlet.
123 – 12 Volt Radio Ready (Option)

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

0-EN to ground
Terminal in radio connector for wire Check fuse ECB-F9, also check circuit 12V. Also check the
12 volts
12V-HA to ground remote radio power converter (121).
4002-120
124 – Right Speaker (Option)

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

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

4002-121
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR
126
130
129
127
128
RCPH10WHL094FAH
BS06H241 / BS06H242
126.AIR SEAT 129.HIGH/LOW SWITCH

127.CIGAR LIGHTER 130.AIR CONDITIONING COMPRESSOR CLUTCH
128.AIR CONDITIONING CLUTCH RELAY
4002-122
126 – Seat Compressor and Switch (Option)

Located in the cab.
Correct
Reading
Terminal for wire 0-DK to ground Continuity Bad ground circuit.
Check fuse ECA-F16 and power relay module B(14). Also

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

Located in the cab.
Correct
Reading
Terminal for wire 19W to ground 24 volts Check fuse ECA-F18, also check circuit 19W.
Terminal for wire 0-DV to ground Continuity Bad ground circuit.
NOTE: If the readings are good replace the cigar lighter.
128 – Compressor Clutch Relay

Correct
Reading
Terminal for wire 0-DJ to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Put fan speed switch (149) to HIGH and
thermostat switch to COLD.
Terminal for wire 61R-B to ground 24 volts Check thermostat switch, also check wire 61R-B.
Terminal for wire 61C to ground 24 volts Bad compressor clutch relay.
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector PR from A/C trinary pressure
switch. Connect a jumper wire between pins A and B of connector PR. Put ignition switch in ON position.
Terminal for wire 61R-C to ground 24 volts Check wires 61R-B and 61R.
4002-123
129 – A/C High/Low Pressure Switch

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

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

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

Terminals for wire 61C-A to ground 24 volts
61C.
4002-124
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL
135 136 137

140 141
131
132 133 134 138 142 139

RCPH10WHL094FAH
131.ELECTRONIC PANEL 137.THERMOCOUPLE SENSOR

132.EXTERNAL AIR TEMPERATURE SENSOR 138.MIXED AIR SENSOR
133.INTERNAL AIR TEMPERATURE SENSOR 139.COMPRESSOR RELAY
134.SUN SENSOR 140.RECYCLING MOTOR
135.BLOWER FAN RESISTOR 141.ELETRONIC WATER VALVE
136.BLOWER MOTORS 142.24 TO 12 VOLT CONVERTER
4002-125
131 – Electronic Panel

Correct
Reading
NOTE: Automatic climate control only.
132 – External Air Temperature Sensor

Correct
Reading
133 – Internal Air Temperature Sensor

Correct
Reading
134 – Sun Sensor

Correct
Reading
135 – Blower Motor Resistor

Correct
Reading
NOTE: Automatic climate control only
136 – Blower Motors

Correct
Reading
137 – Thermocouple Sensor

Correct
Reading

4002-126
138 – Mixed Air Sensor

Correct
Reading
139 – Compressor Relay

Correct
Reading
140 – Recycling Motor

Correct
Reading
141 – Electronic Water Valve

Correct
Reading
142 – 24 to 12 Volt Converter

Correct
Reading

4002-127
STANDARD CLIMATE CONTROL
143 144 145

146 147 148
149 150 151

152 153
RCPH10WHL094FAH
143.ACTUATOR 149.FAN SPEED SWITCH

144.DRIVER 150.AIR CONDITIONING SWITCH
145.ELETRONIC WATER VALVE 151.CONTROL PANEL LIGHTS
146.BLOWER FAN RESISTOR 152.WATER VALVE POTENTIOMETER
147.BLOWER MOTOR 153.AIR RECIRCULATING SWITCH
148.THERMOSTAT
4002-128
143 – Actuator
Correct
Reading
NOTE: Remove connectors from DNS Actuator and DNS Driver prior to testing.
Pin 6 in wiring harness connector to Continuity Bad wire or connector.

pin 4 in Driver module (DNS49)
Pin 5in wiring harness connector to Continuity Bad wire or connector.

pin 5in Driver module (DNS48)
144 – Driver
Correct
Reading
NOTE: Remove connectors from DNS Driver and HVAC2.
Between DNSS2 and DNS75 Continuity Bad wire or connector.
145 – Electronic Water Valve

Correct
Reading
NOTE: No information at time of print.
146 – Blower Motor Speed Resistors with Thermal Fuse

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

Bad blower motor resistor.
motor connector x.x ohms


4002-129
147 – Blower Motor

Correct
Reading
Terminals for wire DNS66 to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the fan speed switch
(149) to position 4.
Terminal for wire DNS65 to ground 24 volts Check the fan speed switch (149).
NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the fan
speed switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the
blower fan resistor (146).
148 – Thermostat
Correct
Reading
NOTE: Remove connector from thernostat.
Continuity
above 5C (41F)
Between terminals on thermostat +/-1C, open Bad thermostat.
below 0C
(32F)+/-1C.
149 – Blower Switch

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

4002-130
150 – Air Conditioning Switch

Correct
Reading
NOTE: Remove connector from AC switch.
Between terminal 1 and 2 on AC Continuity with

Bad AC switch.
switch switch on.
151 – Control Panel Lights

Correct
Reading
NOTE: Remove connector from Control panel lights.
Between terminal 1 and 2 on light. Continuity Bad light(s).
152 – Water Valve Potentiometer

Correct
Reading
NOTE: Remove connector from Water valve potentiometer.
Between terminals measure Resistance

Bad potentiometer.
resistance change. change
153 – Air Recirculating Switch

Correct
Reading
NOTE: Remove connector on Air recirculating switch.
Continuity with
Between terminals 1 and 2. Bad recirculating switch.
switch on.
4002-131
HOOD RAISE AND LOWER SYSTEM
157
156
154
155
RCPH10WHL094FAH
154.HOOD UP RELAY 156.HOOD SWITCH

155.HOOD DOWN RELAY 157.HOOD MOTOR
4002-132
154 – Hood Up Relay

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

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

Located in the right battery compartment with the master disconnect switch.
Correct
Reading
NOTE: Disconnect connector HD, turn the master disconnect ON.
Terminal for wire 19Y-D to ground 24 volts Check fuse ECC-F7, check circuit 19Y.
Hold the hood switch in the raise Continuity Bad hood switch.
position, between pin C and B
Hold the hood switch in the lower Continuity Bad hood switch.
position, between pin A and B
4002-133
157 – Hood Motor

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

4002-134
STARTING / IGNITION SYSTEMS
158
159
160
RCPH10WHL094FAH
158.IGNITION POWER LATCH 160.START LOCKOUT
159.IGNITION POWER CONTROL
4002-135
158 – Ignition Power Latch

Correct
Reading
Terminal for wire 0-EW to ground Continuity Bad ground circuit.
Terminal for wire 13K to ground 24 volts Check circuit 13K, check Ignition switch (10).
Terminal for wire 0-EA to 0-EU on Continuity Bad wire or connector

Program relay module A (13)
Bad ignition power latch relay or ignition power control relay

Terminal for wire 0-ET to ground Continuity
(159).
159 – Ignition Power Control

Correct
Reading
Terminal for wire 0-KA to ground Continuity Bad ground circuit.
Terminal for wire 13K-A to ground 24 volts Check circuit 13K, check ignition switch (10).
Terminal for wire 0-EY to ground Continuity Bad ignition power control relay.
160 – Start Lockout

Correct
Reading
NOTE: Used with Telematics on future models

4002-136
SCR SYSTEM/ JOYSTICK STEERING/ MISC
161 164 167

165
162 166 168
163 169
RCPH10WHL094FAH
161.NOX SENSOR 166.UPSTREAM TEMPERATURE SENSOR
162.HUMIDITY AND AMBIENT TEMPERATURE SENSOR 167.DOWNSTREAM TEMPERATURE SENSOR
163.NOX SENSOR (NOXS) 168.DOSER METERING VALVE
164.TANK HEATER CONTROL VALVE 169.DNOX CONTROLLER
165.DEF LEVEL AND TANK TEMPERATURE
4002-137
161 – NOX Sensor

Correct
Reading
NOTE: See SCR controller manual for details.
162 – Humidity and ambient temperature sensor

Correct
Reading
NOTE: See SCR controller manual for details
163 – NOX Sensor (NOXS)

Correct
Reading
164 – Tank heater control valve

Correct
Reading
165 – DEF Level and tank temperature

Correct
Reading
166 – Upstream temperature sensor

Correct
Reading
167 – Downstream temperature sensor

Correct
Reading
168 – Doser metering valve

Correct
Reading

4002-138
169 – DNOX Controller

Correct
Reading
170 – Rear View Camera / Monitor

Correct
Reading
NOTE: See Camera manual for details
171 – Differential Lock Switch (Manual)

Correct
Reading
NOTE: Remove connector SDM from switch
Normally
open,
Between terminals 2 and 3 Continuity Bad Lock Switch.
when switch is
closed
172 – Differential Lock Switch

Correct
Reading
NOTE: Remove connector from switch
Normally
open,
Between terminals 2 and 3 Continuity Bad Lock Switch
when switch is
closed
173 – Differential Lock Solenoid

Correct
Reading
Terminal for wire 34C-A to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and ignition switch in ON position.
Terminal 1 for wire 34A-D to ground 24 volts Bad TECM module. Also check circuit 34C.
NOTE: If the readings are good, replace the differenital lock solenoid.
NOTE: See transmission section for more details

4002-139
174 – Lockup Solenoid

Correct
Reading
Terminal for wire 24T-B to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and ignition switch in ON position.
Terminal 1 for wire 25R-B to ground 24 volts Bad TECM TRANS module. Also check circuit 25R.
NOTE: If the readings are good, replace the lockup solenoid.
NOTE: See transmission section 6000 for more details
175 – Joystick PVRES

NOTE: See service manual section 5009 for Joystick steering details.
176 – Transmission Kick Down Switch

NOTE: See service manual section 5009 for Joystick steering details..
177 – ARM POS

NOTE: See service manual section 5009 for Joystick steering details..
178 – FNR Switch (option)

179 – FNR Relay

180 – Pilot Dump Valve

181 – JSS Valve

182 – Load Sense Pressure Sensor

183 – Pilot Pressure Switch

4002-140
184 – JSS Relay

185 – Joystick STR Switch (option)

186 – JSS Controller

4002-141
CONNECTORS
CONNECTOR 108F - DIAGNOSTIC CONNECTOR
291663A1
CONNECTOR 197F - MAIN CAB FNR
CONNECTOR 140M - DIODE MODULE

225350C1
245488C1
4002-142
CONNECTOR 197M - FNR-MAIN_CAB CONNECTOR 209F - BACKUP ALARM DISABLE
JUMPER
225351C1
245481C1
CONNECTOR 209M - BACKUP ALARM DISABLE

JUMPER
CONNECTOR 202M - ROLLBACK JUMPER
245480C1
245482C1
4002-143
CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH
225316C1
CONNECTOR 215F - ALTERNATOR RESISTOR CONNECTOR 64F - FLASHER CONNECTOR
245481C1
199436A1
CONNECTOR 216F - ALTERNATOR RESISTOR CONNECTOR 64M - FLASHER CONNECTOR
199436A1
245480C1
4002-144
CONNECTOR AIC2 - ADV INSTRUMENT
CLUSTER 2
CONNECTOR ACT - AIR CONDITIONING

COMPRESSOR CLUTCH
8602417 87410948
CONNECTOR AIC1 - ADV INSTRUMENT

CLUSTER
87419488
4002-145
4002-146
CONNECTOR BUZ - AIC BUZZER
222136A1
4002-147
4002-148
CONNECTOR CAB-RF - CAB TO ROOF CONNECTOR CAB-T - CAB TO TRANMISSION
CONNECTION
380839A1
388710A1
4002-149
CONNECTOR CL - CIGAR LIGHTER
3227856R1
CONNECTOR CNV - 24V TO 12V POWER

CONVERTER
225351C1
4002-150
CONNECTOR DM - DIODE OR
CONNECTOR D-OR - DIODE OR
245485C1
245485C1
CONNECTOR DISC - DISCONNECT ENGINE
245482C1
4002-151
CONNECTOR DNS-DRIVER
411311A1
4002-152
CONNECTOR DS - DOOR SWITCH
CONNECTOR EM - HEIGHT CONT RTT RTD
245482C1
225351C1
CONNECTOR E-HD - TRANSMISSION HOOD
245485C1
4002-153
CONNECTOR ECA - ELECTRICAL CENTER A
87315248
4002-154
4002-155
CONNECTOR ECB - ELECTRICAL CENTER B
87312843
4002-156
4002-157
CONNECTOR ECC - WORK LIGHTS
87315249
4002-158
4002-159
CONNECTOR ECD - ELECTRICAL CENTER D
87312843
4002-160
4002-161
CONNECTOR EDC7 - ENGINE CONTROLLER
BOSCH-89-POLE
4002-162
CONNECTOR ENG-D - DISCONECT HARNESS CONNECTOR ESS - ENGINE SPEED SENSOR
245483C1
291718A1
CONNECTOR ENG-H - ENGINE TO HOOD
CONNECTOR FFH - FULE FILTER HEATER
225320C1
182069A1
4002-163
CONNECTOR FLSHR - FLASHER MODULE
225389C1
CONNECTOR FM - FILTER MAINTENANCE

SWITCH
CONNECTOR FWM - FRONT WIPER MOTOR
371614A1
245715C1
4002-164
CONNECTOR FWMG - FRONT WIPER MOTOR CONNECTOR GHC - GRID HEATER RELAY
GROUND
3227856R1
245480C1
CONNECTOR FWW - FRONT WASHER
3227856R1
4002-165
CONNECTOR - CAB GROUND SPLICE
87324393
CONNECTOR - SPLICE BACK LIGHT GROUND
87324393
4002-166
4002-167
CONNECTOR HD - HOOD SWITCH
245485C1
CONNECTOR HD-E - HOOD HARNESS TO

TRANSMISSION HARNESS
245484C1
4002-168
CONNECTOR HD-N - HOOD TO ENGINE
225319C1 CONNECTOR HOT - HYDRAULIC OIL

TEMPERATURE SENDER
194788A1
CONNECTOR HDM - HOOD LIFT MOTOR
225316C1
4002-169
CONNECTOR HVAC2 - HVAC2
87552622
CONNECTOR ISS - INT-SPEED-SENSOR
291718A1
4002-170
4002-171
CONNECTOR LLF - LH FRONT LIGHTS CONNECTOR LLR-E - LH REAR COMBINATION
LAMP
225351C1
225351C1
CONNECTOR LPL - LICENSE PLATE LAMP
245482C1
4002-172
CONNECTOR LRF - RH FRONT LAMP
CONNECTOR LRR-E - RH REAR COMBINATION

LAMP
225351C1
225351C1
CONNECTOR LSPK - LEFT SPEAKER
195552A1
4002-173
CONNECTOR PAF - AIR FILTER RESTRICTION
SWITCH
291718A1
CONNECTOR OSS - OUTPUT SPEED SENSOR
291719A1
CONNECTOR PBD - BRAKE DECLUTCH
PRESSURE SWITCH
245482C1
4002-174
CONNECTOR PBL - BRAKE LAMP PRESSURE CONNECTOR PO1 - POWER OUTLET
SWITCH
222136A1
12176446
CONNECTOR PO2 - POWER OUTLET
12176446
4002-175
CONNECTOR PRB1 - REDUNDANT BRAKE
SWITCH
245483C1
4002-176
CONNECTOR PSS - SECONDARY STEERING CONNECTOR PXF - RTD
PRESSURE SWITCH
245485C1
245485C1
4002-177
CONNECTOR RAD - RADIO POWER CONNECTOR RAD-J2 - SPEAKER
292495A1 292501A1
CONNECTOR RAD-J1 - RADIO POWER
CONNECTOR RAD-J3 - RADIO JUMPER
411311A1
292497A1
4002-178
CONNECTOR RECT - ENGINE COOLANT CONNECTOR ROOF - ROOF TO CAB
TEMPERATURE CONNECTION
194788A1 388708A1
CONNECTOR RSPK - RIGHT SPEAKER
195552A1
4002-179
CONNECTOR RTHP - THROTTLE PEDAL CONNECTOR RWMG - REAR WIPER MOTOR
GROUND
225351C1
245480C1
CONNECTOR RWW - REAR WASHER
CONNECTOR RWM - REAR WIPER MOTOR
3227856R1
245715C1
4002-180
CONNECTOR S-KEY - IGNITION SWITCH TO CONNECTOR SC - SEAT COMPRESSOR MOTOR
PEDESTAL HARNESS
245482C1
225253C1
CONNECTOR SBE - BEACON SWITCH
CONNECTOR SDC - DECLUTCH SWITCH
382391A1
382391A1
4002-181
CONNECTOR SDR - DRIVING LIGHTS SWITCH CONNECTOR SFWW - REAR WIPER AND
WASHER SWITCH
382391A1 87345132
CONNECTOR SHC - HEIGHT CONTROL SWITCH
382391A1
4002-182
CONNECTOR SPK - SPEAKER
292494A1
CONNECTOR SPB - PARKING BRAKE SWITCH
382391A1
4002-183
CONNECTOR SPL-BCK-LGT - SPLICE BACK CONNECTOR SPL-BCK-LGT
LIGHT GD
87324393 87324393
4002-184
CONNECTOR SPL-PED-BL - SPL BACK LIGHT CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY
POWER 6 PACK
87324462
87324391
4002-185
CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY CONNECTOR SPL-TRNS-PWR - TRANSMISSION
POWER
87324462
87324393
CONNECTOR SRC - RIDE CONTROL SWITCH
382391A1
4002-186
CONNECTOR SRC-1 - STARTER RELAY CONNECTOR SRTD - DETENT SWITCH
225316C1
382391A1
CONNECTOR SRHSTLK - RH STALK SWITCH
87318288
4002-187
CONNECTOR SS-TR - SS-MOD-TRANS CONNECTOR STA - TRANSMISSION AUTO
SWITCH
245489C1
382391A1
CONNECTOR SSM - SECONDARY STEERING

MODULE
225389C1
4002-188
CONNECTOR SWL - WORK LIGHTS SWITCH CONNECTOR TCOT - TORQUE CONVERTER
OUTPUT SENDER
382391A1
291718A1
4002-189
CONNECTOR TECM - TRANSMISSION
411398a1
4002-190
CONNECTOR TRANS - CAB TO TRANSMISSION
CONNECTOR TR-SS - SEC-STR-MOD-OPT 380838A1
245488C1
4002-191
CONNECTOR TRC - TRANSMISSION CONTROL CONNECTOR TS2 - TRANSMISSION SHIFTER
245487C1
371566A1
CONNECTOR TSS - TURBINE SPEED SENSOR
CONNECTOR TS1 - TRANSMISSION SHIFTER
291718A1
245486C1
4002-192
CONNECTOR WF - WATER IN FUEL SENSOR
CONNECTOR YFN - FNA PWM SOLENOID
8602416
CONNECTOR WSH - WATER SEPARATOR

HEATER 256340A1
182069A1
4002-193
CONNECTOR YFR - FAN REVERSING SOLENOID
225316C1
CONNECTOR YPP - PILOT PRESSURE

SOLENOID
245482C1
CONNECTOR YPE - PIN ENGAGE
CONNECTOR YRC - RIDE CONTROL OPT
245482C1
291718A1
4002-194
CONNECTOR YSS - SECONDARY STEERING

SOLENOID
225316C1
4002-195
NOTES
4002-196
ECD
INDEX OF FUNCTIONS SHT SHT SHT SHT
BACKUP ALARM 6
, 14
COLOR ABBREVIATIONS
70
62
SHT SHT SHT SHT SHT
SHT
71
SHT
LARGE CONNECTOR LIST

SHEET
INDEX / WIRE INFORMATION 1

SHEET SHEET SHEET SHEET
CONNECTOR LIST 2
SHEET SHEET SHEET
CONNECTOR LIST 3
3 18
21 13 14 15
20
2
8
158
1
10
Relay in
4 location F5/F6
160
Relay in
location
F3\F4
6 11
16 17
159
COLD START POWER DISTRIBUTION IGNITION SWITCH 4

22
24
162
161
Relay in
location F7\F8
CAN_L3 G-0.8
CAN_H3 Y-0.8
23
163
169
164
168
165
167
166
ENGINE CONTROL 5
92
90
CONNECT FOR NA OPERATION,

OPP SIDE STEADY ON.
DISCONNECT FOR EUROPEAN OPERATION,
OPP SIDE OFF.
Relay in
Relay in location
location
93 F9\F10
F1/F2
95
78
91
North American models

European and International models
101 100 101 100
Turn
Signal
Driving
Lights
Light/
Horn
79
Horn
94
103
96 97
102
LIGHTING 1 BACKUP ALARM 6

89
81
88
87
80
86
85
84
170
83
82
LIGHTING 2 7
172
54
173 171
57
55
59
56
174
46
47
45
61
48
58
49
50
51
52
53
60
TRANSMISSION CONTROLS 8
63
64
68
74
72
67
65
75
69
73
76
66
INSTRUMENT CLUSTER 9
25
35
36
26
29
33
31
32
98
27
37
99
39
28
40
38 34 30
41
42
44
43
MACHINE CONTROLS 10
113
155
154
104
108
105
114
106
115
107
117
109
156
111
116
BLUE BROWN
112
DOWN
LIMIT
UP
LIMIT 113
SWITCH SWITCH
157
110
NO
COM 118
NC
HOOD LIFT 11
121
122
129
122
126
128
130
125
124 123
119
Note: Telematics for future models
127
R R
S S
HVAC AIR SEAT RADIO POWER/CONVERTER 12

184
177
175
8
8
185
176
179
178
181
182
180
183
186
JOYSTICK STEERING (FOR PL18 & PL23 ONLY) 13

145
144
143
146
147
148
153
149 150
152
151
STANDARD HVAC 14
721F, 821F, 921F Tier 4 Wheel Loader
ELECTRICAL SCHEMATIC
LEGEND
INDICATES CONSTANT POWER

INDICATES POWER WHEN KEY
SWITCH IS ON
INDICATES POWER WHEN KEY
SWITCH IS IN START POSITION
POWER RELAY A
POWER RELAY B
POWER RELAY C
POWER RELAY D
ILLUMINATION
ELECTRICAL WIRING INFORMATION 15

COMPONENT NUMBERS
# SHT COMPONENT # SHT COMPONENT # SHT COMPONENT # SHT COMPONENT
1 4 STARTING RELAY 61 8 DIAGNOSTIC CONNECTOR 119 12 DIAGNOSTIC CONNECTOR 177 13 ARM POS
2 4 RESISTOR - 75 OHM 62 1 INSTRUMENT CLUSTER CONNECTOR 1 121 12 POWER CONVERTER - 24 TO 12 VOLT 178 13 FNR SWITCH (OPTION)
3 4 ALTERNATOR 63 9 WARNING BUZZER 122 12 12 VOLT POWER OUTLETS (OPTION) 179 13 FNR RELAY
4 4 CRANK CONTROL RELAY 64 9 PARKING BRAKE RELAY 123 12 RADIO 180 13 PILOT DUMP VALVE
5 4 BATTERIES 65 9 FUEL LEVEL SENDER 124 12 RIGHT SPEAKER 181 13 JSS VALVE
6 4 CRANK REQUEST RELAY 66 9 AIR FILTER RESTRICTION SWITCH 125 12 LEFT SPEAKER 182 13 LOAD SENSE PRESSURE SENSOR
8 4 MASTER DISCONNECT SWITCH 67 9 PARKING BRAKE SOLENOID 126 12 AIR SEAT 183 13 PILOT PRESSURE SWITCH
9 4 STARTER 68 9 RADIATOR COOLANT TEMPERATURE SENDER 127 12 CIGAR LIGHTER 184 13 JSS RELAY
10 4 IGNITION SWITCH 69 9 BRAKE PRESSURE WARNING SWITCH 128 12 AIR CONDITIONING CLUTCH RELAY 185 13 JOYSTICK STR SWITCH (OPTION)
11 4 NEUTRAL START RELAY 70 1 SWITCH PAD 129 12 AIR CONDITIONING HIGH-LOW PRESSURE SWITCH 186 13 JSS CONTROLLER
13 4 POWER RELAY MODULE A 71 1 INSTRUMENT CLUSTER CONNECTOR 2 130 12 AIR CONDITIONING COMPRESSOR CLUTCH
14 4 POWER RELAY MODULE B 72 9 HYDRAULIC FILTER RESTRICTION SWITCH 131 NA ELECTRONIC PANEL
15 4 POWER RELAY MODULE C 73 9 HYDRAULIC OIL TEMPERATURE SENDER 132 NA EXTERNAL AIR TEMPERATURE SENSOR
16 4 GRID HEATER RELAY 74 9 PARK BRAKE SWITCH 133 NA INTERNAL AIR TEMPERATURE SENSOR
17 4 GRID HEATER 75 9 REDUNDANT BRAKE PRESSURE SWITCH 1 134 NA SUN SENSOR
18 4 POWER RELAY MODULE D 76 9 REDUNDANT BRAKE PRESSURE SWITCH 2 135 NA BLOWER FAN RESISTOR
20 4 WATER SEPARATOR HEATER 78 6 BACKUP ALARM RELAY 136 NA BLOWER MOTORS
21 4 FUEL FILTER HEATER 79 6 BACKUP ALARM DISABLE SWITCH 137 NA THERMOCOUPLE SENSOR
22 5 WATER IN FUEL SENSOR 80 7 WORK LAMPS SWITCH 138 NA MIXED AIR SENSOR
23 5 THROTTLE POTENTIOMETER 81 7 DOOR SWITCH 139 NA COMPRESSOR RELAY
24 5 ENGINE CONTROLLER 82 7 ROTATING BEACON (OPTIONAL) 140 NA RECYCLING MOTOR
25 10 RETURN TO TRAVEL FLOAT SWITCH 83 7 DOME LAMP 141 NA ELECTRONIC WATER VALVE
26 10 HEIGHT CONTROL SWITCH 84 7 ROTATING BEACON SWITCH (OPTIONAL) 142 NA 24 TO 12 VOLT CONVERTER
27 10 ELECTROMAGNETIC DETENTS 85 7 LEFT HAND FRONT WORK LAMP 143 14 ACTUATOR
28 10 RETURN TO DIG PROXIMITY SWITCH 86 7 RIGHT HAND FRONT WORK LAMP 144 14 DRIVER
29 10 PILOT CONTROL RELAY ECD-K3 87 7 LEFT HAND REAR WORK LAMP 145 14 ELECTRONIC WATER VALVE
30 10 HEIGHT CONTROL AND RETURN TO TRAVEL PROXIMITY SW 88 7 RIGHT HAND REAR WORK LAMP 146 14 BLOWER FAN RESISTOR
31 10 RETURN TO DIG SWITCH 89 7 DIODES 147 14 BLOWER MOTOR
32 10 PIN ENGAGE SWITCH (OPTION) 90 6 BRAKE LAMP SWITCH 148 14 THERMOSTAT
33 10 PILOT PRESSURE SOLENOID 91 6 BRAKE LAMP RELAY 149 14 FAN SPEED SWITCH
34 10 PIN ENGAGE SOLENOID (OPTION) 92 6 FLASHER MODULE 150 14 AIR CONDITIONING SWITCH
35 10 RIDE CONTROL SWITCH (OPTION) 93 6 HAZARD SWITCH 151 14 CONTROL PANEL LAMPS
36 10 RIDE CONTROL RELAY (OPTION) 94 6 TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 152 14 WATER VALVE POTENTIOMETER
37 10 FAN CONTROL SWITCH (OPTION) 95 6 DRIVING LAMPS SWITCH 153 14 AIR RECIRCULATING SWITCH
38 10 FAN REVERSE RELAY (OPTION) 96 6 LEFT HAND FRONT COMBINATION LAMPS 154 11 HOOD UP RELAY
39 10 PILOT CONTROL SWITCH 97 6 RIGHT HAND FRONT COMBINATION LAMPS 155 11 HOOD DOWN RELAY
40 10 RIDE CONTROL SOLENOID (OPTION) 98 10 HORN RELAY 156 11 HOOD SWITCH
41 10 ROLLBACK PRESSURE SW (XT WITH RIDE CONTROL ONLY) 99 10 HORN RELAY 157 11 HOOD MOTOR
42 10 ROLLBACK JUMPER 100 6 RIGHT HAND REAR COMBINATION LAMPS 158 4 IGNITION POWER LATCH
43 10 FAN PWM SOLENOID 101 6 LEFT HAND REAR COMBINATION LAMPS 159 4 IGNITION POWER CONTROL
44 10 FAN REVERSE SOLENOID (OPTION) 102 6 LICENSE PLATE LAMP 160 4 START LOCKOUT
45 8 OUTPUT SPEED SENSOR 103 6 BACKUP ALARM 161 5 NOX SENSOR
46 8 TRANSMISSION SOLENOID VALVE AND TEMP SENDER 104 11 FRONT WIPER HIGH SPEED RELAY 162 5 HUMIDITY AND AMBIENT TEMPERATURE SENSOR
47 8 FILTER MAINTENANCE SWITCH 105 11 WIPER CUTOUT RELAY 163 5 NOX SENSOR (NOXS)
48 8 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 106 11 FRONT WIPER LOW SPEED RELAY 164 5 TANK HEATER CONTROL VALVE
49 8 ENGINE SPEED SENSOR 107 11 REAR WIPER AND WASHER SWITCH 165 5 DEF LEVEL AND TANK TEMPERATURE
50 8 INTERMEDIATE SPEED SENSOR 108 11 FRONT WIPER AND WASHER SWITCH 166 5 UPSTREAM TEMPERATURE SENSOR
51 8 TURBINE SPEED SENSOR 109 11 FRONT WIPER MOTOR 167 5 DOWNSTREAM TEMPERATURE SENSOR
52 8 TRANSMISSION SHIFTER 110 11 REAR WIPER MOTOR 168 5 DOSER METERING VALVE
53 8 TRANSMISSION ELECTRONIC CONTROL MODULE 111 11 REAR WASHER MOTOR 169 5 DNOX CONTROLLER
54 8 TRANSMISSION ENABLE SWITCH 112 11 FRONT WASHER MOTOR 170 7 REAR VIEW CAMERA/MONITOR
55 8 FNR SWITCH FOR JOYSTICK CONTROLS 113 11 DIODES 171 8 DIFFERENTIAL LOCK SWITCH (MANUAL)
56 8 TRANSMISSION KICK DOWN SWITCH 114 11 SECONDARY STEERING DIODES 172 8 DIFFERENTIAL LOCK SWITCH
57 8 FNR SWITCH FOR SINGLE AXIS CONTROLS 115 11 SECONDARY STEERING SOLENOID 173 8 DIFFERENTIAL LOCK SOLENOID
58 8 TRANSMISSION AUTO SWITCH 116 11 SECONDARY STEERING MODULE 174 8 LOCKUP SOLENOID
59 8 BRAKE DECLUTCH PRESSURE SWITCH 117 11 SECONDARY STEERING MOTOR 175 13 JOYSTICK PVRES
60 8 DECLUTCH SWITCH 118 11 SECONDARY STEERING PRESSURE SWITCH 176 13 TRANSMISSION KICK DOWN SWITCH
COMPONENT NUMBERING INFORMATION 16

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

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

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

(Load) Test. This tool is first used on Page 6.
4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the If damage causes an electrolyte leak, replace the
level of the electrolyte every 1000 hours of operation battery.
or six months, whichever occurs first. For all other
Inspect the battery at regular intervals for dir t,
batteries, check the level of the electrolyte every 250
corrosion, and damage. Electrolyte and dirt on the
hours of operation.
top of the battery can cause the battery to discharge
NOTE: A maintenance free battery will have the by making a passage for the current to flow.
words Maintenance Free on the decal on the top of
If the battery must be cleaned, remove the battery
the battery. If the center part of the decal has been
from the battery carrier and clean the battery, cable
removed for access to the battery caps, it is possible
terminals, and the battery carrier. When available,
that the words Maintenance Free have been removed
use Case Battery Saver and Cleaner according to
from the decal.
the instructions on the container. Case Battery Saver
Check the level of the electrolyte more often during and Cleaner also helps prevent corrosion. If Case
hot weather. The use of a large amount of water by Battery Saver and Cleaner is not available, use
the batter y can be caused by high batter y baking soda and water as a cleaner. DO NOT permit
temperature or a voltage regulator setting that is too any type of cleaner to enter the cells of the battery.
high. Keep the electrolyte level above the top of the
Install the battery in the machine and make sure the
plates in the battery at all times to prevent damage to
fasteners are tight. Apply Case Battery Saver and
the battery.
Cleaner or Urethane Seal Coat to the cable terminals
NOTE: On maintenance free batteries it is to prevent corrosion. See the Parts Counter Catalog.
necessary to remove the center part of the decal for DO NOT apply grease.
access to the battery caps. Do not discard the center
part of the decal. Install the center part of the decal
after the battery caps have been installed.
If the level of the electrolyte is low, add distilled water
or other clean water until the electrolyte is just below
the cell opening. Do not add more water than is
n e e d e d . To o m u c h w a t e r c a n c a u s e b a d
performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.
4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the 1 2
battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check 1. TEMPERATURE IN F 2. TEMPERATURE IN C

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

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

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

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

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

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

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes

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

*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.
Continued on next page

4003-8
Charging Guide For Batteries Other Than Maintenance Free

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

Reserve Capacity under Slow Charge Fast Charge
Specifications

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

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes


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

1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
spe cific gravity is 1 .25 0 or m ore a nd the
2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
electrolyte. This will per mit the volume of
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
3. Install the caps on the battery.
the cell opening.
4. Connect a battery charger to the battery.
Section
4003a
4003a
JUMP POST OPTION

4003-2
TABLE OF CONTENTS
Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4003-3
JUMP POST OPTION

STEP 1 7. Remove the booster battery negative (-) cable
from the jump post and then from the machine
being used for starting. Remove the positive (+)
cable from the jump post terminal and then from
the booster battery.
8. Install the terminal covers.
RCPH10WHL214AAH.PNG
The Jump Post option can be used to provide power

to star t the machine if its batteries become
discharged.
The option can be used to provide power to the
machine for the purpose of raising the hood if its
batteries have become discharged.
The option can be used to star t other disabled
equipment without accessing the main batter y
terminals.
NOTE: Note: Make sure that the voltage of the
booster batteries is the same as that of the machine
system (24 volts). The jump post is located on the left
hand side of the machine inside the main electrical
disconnect compartment.
1. Turn off the ignition and all accessories on the
machine(s). Use the jump post to connect the
auxiliary battery.
2. Remove the terminal covers and connect one
end of the positive (+) cable to the positive (+)
terminal on the booster battery.
3. Connect the other end of the positive (+) cable to
the positive (+) terminal of the jump post (red).
4. Connect the negative (-) cable to the negative (-)
terminal on the booster battery.
5. Connect the other end of the negative (-) cable to
the negative (-) terminal of the jump post (black).
Do not connect it to sheet metal or any rotating
part, as damage can result. Do not connect to
the negative (-) terminal on the battery.
6. Start the engine.
4003-4
Section
4005
INSTRUMENT CLUSTER
4005
4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SELECTIVE CATALYTIC REDUCTION (SCR) FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
.
4005-3
INSTRUMENT CLUSTER
5
4 6
1 2 3 7 8 9 10
15 11
14 12
13
BD06H039
1. LOW BRAKE PRESSURE INDICATOR 9. LACK OF AUX STEER PRESSURE (OPTIONAL)
2. HIGH BEAM INDICATOR 10. PARKING BRAKE INDICATOR
3. TRANSMISSION OIL TEMPERATURE GAUGE 11. RIGHT TURN INDICATOR
4. CAUTION MASTER INDICATOR 12. FUEL LEVEL GAUGE
5. MULTI FUNCTION LCD DISPLAY 13. FUEL LEVEL AT MINIMUM
6. STOP MASTER INDICATOR 14. ENGINE COOLANT TEMPERATURE GAUGE
7. HYDRAULIC OIL TEMPERATURE GAUGE 15. LEFT TURN INDICATOR
8. WAIT TO START ENGINE PREHEAT
The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:
4005-4
Self-Test Power Circuit Test

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

Control Lever is in Forward. The display will show
Forward, Neutral, or Reverse, depending on
where the Directional Control Lever is positioned.
NOTE: Forward and Reverse will blink if the
transmission clutches are disconnected.
3. This example shows the maximum gear allowed
when in Automatic mode. If display is blank the
Manual mode has been selected.
4. This example shows the current transmission
mode that has been selected.
A. If the Transmission is operating normally it will
display either
BD06J132 ● A - Automatic
The LCD Multi-Function Display is located at the ● M - Manual operation.
center of the modular dashboard. On start up the B. If the Transmission is not operating normally
cluster will flash the instructional lamps and the LCD the display will show
Multi-Display will display, CASE, with the machine
model and current hour reading. ● C - Substitute Clutch.
● L - Limp Home.
● S - Transmission Shutdown.
● U - TCU Shutdown.
5. This example (not displayed) will show the
transmission clutches disengaged, if the Park
Brake is OFF.
6. This example shows the Power Boost Status.
● MAX - Maximum Power.
● STD - Normal/Standard mode of Operation.
● AUTO - Switches automatically between
Maximum and Standard Power.
● ECO - Limited Power for fuel efficiency.
7. This example will show the Time in either 12 hour
or 24 hour.
BD06F185
LCD MULTI-FUNCTION DISPLAY
The LCD Multi-function display (liquid crystal display
is located at the center of the modular dashboard. On
start up, the console indicator lamps will momentarily
flash. The LCD Multi-display will flash the machine
model. The initial standard driving screen will then
appear. Once operator preferences are set, the
screen will reflect those selections.
1. In the example, above, the machine hours are
d i s p laye d . M a c h i n e h o u r s w i l l a l way s b e
displayed briefly, on start up. After, the machine
is started, the display will show engine rpm’s.
After, beginning travel, the machine will display
travel speed, if default settings were not changed
by the operator.
4005-6
Navigating Through The LCD Using The Arrow Keys
Multi-function Display Screens At any time, during operation or with the key switch
on, the operator may scroll through three information
screens and two trip screens by using the arrow
keys. These five screens are in a circular loop and
A C may be reached by pressing the up or down key. The
following sequence is using the down key only.
back to the normal driving screen.
B D
BD06F186
Located on the steering column, just to the left of the
Park Switch, is the key pad. Use this key pad to move
fr o m on e s c r e e n to a n o th e r, c h o o s e va r i o u s
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
the same basic manner.
A. Escape key: Use this key to exit and return to
BD06F188
the driving screen. Use this key anytime you
would like to start over and begin again, plus From the driving screen push the down arrow, as
use to check active, acknowledge errors. shown.
B. Enter key: Use this key to confirm, yes, this is

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

arrow from the driving screen. It displays engine
RPM’s, speed, fuel level, and the DEF fluid level.
4005-7
BD06F169
Press the down button again and the Trip 1 screen
BD06F027
will display. The LCD provides two trip computers.
Info 2 will be displayed next. The Info 2 screen will These will display since last reset the total time in
display coolant temperature, engine oil temperature h o u r s , t h e t o t a l f u e l , a n d t h e a ve r a g e f u e l
in either Fahrenheit or Celsius, DEF fluid level, as consumption per hour.
well as oil pressure PSI.
BD06F170
By continuing to scroll down, the fifth screen will
BD06F184
display the Trip 2 screen. Trip 1 and Trip 2 screens
Push the down button again and the Info 3 screen. can be reset independently. The previous screen can
This screen displays the temperature in Fahrenheit or be accessed by using the up arrow key.
Celsius of the transmission oil, hydraulic oil, sump oil,
and DEF fluid level.
4005-8
Reset The Trip Information
BD06F170
Highlight the trip screen you wish to set.
BD06F187
Press the confirm button to reset the trip selection to
zero.
The trip screen will indicate a reset message. At this

screen, press confirm to clear the numbers and reset
the trip information. The current date and time will
display automatically. The hours, fuel consumption,
and fuel used per hour will reset and revert to zero.
4005-9
Entering The Service Screens

After the machine has been started or the key switch has been turned to on the operator or service technican may
use this service menu to adjust machine configurations to working conditions, test components, view faults that
may have occurred, or select preferences.
NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery
disconnect you may loose all of your selections and need to reprogram the LCD Multi-function display.
BD06H038 / BD06F188
Press and hold the confirmation button for two seconds to arrive at the main menu screen. Use down arrow to
scroll through the menu’s.
Items and selections in this menu are:
1. Settings
2. Display
3. Diagnostics
4. Service
4005-10
RCPH10WHL060HAH
4005-11
Service screens
After the machine has been started or the key switch
has been turned to ON, the operator or service
technician may use the main menu to adjust machine
con figura tio ns to wor king c ond itio ns, to te st
components, view faults that may have occurred, or
to select preferences. Languages can be set at the
beginning of the menu configuration to allow the
operator to work in the language of choice.
RCPH10WHL367BAH
Engine selections
RCPH10WHL366AAH
Auto idle (Off, Low, Accelerated)
Settings
Power Mode (Max, Standard, Auto, Eco)
Selections at the setting menu include:
Engine options (fan auto, Work idle)
Engine
Auto Shutdown (optional) is used for interval settings
Transmission
Joystick steering (option will display only if machine
is joystick steering equipped).
RCPH10WHL369BAH
Transmission selections
Max gear
Min gear
POWERINCH (Optional 5-speed)
4005-12
Display Diagnostics
RCPH10WHL447AAH
Highlight the desired selection and press confirm.

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

● Clock (Hour, minute, month, day, year) The power mode allows the operator to choose the
● Backlight (Day display, day LED, night display, most effective machine power for the current job
night LED). conditions. Most commonly auto is chosen, as the
power will automatically increase or decrease
between maximum power and standard power while
the machine is working. This allows for maximum
power if necessary, but will switch to standard mode
for economy. Maximum power can be chosen for
more severe work conditions. Economy can be
chosen for limited power and fuel efficiency.
Press and hold the confirmation button for two
seconds to arrive at the service screen.
RCPH10WHL376BAH
Service
Highlight the desired selection and press confirm.
The tests in the configuration menu should be
performed only by a qualified operator or technician.
Some test require the engine to be running at high
RPM’S.
Items and selections in this menu are: RCPH10WHL372BAH
● Calibration (Park brake and pedal calibration) At the screen shown above, highlight the power
mode and press the confirmation button to move to
● Select tires (tire size) the Power Mode Selection Menu.
4005-13
Auto idle shutoff (optional)
BD06F178
At the Power Mode Menu press the confirmation RCPH10WHL375BAH
bu t t o n a g a i n t o a c t i va t e t h e s e l e c t i o n s. T h e An optional feature that allows the operator to turn

highlighted section will flash to indicate a new the economy auto engine shutdown on or off along
selection can be made. with setting the shutdown intervals (5-60 minutes) in
five minute increments. The engine and key switch
Press the up or down button to select the Power
electric power shut down when the machine is
Mode, and then press the confirmation button again.
stopped, the transmission is in neutral, and the
This changes the mode and locks it into memory.
engine is at idle. the screen will display engine
The selected mode will display in zone 3 (bottom) of shutdown in a count down of seconds. This allows
the Multi-Function Display when power mode is the operator to cancel this operation. The feature is
correctly selected. d e s i g n e d s ave f u e l a n d m a c h i n e we a r w h e n
NOTE: Selecting options and navigating through the machines are at an idling condition for a set period of
screen menus are the same for all functions. The time.
display will tell the operator if errors have occurred. In the engine protection mode, a higher level of
system protection is offered. If a warning occurs
S h o u l d a n e r r o r m e s s a g e d i s p l ay, p r e s s t h e while the machine is moving, the engine speed will
confirmation button to acknowledge and begin again. reduce to low idle (900 RPM’s) to allow continued
movement. When the machine stops, the engine will
shut down. the protection system activates if a critical
problem occurs. At the screen shown, highlight the
selection, and press the confirm key.
4005-14
Preferences Clock
RCPH10WHL358BAH RCPH10WHL363BAH
Language Screen, Measurement Units, To set hour and date, from the select screen choose
and Clock the clock designation and press the confirm key. Use
the arrow keys to show field for time and date by
The LCD screen can be set with language, units, and pressing the arrow key. When the correct time and
clock preferences. Use the arrow keys to scroll to the date have been entered by using the up and down
preferences menu. Press confirm. arrow keys (up increases numbers, down decreases
Choose the preferences desired, language in the numbers), press the confirm key to lock in correct
(English, Italian, Spanish, Portuguese, German, time. Press the escape key to return to the main
French, measurement units in English, Metric, or driving screen and lock selections into memory.
Imperial and clock units in either 12 or 24 hour).
Display backlight menu
Highlight the preference you wish to change and
press the confirm key. The preference will flash and
allow you to scroll through the choices. When the
correct preference is chosen, use the confirm key to
lock in the preference for the display. The escape key
will allow you to leave this application.
RCPH10WHL364BAH
The background and brightness of the screen can be

changed with the backlight menu. Use the arrow keys
to make the selection to suit working conditions. The
screen will change to night function illumination when
the head lamps are turned on.
RCPH10WHL361BAH
4005-15
RPM’S/Speedometer Fan auto (if equipped)
RCPH10WHL373BAH
In automatic mode, the fan speed switches between

RCPH10WHL359BAH high, low, or reverse as conditions require. This will
Speed or RPM’s can be shown on the machine as depend upon system temperatures. Scroll through
desired. Highlight the desired choice, press the selections and selection the desired fan mode.
confirm key, then the escape key to lock selection
Auto idle (if equipped)
into memory. If engine speed or RPM’s settings are
not selected, the screen will display the hourmeter.
Engine settings menu
RCPH10WHL371BAH
The auto idle feature has three settings that control

the engine low idle speed. this feature only applies
when the wheel loader is stationary, in neutral, and
not under load. The OFF setting will keep the low idle
RCPH10WHL366BAH
speed constant at the factory setting independent of
Use the arrow keys to choose the settings menu. engine or ambient temperature. The LOW setting will
Press the enter key, and the settings sub-menu will allow the low idle speed to decrease below the
appear. choose options for the fan, idle, power mode, factory setting. By reducing the low idle speed, fuel
etc. consumption will be reduced. The ACCELERATED
setting will allow the low idle speed to increase above
the factory setting. Increasing the low idle speed
helps at warm-up and can improve A/C performance.
NOTE: If the machine is shifted out of neutral, put
under any load, or if the temperature limits are not
met, the idle will default to the standard factory set
idle speed.
4005-16
Work Idle Calibrating the gear box
After warming the oil temperature:
1. Park the machine on a firm level surface.
2. Place the Transmission Control Lever in
NEUTRAL.
3. Set the Park Brake.
4. With the engine running, at idle, enter the
Service Screen and scroll to Calibration.
RCPH10WHL373BAH
The work idle feature allows the low engine idle

speed to be adjusted to a value different from the
factory set default low idle. This feature only applies
when the transmission is in gear and when the
engine speed has gone above the work idle set
speed. Setting the work low idle to a low engine
speed allows for increased machine control during
delicate work and improves fuel consumption.
Setting the work low idle to a higher engine speed
increases the responsiveness of the machine for
maximum performance. To change the work idle RCPH10WHL37BAH
setting, highlight the Eng Options selection and press Scroll to Calibration, high light and press the confirm
confirm. Select the Work idle selection and press key. always follow the prompts on the screen. Should
confirm. Increase or decrease the work idle speed an error occur, use the escape key to start over
using the arrow keys, then press confirm. Return to again.
the main driving screen by pressing the escape key.
.
NOTE: If the transmission is shifted into neutral, the
work idle feature will be deactivated.
BD06F195
This screen will prompt the operator or technican to

confirm or escape.
If, conditions are not correct, an error message will
appear. Follow the prompts.
There are six, if conditions not met errors:
● Not in neutral
● Park Brake OFF
● Machine moving
● Oil temp too low
4005-17
● Oil temp too high
● Engine RPM low
● Engine RPM high
If conditions are correct the operator or technican will
see six calibration screens pass. They will display in
this order:
● Adjust K1
● Adjust K2
● Adjust K3
● Adjust K4
● Adjust KV
● Adjust KR
● Adjust KW (5-speed only)
Once the process is completed this screen will direct
the operator or technican to shut the engine OFF and
then re-start.
If the process is not completed the operator or
technican will be prompted to escape.
4005-18
RETRIEVING FAULT CODES
General Fault Code Identification Fault Code Grouping

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

C
6. 6000 to 6999 reserved.
7. 7000 to 7999 reserved.
8. 8000 to 8999 optional equipment IE: GPS.
9. 9000 to 9999 internal AIC errors.
B D 10. 19000 to 19999 Selective Catalytic Reduction
(SCR) errors.
BD06F186
A. Escape key
B. enter key
C. up key
D. down key
2. Yellow Faults, buzzer will beep once every 2
seconds:
A. Operator can acknowledge it by pressing the
enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
D. Yellow lamp will stay ON.
E. Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer will be continuous, alternating
sounds:
A. Operator can acknowledge it by pressing the
enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.
4005-19
VEHICLE FAULT CODES
DEFINITION POSSIBLE STEPS FOR REPAIR
1310 Hydraulic filter blocked Change filter

1311 Engine air filter blocked Change filter
1312 Hydraulic oil temperature above normal 1. Stop machine operations
2. Run engine at 1500 rpm
1313 Hydraulic oil temperature to high 3. Check fan operation
1314 4. Check cooling core for clogs
Transmission oil temperature above normal
1315 Transmission oil temperature to high
1. Stop machine operations
1316 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
1317 Steering pressure too low 3. Check steering system for operation
4. Check steering system for leaks
1318 Engine coolant temperature above normal 1. Stop machine operations
1319 Engine coolant temperature high - critical 3. Check fan operation
4. Check radiator core for clogs
1320 Engine oil pressure too low 1. Stop machine operations
2. Check engine oil level
1321 Engine oil pressure below normal 3. Check pressure sender unit
1. Check engine oil for proper type
1322 Engine oil pressure above normal 2. Check pressure sender unit
1323 Battery voltage low
Check charging system
1324 Battery voltage high
1325 Oil temperature too high 2. Run engine at 1500 rpm
3. Check sending unit
1326 Coolant level low Fill radiator level
1327 Moved during accelerated idle No information available at time of print.
1328 Moving when shifting to low idle No information available at time of print
1329 WIF sensor not present No information available at time of print
Electrical charging system voltage low - 1. Stop machine operations
1331 2. Check charging system
critical level
1332 Water detected in fuel Drain fuel filter
1333 Engine overspeed Check engine speeds
1334 Intake manifold temperature high - critical Check for defective or clogged after cooler
4005-20

1335 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
1336 Transmission oil filter blocked Replace filter
1341 Sec. steering pressure too low No information available at time of print.
Check wiring, sensor installation and proper
1342 Steering pressure sensor open circuit
functioning of steering pressure sensor
1343 Sec. steering pressure sensor open circuit
functioning of sec steering pressure sensor
Open circuit, Short to battery or short to Check wiring, switch installation and proper
1812
ground at JSS armrest switch. functioning of armrest switch.
1816 Open circuit / JSS activation switch Check wiring, switch installation and proper
mechanical defect functioning of JSS activation switch.
Check wiring, installation, and proper functioning
Check JSS relay, JSS valve, JSS joystick
1820 of JSS components. See electrical schematics
power supply connections
and section 5009 for details.
Short to ground on JSS relay 85/AIC 1.21 or Check wiring, installation, and proper functioning
1821 short to power on relay 86/87a. Or activation of JSS components. See electrical schematics
switch failure and section 5009 for details.
JSS relay, ground connect., bad elec. Check wiring, installation, and proper functioning
1823 connect. Permanent ground at JSS relay (87) of JSS components. See electrical schematics
open circuit or short to power and section 5009 for details.
1824 Short to battery at activation button. Activation
of JSS components. See electrical schematics
switch failure
Open circuit between activation switch Pin 3
1830 of JSS components. See electrical schematics
and C5.E Pin 1
JSC controller, wrong operation. JSC
1831 of JSS controller. See electrical schematics and
controller internal fault
section 5009 for details.
JSC controller, JSC signal in, out of limits. of JSS components. See electrical schematics
1832 Input signal from JSS joystick to JSC and section 5009 for details. (Joystick Neutral:
controller out of limits. USignal>40%UBat+<60%Ubat;Joystick
actuated: USignal>20%UBat+<80%UBat)
Check connector of JSS valve and JSC
Output signal from JSC controller to valve out
1833 controller.
of limits.
JSS controller, JSC output, SC to BAT Power Check electrical connection for short to power. Or
1834
is applied to one of the JSC controller outputs. JSC internal relay is defective.
4005-21

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

1842 JSS valve Pin2 (alarm signal) open circuit of JSS valve. See electrical schematics and
Pilot pressure switch open when HSS is Pilot dump valve stuck close or short to power on
1843 deactivated. High pilot pressure on JSS valve valve power supply. Or open circuit on JSS pilot
even when JSS is not active. pressure switch lines or JSC/Pin8.
1844 Pilot pressure switch short to ground of pilot pressure switch. See electrical
schematics and section 5009 for details.
Error is displayed when JSS active and Pilot
Pilot pressure switch stays closed (Input pressure stays low. Pilot dump valve stuck open
JSC8+1) although JSS is activated. With low or open circuit or short to ground on JSS valve
1845
pilot pressure on JSS valve no steering with power supply (valve connector Pin4). Or short to
JSS possible. power on JSS pilot pressure switch lines or input
JSC/Pin8.
Standard steering orbit or tank pressure Check wiring, installation, and proper functioning
1846 transducer switch short to power or short to of switch. See electrical schematics and section
ground 5000 for details.
JSC Model type not available, no model type
1847 information available in JSC, probably missing No information available at time of print.
information from AIC
JSS joystick Pins2, 4, or 6 short to ground, Check wiring, installation, and proper functioning
1850 short to battery or open circuit, or JSS joystick of JSS joystick. See electrical schematics and
internal failure. section 5009 for details.
JSS joystick Pins5 open circuit, or JSS joystick
1852 of JSS joystick. See electrical schematics and
internal failure
4005-22
1860 CAN timeout of C5.E detected by JSC No information available at time of print.
1861 CAN timeout of AIC detected by JSC controller No information available at time of print.
Internal malfunction transmission controller.
1863 TCU message JSS F-N-R disabled or JSS No information available at time of print.
F-N-R not activated.
1864 Test No information available at time of print.
NOTE: The following fault codes are for optional climate controlled heating and air conditioning system.
DESCRIPTION AND POSSIBLE

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

1. Check sensor for short circuit to ground or
open circuit.
1910 Short circuit evaporator temperature sensor
2. Check harness between control module and
relay.
1. Verify if the system controls are functioning
Water valve motor output failure, does not properly when requesting heat or AC.
1919
work correctly 2. The motor is working in a degraded mode,
replace valve.
1. Turn system on with fan speed on low, verify
position of flap.
Recirculation actuator DC motor output failure, 2. Place the fan speed on high, check position of
1920
does not work correctly flap.
3. Check harness between controller and flap
motor.
1. Check for proper connection of relay.
2. Replace relay with known good relay and retest
system.
1921 AC relay output failure, does not work. 3. Verify system activation when AC button is
pressed.
4. Check charge level of AC system.
4005-23
ENGINE FAULT CODES

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

or accelerator pedal defect.
3001 Foot throttle sensor signal not plausible
Check wiring, replace idle switch or replace
accelerator pedal.
Short circuit in wiring or in accelerator pedal.
3002 Foot throttle sensor signal above range max.
Check wiring or replace accelerator pedal.
Short circuit in wiring or in accelerator pedal.
3003 Foot throttle sensor signal below range min.
Check wiring or replace accelerator pedal.
3004 Foot throttle sensor - no signal Check wiring or replace accelerator pedal
Coolant temperature sensor signal not See OTS (Oil Temperature Sensor) plausibility
3006
plausible check (Fault 3033)
Sensor defective or short circuit to external
Coolant temperature sensor signal above
3007 source.
range max.
Check wiring or replace sensor.
Coolant temperature sensor signal below Sensor defective or short circuit to ground.
3008
range min. Check wiring or replace sensor.
No CAN plausibility check performed, restart
3009 Coolant temperature sensor null (via CAN) system, if problem reoccurs.
The Engine Control Unit (ECU) generated an
error from a fault associated with the Boost
Pressure sensor. The Boost Pressure sensor is
an integrated sensing device used to sense both
temperature and pressure. This fault is related
to the temperature sensing function of the device.
Air intake temperature sensor - signal above This error could result from a signal out of range
3010
range max. or a signal that is either erratic or intermittent.
When the ECU determines that the Boost
Pressure sensor value is not valid, it will
substitute a default value of 29.96 °C (86 °F).
Cause:
The Boost Pressure sensor signal to the ECU is
out of range of the upper threshold limit.
4005-24

CODE DEFINITION
STEPS FOR REPAIR
The Engine Control Unit (ECU) generated an

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

CODE DEFINITION
STEPS FOR REPAIR
The Engine Control Unit (ECU) generated a fault

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

1. Faulty Oil temp / press sensor.
2. Faulty electrical wiring or intermittent
connection between Oil temp / press sensor and
ECU.
3. Faulty ECU, supply voltages or grounds.
3032 Oil pressure sensor pressure too high Oil pressure sensor pressure too high.
Inaccurate oil or coolant temperature sensors or
insufficient oil or coolant recirculation (low
coolant level etc.).
3033 Oil temperature sensor signal not plausible
Check oil and coolant temperature sensor for
accuracy and check oil and coolant system for
proper functioning.
3034 Oil temperature sensor signal above range
source.
max.
Oil temperature sensor signal below range Sensor defective or short circuit to ground.
3035
min. Check wiring or replace sensor.
Oil temperature sensor signal CAN
3036 system, if problem reoccurs.
transmission disturbed
3037 Boost pressure sensor signal low
Cruise control actuating device - Evaluation
error.
1. Faulty reading from component.
2. Connectors not mated fully, pins not pushed
into connector fully, bent pin or broken wire at
rear of connector.
High pressure Pump relay - Short circuit to
3047 3. Wiring or circuits open.
battery
4. Wiring or circuits shorted.
5. Connector pins corroded or dirty. When
removing connectors inspect and clean pins.
Clean female pins by installing and removing.
4005-26

CODE DEFINITION
STEPS FOR REPAIR
High pressure Pump relay - Short circuit to 1. Faulty reading from component.
3048
ground. 2. Wiring or circuits shorted.
Alternator voltage governor defect.
3051 Battery voltage to ECM too high
Replace alternator governor device or alternator.
Battery defect, alternator defect, wiring problems
(too high resistance) or ECU defect. Occurrence
3052 Battery voltage to ECM too low possible during cold start.
Replace battery or alternator. Check ECU and
wiring.
rear of connector.
3059 ECM afterrun was interrupted. 3. Wiring or circuits open.
Clean female pins by installing and removing.
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3060 Cylinder 1 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU
Cylinder 1 injector cable short-circuit low side Short circuit in wiring with external source.
3061
to battery Check the wiring or replace injector
3062 Cylinder 1 signal low
replace ECU
Defective coil of injector.
3063 Cylinder 1 short-circuit high side to low side
Check the wiring and replace injector
replace ECU
3065
3066 Check the wiring and the injection signals,

Cylinder 5 signal low
replace ECU.
Cylinder 5 injector cable short-circuit high side Defective coil of injector.
3067
to low side Check the wiring and replace injector
replace ECU
4005-27

CODE DEFINITION
STEPS FOR REPAIR
3069
replace ECU.
Defective coil of injector.
3071 Cylinder 3 short-circuit high side to low side
Check the wiring and replace injector
replace ECU
3073
replace ECU.
3075 Cylinder 6 injector cable short-circuit high side Defective coil of injector.
replace ECU
3077
3078 Check the wiring and the injection signals,

Cylinder 2 signal low
replace ECU.
3079 Cylinder 2 injector cable short-circuit high side Defective coil of injector.
replace ECU
3081
replace ECU.
Cylinder 4 injector cable short-circuit high side Defective coil of injector.
3083
Signal interrupted due to wiring problem,
defective or incorrectly installed crankshaft speed
sensor.
3088 Crankshaft sensor lost synchronization
functioning of crankshaft sensor (evaluate raw
signals)
4005-28

CODE DEFINITION
STEPS FOR REPAIR

3089 Crankshaft sensor defective functioning of crankshaft sensor (evaluate raw
signals).
defective or incorrectly installed camshaft phase
sensor.
3090 Camshaft sensor lost phase
functioning of camshaft phase sensor (evaluate
raw signals)
Camshaft sensor phase synchronization
3091 functioning of camshaft phase sensor (evaluate
failure
raw signals).
Offset between camshaft and crankshaft - Not
plausible.
defective or incorrectly installed camshaft or
Offset between camshaft and crankshaft crankshaft sensor.
3093
outside boundaries Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)
3095 Operating with camshaft sensor only functioning of crankshaft sensor (evaluated raw
signals).
3096 ECM Busoff on vehicle CAN See engine manual for details.
3097 ECM Busoff on Engine private CAN See engine manual for details.
Timeout of CAN Message TSC1-TE (when
active).
Timeout of CAN Message TSC1-TE (when
inactive).
Timeout of CAN Message TSC1 -AE (when
active).
3101 Timeout of CAN Message TSC1-AE (when

See engine manual for details.
inactive).
Short circuit of wiring to ground or defective
Rail pressure sensor CP3 signal below range pressure sensor.
3102
min. Check wiring and proper functioning of rail
pressure sensor
Defective rail pressure sensor, defect in other
injection relevant component.
3104 Rail pressure relief valve open Check rail pressure sensor for plausible values,
ensure proper functioning of the injection
components
4005-29

CODE DEFINITION
STEPS FOR REPAIR
PRV does not open once the pressure limit is

reached: Mechanical defect or wrong application
Rail pressure relief valve pressure shock
3105 parameter.
requested
Check application value of maximum rail
pressure, check functioning of the PRV
PRV does not open even after pressure shock:
3106 Rail pressure relief valve did not open after Stuck PRV or wrong application parameter.
pressure shock Check application value of maximum rail
pressure, check functioning of the PRV
Short circuit of wiring to external source or inside
Metering unit output short-circuit to battery on
3107 relay.
low side
Check wiring or replace relay
The engine control unit (ECU) has determined
that a short to low source circuit condition exists
in the fuel high pressure pump low side circuit.
The metering unit of the fuel high pressure pump
regulates the pressure in the common rail. The
metering unit is closed-loop controlled by both
main relay 1 (high side) and a low side power
stage (Main Relay 1 is an electronic control circuit
within the ECU, providing source voltage to
devices external to the ECU. The low side power
stage works in conjunction with the Main Relay 1
3108 Metering unit - short circuit to Ground. source, providing sensing and current limiting for
the circuit). The monitoring at low side is stopped
if a short circuit to ground at the high side (main
relay 1) is detected or it is switched off for some
reason. Failure detection of is only possible if the
low side power stage is switched off. With
the current settings, the monitoring is shut off
during after-run. This error is the result of the
power stage hardware report of ’short circuit to
ground’ (on the low side of the metering unit)
longer than 0.28 seconds and the power stage
has most likely switched off.
Rail pressure sensor offset monitoring signal
3110 Rail pressure sensor inaccurate.
above range max.
Ensure correct wiring and proper functioning of
3111 Rail pressure sensor offset monitoring signal rail pressure sensor, replace sensor
below range min.
Short circuit of wiring to external source or
defective pressure sensor, rail pressure
Rail pressure sensor CP3 signal above range
3112 overshoot.
max.
Check wiring and proper functioning of rail
pressure sensor
Short circuit of main relay to external source or
Main Relay 1 (High Pressure Pump) short to defective main relay.
3113
battery. Check the wiring connecting the battery to the
EDC or replace main relay
4005-30

CODE DEFINITION
STEPS FOR REPAIR
Short circuit to ground of main relay or defective

Main Relay 1 (High Pressure Pump) short to main relay.
3114
GND. Check the wiring connecting the battery to the
EDC or replace main relay
3118 ECM 12V sensor supply voltage high Ambient pressure sensor inside ECU is defective.
Replace ECU (not necessary if never running in
3119 ECM 12V sensor supply voltage low high altitude and if turbocharger without VGT)
Short circuit to ground of grid heater.
3131 Grid heater always switched on
Check grid heater switch and replace it
3133 Cold start lamp - No load See engine manual for details.
3134 Cold start lamp - Short circuit to battery See engine manual for details.
3135 Cold start lamp - Short circuit to ground. See engine manual for details.
3136 Cold start lamp - Excessive temperature. See engine manual for details.
Broken or disconnected wiring or defective relay.
3137 Metering unit open load
Check of wiring or replace relay
Defective wiring, ECU, power stage or metering
unit.
3138 Metering unit signal not plausible
Check wiring, ECU, power stage and metering
unit
High pressure system: Rail pressure sensor
inaccurate, high pressure pump defective.
Set point of fuel volume flow through metering
3141 Low pressure system: Metering unit reflux too
unit is lower than calculated limit
low.
Check for defects according to failure list.
The engine control unit (ECU) has acknowledged
that the ’High Pressure Test’ is running. The ’High
Pressure Test’ is a test procedure used to
evaluate the performance of the fuel high
pressure unit (pump, rail pressure control valve,
etc.) and is executed via a diagnostic tester
3142 High pressure test - Test active
request. If this test is running the rail pressure
monitoring has to be deactivated, which is done
by setting this fault path. Therefore, this failure
path is used more for information purposes
and inhibit handling than as an actual error
status.
4005-31

CODE DEFINITION
STEPS FOR REPAIR
NOTICE: Fault Code 3145 is stored historical

information. For multiple occurrences of this fault
proceed with the following tests.
NOTE: See engine repair manual for electrical
schematic information. When available use special
tool 380040185 harness diagnostic/repair kit.
Cause:
3145 Terminal 15 - No signal
rear of connector.
3. Wiring or circuits open.
5. Connector pins corroded or dirty.
Oil temperature sensor signal above normal Check oil temperature sensor for accuracy and
3147
range check oil system.
Coolant temperature sensor dynamic test -
3148 Failure (Minimum temperature raise not See engine manual for details.
reached).
3154 Grid heater relay short-circuit to battery relay.
Short circuit of wiring to ground or inside relay.
3155 Grid heater relay short-circuit to ground
3156 Grid heater relay no load
Engine dataset information was not available
from EDC in required time
Engine dataset does not match dataset
registered for this machine
3160 Fan actuator - Short circuit to battery See engine manual for details.
3161 Fan actuator signal low See engine manual for details.
3162 Fan actuator - Open load See engine manual for details.
3163 Fan actuator - Temperature too high See engine manual for details.
3166 Fuel filter heater relay - Short circuit to battery See engine manual for details.
3167 Fuel filter heater relay - Short circuit to ground. See engine manual for details.
3168 Fuel filter heater relay - Open load. See engine manual for details.
3169 Fuel filter heater relay - Signal not plausible. See engine manual for details.
4005-32

CODE DEFINITION
STEPS FOR REPAIR
High pressure system: Leakage in the high

pressure section, injection nozzle stuck in open
position, worn or defective high pressure pump,
Fuel delivery exceeded threshold for pressure worn injector, leaking pressure relieve valve.
3176
in overrun mode Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering
unit).
Check for defects according to failure list.
The Engine Control Unit (ECU) has detected an
engine over-speed condition. An engine
over-speed can occur both during certain engine
operating conditions without any defect in a
component, for example downhill driving, or as a
result of, for example another ECU error. This
error is for information purposes and is initiated
by engine speed in excess of 2800 RPM for over
5 seconds and is reset once the engine speed is
3177 Engine overspeed detected.
below the threshold for over 2 seconds.
Though this error by itself does not require any
action, the over-speed state can cause an
injection shutoff request within the ECU. If this
error reoccurs frequently, check driving
conditions of the vehicle, engine speed
acquisition and injection system for quantity
set-point and actual value during fault
recognition, check also for other ECU errors.
Defective CAN controller of Body Computer,
3178 Time-out of CAN message BC2EDC1 undervoltage of BC, missing BC, CAN cable
connecting the BC is disconnected or broken.
Short circuit in wiring. Check presence and
correct connection of the BC to the network,
3179 Time-out of CAN message BC2EDC2 Check correct functioning of the BC CAN
controller and its voltage supply. Check wiring.
Defective CAN controller of Vehicle Control
Module, undervoltage of VCM, missing VCM,
CAN cable connecting the VCM is disconnected
or broken. Short circuit in wiring. Check presence
3180 Time-out of CAN message VCM2EDC
and correct connection of the VCM to the
network, Check correct functioning of the VCM
CAN controller and its voltage supply. Check
wiring.
Rail pressure positive deviation too high
concerning setpoint.
3182 Timeout of CAN Message RXCCVS See engine manual for details.
Timeout of CAN Message TSC1-VR (when
active)
3184 Timeout of CAN Message TXC1-VR (when

inactive)
3185 Timeout of CAN message TF See engine manual for details.
4005-33

CODE DEFINITION
STEPS FOR REPAIR
3188 Cylinder 1 open load

3196 Cylinder 3 open load Broken wire or disconnection of wiring or inside
injector.
3200 Cylinder 4 open load Check the wiring or replace injector.
Short circuit of high-side to battery or ground.
3210 Bank 1 general short-circuit on injection cable
Check the wiring or replace injector.
Short circuit of low-side to ground in injector
Bank 1 injection cable short-circuit low side to
3211 cable.
ground
3212 Bank 1 no signal See engine manual for details.
cause the defect, internal ECU problem.
3213 Bank 1 unclassified error
replace ECU
Short circuit of high-side to battery or ground.
3218 Bank 2 general short-circuit on injection cable
Short circuit of low-side to ground in injector
Bank 2 injection cable short-circuit low side to
3219 cable.
ground
3220 Bank 2 no signal See engine manual for details.
cause the defect, internal ECU problem.
3221 Bank 2 unclassified error
replace ECU
Clock error or interruption of the power supply
voltage.
3227 Injection processor error - stop engine
Check the power supply or replace ECU if
problem reoccurs.
Defective ECU, reset ECU.
If no recovery, replace ECU.
Internal failure of ECU or 'TESTMODE' takes too
3229 long.
Injection processor error - stop engine
Check 'TESTMODE' parameters or replace ECU
if problem reoccurs
Defective SPI-bus participant, timing problem
due to software bug.
Replace ECU if problem reoccurs (Send in ECU
for investigation)
4005-34

CODE DEFINITION
STEPS FOR REPAIR

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

Electric disturbances, internal defect of the ECU
3238 Communication error of CJ940 processor leading to a SPI bus communication error.
Replace ECU if failure remains present
The engine control unit (ECU) has detected an
error during the last EEPROM read operation.
The hardware encapsulation of the ECU checks
each data block of the EEPROM and sets a status
flag depending on if an error is found or not found.
These flags are processed every 20 milliseconds
by the Diagnostic System Management (DSM)
3239 ECM EEPROM - Read operation failure and depending on their value a failure or no
failure is detected. If a failure is detected this
error sets and should reset immediately if the
EEPROM operates correctly. This failure can be
the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU
correctly with the proper data set. If the error
persists, replace the ECU.
error during the last EEPROM write operation.
The hardware encapsulation of the ECU checks
each data block of the EEPROM and sets a status
flag depending on if an error is found or not found.
These flags are processed every 20 milliseconds
by the Diagnostic System Management (DSM)
3240 ECM EEPROM - Write operation failure and depending on their value a failure or no
failure is detected. If a failure is detected this
error sets and should reset immediately if the
EEPROM operates correctly. This failure can be
the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU
correctly with the proper data set. If the error
persists, replace the ECU.
4005-35

CODE DEFINITION
STEPS FOR REPAIR
The engine control unit (ECU) has detected that

substitute values for the EEPROM values are
used. This happens if a checksum error (CRC) is
registered during reading. The hardware
encapsulation of the ECU checks each data block
of the EEPROM and sets a status flag depending
on if an error is found or not found. These flags
are processed every 20 milliseconds by the
3241 ECM EEPROM - Default value used Diagnostic System Management (DSM) and
depending on their value a failure or no failure
is detected. If a failure is detected this error sets
and should reset immediately if the EEPROM
operates correctly. This failure can be the result
of wrong programming / flashing of the ECU or an
internal defect. Try to flash the ECU correctly with
the proper data set. If the error persists, replace
the ECU.
3242 Recovery which is locked Electronic disturbances, various hardware
defects (ECU internal) or configuration problems.
3243 Recovery which is suppressed
Analyze what error triggered the recovery (Read
out label HWEMon_numRecovery and compare
the value with the according table). If error occurs
3244 Recovery which is visible
repeatedly, reprogram EDC. If error remains,
replace EDC.
Defective monitoring module or CPU (e.g.
impaired functioning of the CPU clock) of the
EDC. Disturbed SPI-Bus.
Communication supervision watchdog control If error exists only temporary (i.e. injection
3245
flag reoccurs) error can be ignored and error deleted
in the fault memory. In case of a permanent error
the injection remains blocked and the ECU has to
be replaced
Watch dog switch off path defect.
3246 Redundant shutoff paths during initial If failure remains after ECU initialization: replace
ECU
3247 Redundant shutoff paths during initial Electronic disturbances, internal ECU problem.
If failure remains after ECU initialization: replace
3248 Redundant shutoff paths during initial ECU
4005-36

CODE DEFINITION
STEPS FOR REPAIR
The engine control unit (ECU) has detected that

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

CODE DEFINITION
STEPS FOR REPAIR
3253 Error status ADC monitoring

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

Short-circuit to battery at high side power
3258 relay.
stage
Short-circuit to ground at high side power Short circuit of wiring to ground or inside relay.
3259
stage Check of wiring or replace relay
3260 Open load at low side power stage
Short-circuit to battery or excessive
3261 relay.
temperature at low side power stage
Short circuit of wiring to ground or inside relay.
3262 Short-circuit to ground at low side power stage
Electronic disturbances, requested torque
increase via tester, wrong application of injection
3265 Energizing time exceeds limit of over run
relevant parameters, defective ECU.
monitoring
Check injection relevant application, if failure
persists replace ECU
Electronic disturbances, internal ECU problem.
3266 Plausibility error in engine speed check
If failure persists after reinstallation replace ECU
3267 Main relay 3 - Short circuit to battery See engine manual for details.
3268 Main relay 3 - Short circuit to ground See engine manual for details.
Excessive voltage supply of a CJ940 component:
High battery voltage, defective wiring, internal
defect of the EDC.
3278 Supply voltage CJ940 upper limit
Check the battery for correct voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Insufficient voltage supply of a CJ940
component: Low battery voltage, defective wiring,
internal defect of the EDC.
3279 Supply voltage CJ940 lower limit
Check the battery for sufficient voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3280 Sensor supply voltage 1 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
4005-38

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

harness, electrical failure connected sensors or
in the EDC.
3281 Sensor supply voltage 1 low
replace EDC
or in the EDC.
replace EDC
in the EDC.
replace EDC
or in the EDC.
replace EDC
in the EDC.
replace EDC
3290 Turbo compound monitoring signal not

plausible
Rail pressure governor deviation exceeded
max limit with fuel delivery quantity on limit.
min limit with fuel delivery quantity on limit.
Rail pressure governor deviation below min
limit for speed
max limit
Rail pressure drop rate is higher than
expected.
Minimum number of injections not reached -
stop engine.
4005-39

CODE DEFINITION
STEPS FOR REPAIR
The engine control unit (ECU) has determined

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

3318 stop engine. See engine manual for details.
DM1DCU SPN2 message - Error in DCU

active.
active.
active.
active.
CAN Data Link communications from the ECU
have been lost.
Cause:
have been lost. This fault code will be displayed
with other CAN Data Link fault messages. The
engine may go into Limp Home Mode and engine
speed will be set to 1500 RPM.
Timeout of CAN message TSC1-PE Torque
3334
(when active).
1. Connectors not mated fully, pins not fully
seated in connector, bent pin or broken wire at
rear of connector.
4. Faulty Instrument Cluster
5. Faulty ECU
4005-40

CODE DEFINITION
STEPS FOR REPAIR
Timeout of CAN message TSC1-PE Torque

(when inactive).
Timeout of CAN message TSC1-VE Torque
(when inactive).
have been lost.
Cause:
have been lost. This fault code will be displayed
with other CAN Data Link fault messages. The
engine may go into Limp Home Mode and engine
speed will be set to 1500 RPM.
Timeout of CAN message TSC1-VE Torque
3339
(when active).
1. Connectors not mated fully, pins not fully
seated in connector, bent pin or broken wire at
rear of connector.
4. Faulty Instrument Cluster
5. Faulty ECU
NOTICE: Replace Starter Relay and test system
before proceeding.
schematic information.
Cause:
3350 Terminal 50 - Always On
rear of connector.
Clean female pins by installing
and removing.
Main Relay 4 (Engine brake exhaust valve) -
Short circuit to ground.
Main Relay 4 (Engine brake exhaust valve) -
Short circuit to battery or open load.
3358 CAN Transmit timeout See engine manual for details.
Atmospheric pressure sensor - signal not schematic information.
3363
plausible. Cause:
1. ECU internal error
3367 Coolant temperature test failure. See engine manual for details.
4005-41

CODE DEFINITION
STEPS FOR REPAIR
Info: Torque limitation due to OBD

performance limiter by legislation.
3369 Torque reduction due to smoke limitation. See engine manual for details.
Info: Torque limitation due to engine protection
3370 (against excessive torque, Engine overspeed See engine manual for details.
and overheat)
Info: Torque limitation due to fuel quantity
limitation because of injection system errors.
3512 DCU State monitoring - DCU not ready in time See engine manual for details.
SCR catalyst not present - Relation of
3513 temperature behavior between both catalyst See engine/SCR manual for details.
temperatures not plausible
Ambient air temperature sensor failure (of
3517 See engine/SCR manual for details.
humidity sensor) - Signal too high
Ambient air temperature sensor failure (of
humidity sensor) - Signal too low
NOX estimation failure - Estimated NOX signal
not reliable.
NOX sensor plausibility failure - signal not
plausible
3529 NOX sensor failure - Open load See engine/SCR manual for details.
3530 NOX sensor failure - Short circuit See engine/SCR manual for details.
3532 NOX sensor failure - Sensor not ready in time See engine/SCR manual for details.
CAN message timeout NOX (from NOX
sensor) - CAN timeout
3537 Message DM1DCU timeout See engine/SCR manual for details.
3541 Message SCR1 timeout See engine/SCR manual for details.
Info: SCR Dosing valve overheat protection -
3545 Torque limitation level2 for SCR protection See engine/SCR manual for details.
active
Info: SCR Dosing valve overheat protection -
3546 Torque limitation level1 for SCR protection See engine/SCR manual for details.
active
Humidity sensor signal ratio failure - Signal
ratio above limit
Humidity sensor signal ratio failure - Signal
ratio below limit
CAN message timeout SCR2 (from DCU) -
CAN timeout
Info: Humidity sensor possibly saturated with
water droplets - Signal ratio above limit
4005-42

CODE DEFINITION
STEPS FOR REPAIR
Info: Humidity sensor possibly saturated with

water droplets - Signal ratio below limit
NOX value not plausible (After treatment
plausibility)
3577 DM1DCU SPN1 message- Error in DCU active See engine/SCR manual for details.
Performance limit active due to either stage -
Performance limitation active
3585 Engine shut off (after idling phase) See engine/SCR manual for details.
Plausibility check of catalyst system -
Temperature after catalyst not plausible
Temperature before catalyst not plausible
Plausibility check of catalyst system - Ambient
3588 temperature of humidity sensor or both See engine/SCR manual for details.
catalyst temperatures not plausible
Temperature deviation between up and
downstream catalyst temperature too high
during operation
SCR Catalyst thermal ageing limit exceeded -
Main catalyst efficiency below threshold
3593 Poor reagent quality See engine/SCR manual for details.
3594 Indicates torque limitation due to SCR See engine/SCR manual for details.
3599 Error path of oxidation catalyst not present:

See engine/SCR manual for details.
Warm up catalyst efficiency below threshold
3602 Defect ratio between threshold limits - Catalyst

See engine/SCR manual for details.
temperature sensor circuit
Catalyst efficiency lower than first NOX
prediction threshold level
Catalyst efficiency lower than second NOX
prediction threshold level
3613 Too high efficiency of catalyst system See engine/SCR manual for details.
3614 SRA2EDC high effort fault See engine/SCR manual for details.
3615 SRA2EDC initialization fault See engine/SCR manual for details.
Torque limitation due to turbo charger
protection
4005-43
TRANSMISSION FAULT CODES
CODE DEFINITION POSSIBLE STEPS FOR REPAIR
1. Check the cables from the TCU to the FNR

switch.
4113 Logical error at Gear Range Signal 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch.
switch.
4114 Logical error at direction select signal 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.
1. Check the cables from the TCU to the
4116 Logic error at park brake status instrument cluster connector 2 pin 6.
2. Check park brake switch.
switch.
4117 Logic error at direction select signal 2 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.
4119 Short circuit to ground at ride control 1. Check the cables from the TCU to the ride
control relay.
4120 Short circuit to battery voltage at ride control 2. Check the connectors from the TCU to the ride
control relay.
4121 Open circuit at ride control 3. Check the ride control relay.
1. Check the cable from TCU to brake light
2. Check the connectors from brake light device to
4122 Short circuit to ground at brake light 1 TCU
3. Check the resistance of brake light
4123 Short circuit to battery voltage at brake light 1 TCU
4124 Open circuit at brake light 1 TCU
4125 Short circuit to ground at brake light 2 TCU
4126 Short circuit to battery voltage at brake light 2 TCU
4127 Open circuit at brake light 2 TCU
4005-44
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4133 at transmission sump temperature sensor 2. Check the connectors.
input 3. Check the temperature sensor.
Short circuit to ground at transmission sump

4134
temperature sensor input
4135 at retarder/torque converter temperature 2. Check the connectors.
sensor input 3. Check the temperature sensor.
4136 Short circuit to ground at retarder/torque

converter output temperature sensor input
1. Check the cables from TCU to the sensor.
Short circuit to battery voltage or open circuit 2. Check the connectors.
4137
at parking brake sensor input 3. Check the parking brake sensor.
4138 Inchsensor - Signal mismatch 2. Check the connectors.
3. Check the sensor.
Short circuit to battery voltage or open circuit 1. Check the parking brake fuse.
4145
at engine speed input 2. Check the parking brake relay.
4146 3. Check the parking brake solenoid.
Short circuit to ground at engine speed input
2. Check the connectors.
3. Check the speed sensor.
4147 Logical error at engine speed input
NOTE: This fault code is reset after power up of the
TCU. It is also reset if the signal is above zero
speed threshold.
4148
at turbine speed input 2. Check the connectors.
4149 3. Check the speed sensor.
Short circuit to ground at turbine speed input
4150 Logical error at turbine speed input 3. Check the speed sensor.
TCU.
Short circuit to battery voltage or open circuit
4151 1. Check the cables from TCU to the sensor.
at intermediate speed input
Short circuit to ground at intermediate speed 3. Check the speed sensor.
4152
input
4153 Logical error at intermediate speed input 3. Check the speed sensor.
TCU.
4005-45
4154
at output speed input 2. Check the connectors.
4155 3. Check the speed sensor.
Short circuit to ground at output speed input
4156 Logical error at output speed input 3. Check the speed sensor.
TCU.
1. Check the sensor signal of the output speed
sensor.
2. Check the connector connected to the output
Output speed zero, doesn’t fit to other speed speed.
4158
signals. 3. Check the cable from the TCU to the sensor.
TCU.
1. Check the cluster controller.
4180 Vehicle controller time-out (CAN) 2. Check wire of CAN-Bus
3. Check the cable to the cluster controller
1. Check Joystick steering controller.
4181 JSS timeout 2. Check wire of CAN-Bus.
3. Check cable to Joystick steering controller.
1. Check engine controller
4182 Engine CONF timeout 2. Check wire of CAN-Bus
3. Check cable to engine controller
1. Check EEC controller
4183 EEC1 timeout 2. Check wire of CAN-Bus
3. Check cable to EEC controller
1. Check the cluster controller.
4185 Invalid test mode signal (CAN) 2. Check wire of CAN-Bus
3. Check the cable to the cluster controller
1. Check I/O controller
4193 AEB Request signal 2. Check wire of CAN-Bus
3. Check cable to I/O controller
4197 Engine torque signal 2. Check wire of CAN-Bus
4201 Reference engine torque signal 2. Check wire of CAN-Bus
4202 Actual engine torque signal 2. Check wire of CAN-Bus
4203 NOM friction torque signal 2. Check wire of CAN-Bus
4005-46
1. Check EEC timeout

1. Check the cable from TCU to the gearbox
2. Check the connectors from TCU to the gearbox
4209 Short circuit to battery voltage at clutch K1 3. Check the regulator resistance
4. Check internal wire harness of the gearbox
4210 Short circuit to ground at clutch K1 3. Check the regulator resistance
4211 Open circuit at clutch K1 3. Check the regulator resistance
Short circuit to battery voltage at converter 1. Check the cable from TCU to the valve
4218 2. Check the regulator resistance
clutch.
1. Check the cable from TCU to the valve
4219 Short circuit to ground at converter clutch 2. Check the regulator resistance
4220 Open circuit at converter clutch 2. Check the regulator resistance
2. Check the connectors from gearbox to TCU
4005-47

4228 Short circuit to battery voltage at clutch KV 3. Check the regulator resistance
4229 Short circuit to ground at clutch KV 3. Check the regulator resistance
4230 Open circuit at clutch KV 3. Check the regulator resistance
4231 Short circuit to battery voltage at clutch KR 3. Check the regulator resistance
4232 Short circuit to ground at clutch KR 3. Check the regulator resistance
4233 Open circuit at clutch KR 3. Check the regulator resistance
Short circuit to ground at DLM transversal 2. Check the connectors
4234
output 3. Check the resistance of valve
Short circuit to battery voltage at DLM 2. Check the connectors
4235
transversal output 3. Check the resistance of valve
4236 Open circuit at DLM transversal output 2. Check the connectors
3. Check the resistance of valve
Short circuit to ground at relay reverse warning 1. Check the cable from the TCU to the backup.
4241
alarm alarm relay.
2. Check the connectors from the backup alarm
Short circuit to battery voltage at relay reverse relay to TCU.
4242
warning alarm 3. Check the resistance of backup alarm relay
4243 Open circuit at relay reverse warning alarm circuit.
4005-48
1. Check pressure at clutch K1.

2. Check main pressure in the system.
4273 Slippage at clutch K1 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
5. Replace clutch.
5. Replace clutch.
5. Replace clutch.
1. Check pressure at clutch KV.
4277 Slippage at clutch KV 3. Check signal at internal speed sensor.
5. Replace clutch.
1. Check pressure at clutch KR.
4278 Slippage at clutch KR 3. Check signal at internal speed sensor.
5. Replace clutch.
1. A critical stop function warning has occurred.
2. Red stop indicator comes on and continuous
buzzer sounds.
3. Stop machine and perform required service on
4279 Overtemp SUMP the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
4281 Overspeed Engine Check engine speed sensor
1. Check oil filter.
2. Check wiring from TCU to filter maintenance
4282 Differential Pressure Oil Filter switch.
3. Check filter maintenance switch (measure
resistance).
4005-49
1. Check pressure at converter lockup clutch

2. Check main pressure in the system
3. Check sensor gap at engine speed sensor
4283 Slippage at converter lockup clutch 4. Check sensor gap at turbine speed sensor
5. Check signal at engine speed sensor
6. Check signal at turbine speed sensor
7. Replace clutch
4284 Overspeed output No information available at time of print.
4288 Engine torque or engine power overload No information available at time of print.
4289 Transmission output torque overload No information available at time of print.
4290 Transmission input torque overload No information available at time of print.
1. A critical stop function warning has occurred.
2. Red stop indicator comes on and continuous
buzzer sounds.
3. Stop machine and perform required service on
4291 Overtemp converter output the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
1. Check the cables from the TCU to the joystick.
Short circuit to ground at joystick status 2. Check the connectors from the TCU to the
4292
indicator. joystick.
3. Check the resistance of the joystick.
Short circuit to battery voltage at joystick 2. Check the connectors from the TCU to the
4293
status indicator joystick.
2. Check the connectors from the TCU to the
4294 Over current at joystick status indicator joystick.
4298 Engine retarter config timeout 2. Check wire of CAN-Bus
4299 ERC1 timeout 2. Check wire of CAN-Bus
Short circuit to battery voltage at power supply 1. Check the cables from the sensors TCU.
4305 2. Check the connectors from the sensors to the
for sensors.
TCU.
Short circuit to ground at power supply for
4306
sensors.
4307 Low voltage at battery 1. Check batteries.
2. Check B+ wires from batteries to TCU.
4308 High voltage at battery 3. Check voltage at TCU connector pin 45.
4309 Error at VPS 1 for solenoid power supply 1. Check fuse A2.
2. Check cable from control valve to TCU.
4310 3. Check connectors from control valve to TCU.
Error at VPS 2 for solenoid power supply
4. Replace TCU.
4005-50
1. Check the cable from TCU to the display

Short circuit to battery voltage at display 2. Check the connectors at the display
4323
output. 3. Change display
1. Check the cable from TCU to the display
4324 Short circuit to ground at display output 2. Check the connectors at the display
3. Change display
1. Check display controller
4325 Vehicle ID #1 time out 2. Check wire of CAN-Bus
3. Check cable to display controller
4326 Illegal ID request via CAN. No information available at time of print.
4337 General EEPROM fault Replace the TCU.
Reprogram the correct configuration for the
4338 Configuration lost
vehicle.
4339 Application error Replace the TCU.
4341 Clutch failure during AEB
Clutch adjustment data lost or inchpedal Do the transmission clutch calibration procedure.
4342
calibration data lost
4005-51
INSTRUMENT CLUSTER FAULT CODES

CODE DEFINITION
STEPS FOR REPAIR
9100 CreateMbx 20ms DM1 BAM No information available at time of print.

9101 AddMsg DM1 BAM No information available at time of print.
9102 AddMsg DM1 PCK No information available at time of print.
9103 Timeout Packet No information available at time of print.
9104 Missed a Packet No information available at time of print.
9105 CreateMbx 20ms DM1 Packets No information available at time of print.
9106 InitCAN, check diagmsg No information available at time of print.
9110 Error Index out of range in set error No information available at time of print.
9111 Null error, not permitted No information available at time of print.
9121 Logical error when retrieving flash data No information available at time of print.
9125 Never started receiving message No information available at time of print.
9128 CAN timed out during operation 1. CAN communication interrupted during normal
operation.
9129 CAN timed out during operation 2. Faulty reading from component.
3. Connectors not mated fully, pins not pushed into
connector fully, bent pin or broken wire at rear of
9130 CAN timed out during operation connector.
9131 CAN timed out during operation No information available at time of print.
9132 CAN timed out during operation No information available at time of print.
CAN timed out during operation C5.E detected
9134 No information available at time of print.
by AIC
CAN timed out during operation JSC detected
by AIC
9136 CAN time out speed limit module C5F No information available at time of print.
9138 HW Part number unknown in SW No information available at time of print.
4005-52

CODE DEFINITION
STEPS FOR REPAIR
9140 LogicalError in list0 No information available at time of print.

9141 LogicalError in list1 No information available at time of print.
9142 Logical Error in list2 No information available at time of print.
9151 Logical Error when retrieving flash data No information available at time of print.
1. CAN communication interrupted during normal
operation.
3. Connectors not mated fully, pins not pushed into
9160 HourMeter Failure - Both copies are wrong connector fully, bent pin or broken wire at rear of
connector.
operation.
HourMeter Failure - One of two copies are 3. Connectors not mated fully, pins not pushed into
9161
wrong connector fully, bent pin or broken wire at rear of
connector.
operation.
HourMeter Failure - Pre-crank and after-crank 3. Connectors not mated fully, pins not pushed into
9162
check are wrong connector fully, bent pin or broken wire at rear of
connector.
9173 SCR controller CAN timeout No information available at time of print.
9174 SCR controller CAN did not start No information available at time of print.
9175 CreateMbx 20ms DM1 BAM (SCR controller) No information available at time of print.
4005-53

CODE DEFINITION
STEPS FOR REPAIR
9176 AddMsg DM1 BAM (SCR controller) No information available at time of print.
9177 AddMsg DM1 PCK (SCR controller) No information available at time of print.
9178 TimeOut Packet (SCR controller) No information available at time of print.
CreateMbx 20ms DM1 Packets (SCR
controller)
9180 VCM controller CAN timeout No information available at time of print.
9181 VCM controller CAN did not start No information available at time of print.
Wheel Loader Configuration Plausibility
Failure - Wrong engine type
4005-54
SELECTIVE CATALYTIC REDUCTION (SCR) FAULT CODES

CODE DEFINITION
STEPS FOR REPAIR
1. Faulty electrical wiring or connections
19001 Battery voltage evaluation - Above upper limit 2. Faulty DCU
19002 Battery voltage evaluation - Below lower limit 2. Faulty DCU
The selective catalytic reduction (SCR) controller
has detected a high voltage condition in the
voltage supply circuit. The fault becomes active
when the supply voltage is greater than 36.738 V
for at least 0.3 s. The code will heal if the supply
voltage returns to less than 36.738 V for 0.8 s.
Battery voltage sensing (electrical) - Above Cause:
19003
upper limit. The supply voltage to the SCR controller is
greater than 36.738 V.
2. Faulty Power converter
3. Faulty SCR controller
has detected a low voltage condition in the
voltage supply circuit. The fault becomes active
when the supply voltage is less than 13.143 V for
at least 0.3 s. The code will heal if the supply
voltage returns to greater than 13.143 V for 0.8 s.
Battery voltage sensing (electrical) - Below Cause:
19004
lower limit The supply voltage to the SCR controller is less
than 13.143 V (13.143 V).
2. Faulty Power converter
3. Faulty SCR controller
1. Faulty sensor
Catalyst temperature sensor circuit high - After 2. Faulty electrical wiring or connection
19010
catalyst 3. Faulty denox module
1. Faulty sensor
Catalyst temperature sensor circuit low - After 2. Faulty electrical wiring or connection
19011
catalyst 3. Faulty denox module
1. Faulty sensor
Catalyst temperature sensor circuit high - 2. Faulty electrical wiring or connection
19019
Before catalyst 3. Faulty denox module
1. Faulty sensor
Catalyst temperature sensor circuit low - 2. Faulty electrical wiring or connection
19020
Before catalyst 3. Faulty denox module/supply module
Temperature sensor before catalyst
(electrical) - signal above high error threshold
Temperature sensor before catalyst
(electrical) - signal below low error threshold
4005-55

CODE DEFINITION
STEPS FOR REPAIR
The denox module/supply module has detected a

high supply voltage for urea pressure sensors,
located inside the denox module/supply module.
Reagent - pressure sensor - Short circuit high
19037 Attempt to clear the code. If this code reoccurs,
(high supply voltage)
there is a problem with the supply voltage internal
to denox module/supply module. Replace the
denox module/supply module.
high supply voltage for urea pressure sensors,
located inside the denox module/supply module.
Reagent - pressure sensor - Short circuit low
19038 Attempt to clear the code. If this code reoccurs,
(low supply voltage)
there is a problem with the supply voltage internal
to denox module/supply module. Replace the
denox module/supply module
failure of the urea pressure sensor, located inside
the denox module. This error occurs when the
sensor signal level has reached its internal limit.
This error is corrected if sensor returns to its
19046 Reagent - pressure sensor - Open circuit
normal output. Ensure all connectors are secured
properly on the denox module/supply module and
all lines are in operable condition. If the fault does
not reset or reoccurs, replace the denox
module/supply module.
the denox module. The sensor signal level is
19047 Reagent - pressure sensor - Short circuit high above 5.0 V for over 700 ms. This fault will reset
(signal high) if the raw signal level goes below 5.0 V for over
1000 ms. Attempt to clear the code. If this code
reoccurs, the sensor is defective and the denox
module should be replaced.
the denox module. This error occurs when the
sensor signal level is below 0.152 V for over 700
Reagent - pressure sensor - Short circuit low ms. This error is corrected if sensor returns to
19048
(signal low) normal output for greater than 1.0 s. Ensure all
connectors are secured properly on the denox
module and all lines are in operable condition. If
the fault does not reset or reoccurs, replace the
denox module.
failure of the urea temperature sensor, located
inside the denox module. The sensor signal level
Reagent - temperature sensor of pump
19055 is above 5.0 V for over 700 ms. This fault will
module - Short circuit high
reset if the raw signal level goes below 5.0 V for
over 1000 ms. If the sensor is defective the denox
module should be replaced.
4005-56

CODE DEFINITION
STEPS FOR REPAIR

failure of the urea temperature sensor, located
inside the denox module. This error occurs when
the sensor signal level is below 0.283 V for over
Reagent - temperature sensor of pump 700 ms. This error is corrected if sensor returns
19056
module - Short circuit low to normal output for greater than 1.0 s. Ensure all
module and all lines are in operable condition. If
denox module.
UREA Temperature sensor in box (electrical) -
signal above high error threshold Out of range
UREA Temperature sensor in box (electrical) -
signal below low error threshold Out of range
The denox module/supply module has sensed a
fault with the voltage supply for the internal
heaters, located in the supply module. Ensure all
19064 Voltage supply internal heaters 1 (UB1)
electrical - Internal heating Open circuit
module/supply module and all lines are in
operable condition. If the fault does not reset or
reoccurs, replace the supply module.
heaters, located in the supply module. Ensure all
19065 Pump module - Internal heating - Short circuit
high
heaters, located in the denox module/supply
Voltage supply 2 - tube heaters (UB2) module. Ensure all connectors are secured
19073
electrical - Short circuit high properly on the denox module/supply module and
Voltage supply 2 - tube heaters (UB2) module. Ensure all connectors are secured
19074
electrical - Short circuit low properly on the denox module/supply module and
4005-57

CODE DEFINITION
STEPS FOR REPAIR

module. Ensure all connectors are secured
19075 Reagent - suction tube heating - open circuit properly on the denox module/supply module and

fault with the voltage supply for the coolant
control valve and the reverting valve, located in
the denox module/supply module. Ensure all
Vent valve (Reductant purge control valve) -
19082 connectors are secured properly on the denox
Short circuit high
reoccurs, replace the denox module/supply
module.
fault with the voltage supply for the coolant
control valve and the reverting valve, located in
the denox module/supply module. Ensure all
Voltage supply 3 - Coolant control valve and
19083 reverting.valve (UB3) electrical - Short circuit
low
reoccurs, replace the denox module/supply
module.
If this error has occurred, there is a failure in

denox module/supply module. Ensure all
Vent valve (Reductant purge control valve) - connectors are ensured properly on the denox
19084
Short circuit low module/supply module and all lines are in
operable condition. If fault does not reset or
reoccurs, replace denox module/supply module.
12 Volt supply for dosing module - Above 1. Problem with battery or charging system
19091 2. Denox module/supply module internal failure.
upper limit
12 Volt supply for dosing module - Below lower 1. Problem with battery or charging system
19092 2. Denox module/supply module internal failure.
limit
19093 Dosing valve/Pump motor - Above upper limit No information available at time of print.
19094 Dosing valve/Pump motor - Below lower limit. No information available at time of print.
The dosing control unit (DCU) has detected a
failure of the Internal level sensor, located inside
the DCU. This error occurs when there is a short
UREA level sensor (electrical) - supply voltage circuit or broken supply wire inside the denox
19100
error. module/supply module. Ensure all connectors are
secured properly on the DCU and all lines are in
reoccurs, replace the DCU.
4005-58

CODE DEFINITION
STEPS FOR REPAIR
The dosing control unit has sensed the level of

AdBlue™/Def drops below a predetermined level.
If the signal is higher than 4.7 V for 0.5 s.
Cause:
There is an short circuit in the AdBlue™/Def level
19101 Reagent - tank level sensor - Short circuit high sensor circuit.
1. Faulty Sensor.
2. Faulty electrical wiring or connection.
3. Faulty DCU.
The Dosing Control Unit (DCU) has sensed the
level of AdBlue™/Def has dropped below a
predetermined level. If the signal is lower than 0.2
V for 0.5 s this error will occur.
Cause:
19102 Reagent - tank level sensor - Short circuit low There is an short to ground in the AdBlue™/Def
level sensor circuit.
1. Faulty sensor.
3. Faulty DCU.
Reagent - tank temperature sensor 1. Faulty wiring
19109 (temperature of the reagent - solution in the 2. DEF/AdBlue® tank temperature sensor is faulty.
tank) - Short circuit high
Reagent - tank temperature sensor 1. Faulty wiring
19110 (temperature of the reagent - solution in the 2. DEF/AdBlue® tank temperature sensor is faulty.
tank) - Short circuit low
1. Dosing valve harness short to power
19145 Reductant injector circuit high - Dosing valve 2. Denox module/supply module is faulty
19146 Reductant injector circuit low - Dosing valve No information available at time of print.
1. Dosing valve harness open circuit
19147 Reductant injector circuit/open - Dosing valve 2. Dosing valve solenoid open circuit
3. Denox module/supply module is faulty
Reagent - dosing nozzle - Pressure too high - 1. Dosing valve faulty.
19148 2. Denox module/supply module is faulty
Dosing valve
The dosing injection valve, which is fed with
AdBlue™/DEF, is an injector located on the
exhaust pipe.
Cause:
There is a open circuit in the dosing injection
Dosing valve (electrical) - short circuit to valve circuit.
19149 Possible failure modes:
ground.
1. Faulty dosing injection valve.
2. Faulty electrical wiring or connections X904,
X914.
3. Faulty selective catalytic reduction (SCR)
controller.
4005-59

CODE DEFINITION
STEPS FOR REPAIR
The dosing control unit (DCU) has detected an

error with the dosing module.
Cause:
There is a short circuit in the dosing module
Dosing valve (electrical) - dosing valve circuit.
19150
permanent.”ON” - Pressure too high Possible failure modes:
1. Faulty dosing valve.
2. Faulty electrical wiring or connections.
3. Faulty DCU.
The supply module/denox module has detected a
urea pump speed sensor fault. This error occurs
when the supply module/denox module has
sensed all three hall sensors outputs are high for
greater than 7 s. This error is corrected if all three
19154 Reagent - pump - not delivering sensors return to normal output for greater than 1
s. Ensure all connectors are secured properly on
the supply module/denox module and all lines are
in operable condition. If the fault does not reset or
reoccurs, replace the supply module/denox
module.
The denox module/supply module has detected
this failure because the averaged pump flow is
less than a predetermined flow rate, and pump
control duty cycle is greater than expected as
determined by the denox module/supply module.
The pump is blocked internally because of con-
19155 Reagent - pump motor blocked
tamination, frozen DEF/AdBlue®, damaged pump
motor, or damaged pump flow measurement.
Ensure all connectors are secured properly to the
denox module/supply module and all lines are in
operable condition. If fault does not reset, replace
the denox module/supply module.
The denox module/supply module has detected this
failure because the averaged pump flow is greater
than a predetermined value for over 7.0 s. Check
hose from DEF/AdBlue® tank to pump module. If
hose is detached, reconnect hose and secure to
19156 Reagent - pump - over speed
pump. If hose is defective, replace the hose. Ensure
all connectors are secured properly on the denox
module/supply module and all lines are in operable
condition. Replace denox module/supply module if
fault reoccurs
4005-60

CODE DEFINITION
STEPS FOR REPAIR
The supply module/denox module has detected a

urea pump speed sensor fault. This error occurs
when the supply module/denox module has sensed
all three hall sensor outputs are low for greater than
19157 Reagent - pump - not delivering
7 s. This error is corrected if all three sensors return
to normal output for greater than 1 s. If the fault
does not reset or reoccurs, replace the supply mod-
ule/denox module.
failure of the SCR Coolant control valve. If this
error is detected, the power stage is switched
OFF and ON again and the check is repeated for
Vent valve (Cooling control valve) - Short
19163 ten times. Failure is reported if test fails each
circuit high
time. Ensure all connectors are secured properly
on the DCU and all lines are in operable
condition. If fault does not reset or reoccurs,
replace the DCU.
error is detected, there is a short internal to the
19164 Vent valve (Cooling purge control valve) -
pump module. Ensure all connectors are secured
Open circuit
properly on the DCU and all lines are in operable
replace the DCU.
error is detected, there is a internal failure to the
Vent valve (Cooling purge control valve) -
19172 pump module. Ensure all connectors are secured
Short circuit low
properly on the DCU and all lines are in operable
replace the DCU.
failure of the reverting valve, located inside the
denox module/supply module. Ensure all connec-
19181 Vent valve (Reverting purge control valve) -
tors are secured properly on the denox module/sup-
Short circuit high
ply module and all lines are in operable condition. If
Vent valve (Reverting purge control valve) - supply module. Ensure all connectors are
19182
Short circuit low secured properly on the DCU and all lines are in
4005-61

CODE DEFINITION
STEPS FOR REPAIR

denox module/supply module. Ensure all connec-
Vent valve (Reverting purge control valve) -
19183 tors are secured properly on the denox module/sup-
Open circuit
ply module and all lines are in operable condition. If
19184 Reverting valve electrically - Short circuit to

No information available at time of print.
ground
A valve remote from the storage tank is used to con-
trol coolant to prevent DEF/AdBlue® from freezing
in cold temperatures. The valve will respond to a
signal from the denox module/supply module based
on temperature signals from the temperature sen-
sor.
19262 Tank heating valve - Short circuit high Cause:
A open circuit has been detected in the tank heater
control valve circuit.
1. Faulty DEF tank heater control valve.
3. Faulty denox module/supply module.
A valve remote from the storage tank is used to
control coolant to prevent AdBlue™/DEF from
freezing in cold temperatures. The valve will
19263 Tank heating valve - Short circuit low
respond to a signal from the DCU based on
temperature signals from the temperature
sensor.
sor.
19264 Tank heating valve - Open circuit Cause:
A open circuit has been detected in the DEF tank
heater control valve circuit.
1. Faulty DEF tank heating control valve.
4005-62

CODE DEFINITION
STEPS FOR REPAIR

sor.
19265 Tank heating valve - short circuit to ground. Cause:
A short circuit has been detected in the DEF tank
heater control valve circuit.
1. Faulty DEF tank heating control valve.
A valve remote from the storage tank is used to
control coolant to prevent DEF/AdBlue® from
freezing in cold temperatures. The valve will
19289 Temperature after catalyst too low
respond to a signal from the denox
module/supply module based on temperature
signals from the temperature sensor.
NOTE: After the repair has been completed, the
code will still be present and active until it has
been determined that the selective catalytic
reduction (SCR) system is operating properly.
The engine must be brought to normal operating
temperature and run under load until the fault
clears. If the code is still present and active after
running the engine for 30 minutes, further
diagnostics is necessary.
Context:
has sensed the Downstream catalyst
Catalyst temperature sensor circuit temperature sensor is giving an implausible
19290 reading. This occurs when the SCR controller
range/performance
senses the Downstream catalyst temperature
sensor reading is less than 110 °C (230 °F) for
longer than 450 s (450 s) with engine speed of
greater than 800 RPM (800 RPM) and an engine
load of at least 15 % (15 %).
Cause:
The SCR controller has sensed a low
Downstream catalyst temperature sensor
reading.
1. Downstream catalyst temperature sensor not
installed properly.
4005-63

CODE DEFINITION
STEPS FOR REPAIR
The denox module/supply module has detected the

DEF/AdBlue® pressure has not reached 500 kPa
within 2.5 min. Manually check DEF/AdBlue® level
Reagent - pump - Not delivering; UREA is filled to operating level. Check feeding tubes, con-
19298
pressure too low at system start nectors and O-rings in connectors for any air leaks.
If error is still present, use the electronic service tool
(EST) to run urea dosing system test (UDST) to
troubleshoot the system further.
code will still be present and active until it has been
determined that the selective catalytic reduction
(SCR) system is operating properly. The engine
must be brought to normal operating temperature
and run under load until the fault clears. If the code
is still present and active after running the engine for
30 minutes, further diagnostics is necessary.
Reagent - pressure - Above threshold; UREA

19307 pressure not plausible (urea pressure too
high) DEF/AdBlue® pressure exceeds 6.5 bar for 30 s.
Reasons for failure could be internal control valve
blocked or pump speed to high. These are indica-
tions of internal failure of supply module. Use the
electronic service tool (EST) to run the urea dosing
system test (UDST) to monitor the DEF/AdBlue®
pressure and pump speed. DEF/AdBlue® pressure
should not exceed 500 kPa, and the pump speed
should not exceed 6000 RPM. Replace denox mod-
ule/supply module if values are out of range.
DEF/AdBlue® temperature in module box is less
than 75 °C (167°F) or greater than 9 °C (48 °F), and
system is not in defreezing mode. This error occurs
if, in the previous driving cycle, box temperature was
less than 85 °C (185 °F) and in shutdown mode. If
Reagent - temperature sensor of pump during the actual driving cycle the box temperature
19316
module - Out of range remains less than 70 °C (158 °F) for more than 10.0
s, the system goes into emergency shutdown and
will not start until EEPROM is cleared. Use the elec-
tronic service tool (EST) to clear code. Verify tank
heater codes are not present, and there is no tem-
perature plausibility errors. If other errors are
present, correct as well.
4005-64

CODE DEFINITION
STEPS FOR REPAIR
The DEF/AdBlue® temperature in tank is greater

than 75.0 °C (167.0 °F) for 300 s and system is not
in defreezing mode. This code will heal when the
temperature returns below 75.0 °C (167.0 °F) for
Reagent - tank temperature sensor 1.0s.
19325 (temperature of the reagent - solution in the Cause:
tank) - Out of range The DEF/AdBlue® tank temperature is out of range.
1. Tank heating valve stuck open.
2. Check for other DEF tank heater control valve
related error codes.
failure when ambient temperature is below 17.0 °F
at system start up. If DEF/AdBlue® pressure does
not reach 390 kPa within 2.5 min the inlet line is fro-
zen. This failure is stored after 30 repetitions with
2.5 min heating phases between the checks.
Defreezing mode and detection errors (inlet Cause:
19334
line defreezing failed) The denox module/supply module has detected this
error because of no DEF/AdBlue® pressure.
1. AdBlue™/DEF tank empty.
2. Inlet line broken.
3. Pump does not feed.
4. DEF/AdBlue® box heater does not work correctly.
at system
start up, and inlet line is detected open. If
DEF/AdBlue® pressure does not drop to 350 kPa
within 40 s with the
dosing valve open to 99.0 %, the pressure line is
Defreezing mode and detection errors frozen. This failure is stored after 28 repetitions with
19335 2.5 min heating phases between the checks.
(pressure line defreezing failed)
Cause:
error because of no DEF/AdBlue® injection.
1. Dosing valve does not open
2. Pressure line blocked
3. Injection nozzle blocked
4. Faulty box heater
4005-65

CODE DEFINITION
STEPS FOR REPAIR
The dosing control unit (DCU) has detected this fail-

ure when ambient temperature is below 17.0 °F at
system start up. The pressure line and inlet line is
Defreezing mode and detection errors detected open. If DEF/AdBlue® pressure does not
19336 (pressure build-up in detection mode failed); reach 390 kPa within 40 s with full pump speed, the
Pump module - Internal heating - Open circuit system is not unfrozen. This failure is stored after 26
repetitions with 2.5 min heating phases between
the checks. Check if the internal heater is working
correctly.
at system start up. The inlet and pressure line is
detected open and pressure build up was OK. If
DEF/AdBlue® pressure does not drop to 140 kPa
within 50 s with the vent valve open to 100 %, the
back flow line is frozen. This failure is stored after 24
repetitions with 2.5 min heating phases between
Defreezing mode and detection errors the checks.
19337
(Back-flow line defreezing failed) Cause:
error because of no DEF/AdBlue® back flow line is
frozen.
1. DEF/AdBlue® tank ventilation clogged
2. Back flow line clogged
3. Ventilation valve does not open
4. Back flow line frozen
short circuit. If at normal operating speed the
AdBlue™/DEF pressure is greater than 450 kPa,
and the cooling valve is closed from 100 - 0 %,
Coolant control valve mechanically -
19343 the AdBlue™/DEF pressure must rise at least 15
Mechanical defective blocked open
kPa within 2 s. Ensure all connections and
connectors are secured to the DCU properly. If
error is still present, there is an internal failure of
the box. Replace the DCU.
open circuit. If at normal operating speed the
AdBlue™/DEF pressure is greater than 450 kPa,
and the cooling valve is open from 0 - 100 %, the
Coolant control valve mechanically -
19344 AdBlue™/DEF pressure must drop at least 15
Mechanical defective blocked closed
kPa within 2 s. Ensure all connections and
connectors are secured to the DCU properly. If
error is still present, there is an internal failure of
the box. Replace the DCU.
Vent valve (Reductant purge control valve) -
19352 1. Valve is mechanically stuck
Open circuit; reverting control valve
2. System was empty, needs primed
4005-66

CODE DEFINITION
STEPS FOR REPAIR

19361 Battery voltage evaluation - Below lower limit 1. Problem with battery or charging system.
2. Denox module/supply module internal failure.
19362 Battery voltage evaluation - Above upper limit 1. Problem with battery or charging system.
2. Denox module/supply module internal failure.
During operation, the ventilation valve is fully
opened, the pump is then set to 100 % operation
until DEF/AdBlue® pressure has reached 500 kPa.
The ventilation valve is then closed. If DEF/AdBlue®
pressure does not reach 500kPa within 2.5 min,
this error occurs.
Pump motor error during commissioning Cause:
19370
(pump not delivering); UREA pressure too low The denox module/supply module has detected the
pump motor is not delivering.
1. No DEF/AdBlue® in tank
3. Faulty pump
4. Faulty feeding line
temperatures are not correct within 30 min of oper-
ation. The module box temperature is less than -9
°C (16 °F) or greater than 75 °C (167 °F), or the
Temperatures not plausible during DEF/AdBlue® tank is less than -17 °C (2 °F) or
19379
commissioning greater than 75 °C (167 °F). Bring temperature to a
normal level, between 0 - 30 °C (32 - 86 °F).
1. Extreme cold ambient conditions.
2. DEF/AdBlue® tank temperature sensor is faulty.
DEF/AdBlue® level is constantly less than 0.1 % for
19415 more than 25 s.
Empty UREA tank - fluid level in tank too low
1. Tank is empty
2. Faulty level sensor
19496 Pressure - Above threshold No information available at time of print.
Plausibility of pump module temp. sensor;
dynamic
Plausibility of UREA tank temp. sensor;
dynamic
4005-67

CODE DEFINITION
STEPS FOR REPAIR
The denox module/supply module has generated

this fault because it has sensed the back flow line is
clogged. This fault occurs when the denox mod-
ule/supply module performs the a test and deter-
mines: DEF/AdBlue® pressure is greater than 345
kPa (50 psi), pump speed greater than 300 RPM
(300 RPM), downstream temperature is greater
than 60 °C (140 °F), and dosing is greater than 6 %
Back flow line blocked; dosing valve - Short
19532 (6 %) for 20 s (20 s). If these parameters are met,
circuit low
the cooling valve is closed, the DEF/AdBlue® pump
is stopped and the dosing valve is fully opened and
the pressure is rechecked by the denox mod-
ule/supply module. If the pressure is less than 30
kPa (4.35 psi), the back flow line is clogged. Ensure
the lines are open and free flowing. If the lines are
free of blockage, replace the denox module/supply
module.
The denox module/supply module has detected at
start up, after opening the coolant control valve for
40 s, DEF/AdBlue® pressure is less than 150 kPa.
Vent valve test - Plausibility test (start-up) ;
19541 First check that pressure and back flow line are not
cooling control valve
frozen or clogged. If all lines are open and in proper
operation, the denox module/supply module has
failed. Replace the denox module/supply module
code will still be present and active until it has been
determined that the selective catalytic reduction
(SCR) system is operating properly. The engine
must be brought to normal operating temperature
19550 Dosing nozzle - Pressure too high and run under load until the fault clears. If the code
is still present and active after running the engine for
30 minutes, further diagnostics is necessary.
1. Dosing nozzle blocked.
2. Crimped , or collapsed supply line to dosing
nozzle.
4005-68

CODE DEFINITION
STEPS FOR REPAIR
The denox module/supply module has detected low

DEF/AdBlue® level. This error occurs when the
DEF/AdBlue® fluid level is too low or level sensor
has faults present. Ensure the heated level sensor
is connected properly. Check DEF/AdBlue® tank
level is full. If fluid level is low, fill tank to proper
19559 Low UREA level 1 (warning) - Too low capacity. Check for any other errors that may be
present. Correct those errors first, then recheck
original error has been corrected. Ensure all con-
nectors are secured properly on the denox mod-
ule/supply module and all lines are in operable
condition. If the fault does not reset or reoccurs,
replace the denox module/supply module.
The denox module/supply module has detected low
DEF/AdBlue® level. This error occurs when the
DEF/AdBlue® fluid level is too low or level sensor
has faults present. Ensure the heated level sensor
is connected properly. Check DEF/AdBlue® tank
level is full. If fluid level is low, fill tank to proper
19568 Low UREA level 2 (warning) - Too low capacity. Check for any other errors that may be
present. Correct those errors first, then recheck
original error has been corrected. Ensure all con-
nectors are secured properly on the denox mod-
ule/supply module and all lines are in operable
condition. If the fault does not reset or reoccurs,
replace the denox module/supply module.
CAN receive frame E2SCR: (UREA quantity Possible failure modes:
19577
not in range. 1. Controller communication error
CAN receive frame E2SCR (Dosing status not Possible failure modes:
19578
in range). 1. Controller communication error

CAN receive frame E2SCR - timeout
1. Controller communication error
CAN receive frame E2SCR - too many Possible failure modes:
19580
messages 1. Controller communication error
CAN receive frame E2SCR - Serial Possible failure modes:

19581
Communication link 1. Controller communication error
CAN receive frame EEC1 (Engine torque not Possible failure modes:
19595
CAN receive frame EEC1 (Engine speed not in Possible failure modes:
19596
range). 1. Controller communication error

CAN receive frame EEC1 - timeout
CAN receive frame EEC1 - too many Possible failure modes:
19598
messages 1. Controller communication error
4005-69

CODE DEFINITION
STEPS FOR REPAIR
CAN receive frame EEC1 (Torque driver Possible failure modes:

19599
demand not in range). 1. Controller communication error
CAN receive frame ET1 (Oil temperature not Possible failure modes:
19604

CAN receive frame ET1 - timeout

CAN receive frame ET1 - too many messages
CAN receive frame ET1 (Water temperature Possible failure modes:
19607
not in range). 1. Controller communication error
Cause:
There was an open circuit detected in the
DEF/AdBlue® level sensor circuit.
19649 UREA Tank level sensor - open circuit Possible failure modes:
1. Faulty Sensor.
3. Faulty DCU.
Cause:
There was a short to power detected in the
19650 UREA Tank level sensor - Short circuit high Possible failure modes:
1. Faulty Sensor.
3. Faulty DCU.
Cause:
There was a short to ground detected in the
19651 UREA Tank level senor - Short circuit low Possible failure modes:
1. Faulty Sensor.
3. Faulty DCU.
UREA Tank level error (CAN message or
electrical with real sensor) - (timeout))
UREA Tank level error (too many CAN
messages)
19654 UREA Tank level error - Open circuit No information available at time of print.
4005-70

CODE DEFINITION
STEPS FOR REPAIR

failure because the ambient air temperature is out of
range. Ambient air is measured through the denox
module/supply module. If the tractor has been
exposed to extreme ambient temperatures, either
Ambient temperature CAN receive signal:
19676 high or low, take steps to get tractor back into nor-
(Ambient air temperature not in range)
mal operating temperature range. Ensure all con-
nectors are secured properly to the denox
module/supply module and all lines are in operable
condition. If fault does not reset, replace the denox
failure because the ambient air temperature has
Ambient air temperature sensor timed out. Ensure all connectors are secured prop-
19677
range/performance - CAN timeout erly to the denox module/supply module and all
lines are in operable condition. If fault does not
reset, replace the denox module/supply module.
faulty can bus signal. Ensure all connectors are
Ambient air temperature sensor
19678 secured properly to the denox module/supply mod-
range/performance - too many CAN messages
ule and all lines are in operable condition. If fault
does not reset, replace the denox module/supply
module.
faulty sensor range. Ensure all connectors are
Ambient temperature CAN receive signal:
19679 secured properly to the denox module/supply mod-
(Barometric pressure not in range)
ule and all lines are in operable condition. If fault
does not reset, replace the denox module/supply
module.
The denox module/supply module has suffered a
detection error. This error indicates a defect in the
EEPROM/Checksum failures - EEPROM write dataset that is presently loaded in the denox mod-
19721
error (P062F) ule/supply module. If this error is present and active,
reload the software dataset. If this error then reoc-
curs, replace the denox module/supply module.
4005-71

CODE DEFINITION
STEPS FOR REPAIR
The denox module/supply module has an internal

cycle counter to check if the afterrun is correctly fin-
ished. This cycle counter data is then stored in the
EEPROM memory. This error indicates the denox
module/supply module has attempted to store this
EEPROM/Checksum failures -No
19722 data in a protected area of memory. If this error is
corresponding variant number error (P062F)
present and active, first verify the denox mod-
ule/supply module and other components have not
been tampered with and reload the software. If this
error reoccurs replace the denox module/supply
module.
The denox module/supply module memory in
EEPROM is not correct or a SPI communication
error has occurred. This error indicates an internal
EEPROM/Checksum failures -EEPROM denox module/supply module error. If this error is
19723
communication error (P062F) present and active, ensure all electrical connectors
are secure and reload the denox module/supply
module software. If this error reoccurs, replace the
The denox module/supply module has an internal
EEPROM/Checksum failures -EEPROM error in software. If the code is present and active,
19724
detection error or codierwort error (P062F) reload the software. If this error reoccurs, replace
the denox module/supply module.
The denox module/supply module has the incorrect
EEPROM installed. This error would only occur dur-
EEPROM/Checksum failures -Wrong
19725 ing initial startup when the denox module/supply
EEPROM size (P062F)
module has previously been replaced. Replace the
19730 Ignition switch - plausibility error 1. Faulty connector
2. Faulty ignition switch
Context:
main relay is not switched off within 2 s.
Cause:
ECM/PCM Power relay control circuit/open - The main relay is shutting off too late.
19739
main relay shut off too late
1. Faulty relay
2. Faulty electrical wiring or connection
3. Denox module/supply module error
Cause:
Switched power relay control circuit open.
ECM/PCM Power relay control circuit/open - Possible failure modes:
19740
main relay short circuit 1. Faulty relay
4005-72

CODE DEFINITION
STEPS FOR REPAIR
Cause:
Switched power relay control circuit high.
19741
main relay open circuit 1. Faulty relay
Cause:
Switched power relay control circuit open.
19742
main relay shut off too early 1. Faulty relay
Cause:
High urea temperature in pump module.
UREA Temperature sensor of pump module - Possible failure modes:
19748
Out of range 1. Tank heating valve stuck open.
2. Check for other tank heating valve/coolant flow
solenoid related error codes.
Cause:
High urea temperature in pump module.
Dynamic UREA leakage test - Leakage Possible failure modes:
19749
detected 1. Tank heating valve stuck open.
2. Check for other tank heating valve/coolant flow
solenoid related error codes.
The dosing control unit (DCU) has activated this
fault due to other fault codes associated with the
DEF / AdBlue® injection control being active.
19757 Reagent - pump - Not delivering Diagnose those fault codes to clear this fault. If
this fault is active without any other codes active,
reload the software in the DCU or replace the
DCU.
19766 Compressed air regulation valve Diagnose those fault codes to clear this fault. If
DCU
DEF / AdBlue® injection temperature being
Plausibility of catalyst temperature sensors -
19775 active. Diagnose those fault codes to clear this
Plausibility error
fault. If this fault is active without any other codes
active, reload the software in the DCU or replace
the DCU.
4005-73

CODE DEFINITION
STEPS FOR REPAIR

19784 NOX Trap efficiency below threshold Diagnose those fault codes to clear this fault. If
DCU.
DEF / AdBlue® system urea low tank level.
19793 Fluid level in UREA tank - Too low Confirm the urea tank is full. Diagnose those fault
codes to clear this fault. If this fault is active
without any other codes active, reload the
software in the DCU or replace the DCU.
Context:
urea tank temperature and denox module/supply
19802 UREA Tank temperature Temp over CAN
timeout module temperature are not in agreement.
1. Can communication error.
Context:
19803 UREA Tank temperature - Temp over CAN:
SAE J1939 Too many messages module temperature are not in agreement.
Context:
UREA Tank temperature Temp over CAN:
19804 module temperature are not in agreement.
SAE J1939 erroneous signal - Open circuit
Context:
UREA Tank temperature - SRC High: Short
circuit high
1. Extreme hot ambient conditions.
4005-74

CODE DEFINITION
STEPS FOR REPAIR
Context:
UREA Tank temperature - SRC Low: Short
circuit low.
Context:
UREA Tank temperature - SRC High: UREA
temperature too high - Out of range
1. Extreme hot ambient conditions.
Context:
19808 UREA Tank temperature - SRC Low: UREA
temperature too low - Out of range module temperature are not in agreement.
Context:
During operation, the ventilation valve is fully
opened, the pump is then set to 100 % operation
until DEF/AdBlue® pressure has reached 500 kPa.
The ventilation valve is then closed. If DEF/AdBlue®
pressure does not reach 500kPa within 2.5 min,
this error occurs.
19813 Reagent - pump - Not delivering Cause:
pump motor is not delivering.
1. No DEF/AdBlue® in tank
3. Faulty pump
4. Faulty feeding line
4005-75

CODE DEFINITION
STEPS FOR REPAIR

DEF/AdBlue® pressure exceeds 6.5 bar for 30 s.
Reasons for failure could be internal control valve
blocked, blocked dosing valve nozzle or too high a
pump speed. These are indications of internal fail-
ure of supply module. Use the electronic service
19817 Dosing valve - Blocked (only stuck closed)
tool (EST) to run the Urea dosing system test
(UDST) to monitor the DEF/AdBlue® pressure and
pump speed. DEF/AdBlue® pressure should not
exceed 500kPa, and the pump speed should not
exceed 6000 RPM. Replace denox module/supply
module if values are out of range.
leakage. Visual inspect all urea lines and connec-
tions for leakage. These are indications of internal
leakage of supply module. Use the electronic ser-
vice tool (EST) to run the urea dosing system test
19818 Dynamic UREA leakage test - Leakage
(UDST) to monitor the DEF/AdBlue® pressure and
detected
exceed 500 kPa , and lower values can indicate
leakage, and the pump speed should not exceed
6000 RPM. Replace denox module/supply module if
values are out of range.
leakage. Visual inspect all urea lines and connec-
tions for leakage. These are indications of internal
leakage of supply module. Use the electronic ser-
vice tool (EST) to run the urea dosing system test
Dynamic UREA leakage test - Leakage
19822 (UDST) to monitor the DEF/AdBlue® pressure and
detected
exceed 500 kPa , and lower values can indicate
leakage, and the pump speed should not exceed
6000 RPM. Replace denox module/supply module if
values are out of range.
4005-76
5001
Section
5001
REMOVAL AND INSTALLATION OF STEERING

COMPONENTS
5001-2
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5001-3
STEERING CONTROL VALVE
Removal STEP 7
STEP 1
Remove the cab skirts from the cab or canopy.
STEP 2
Remove all dirt and grease from steering control
valve.
STEP 3
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.
BD06G245
STEP 4 Remove the mounting nut and washers from the
Tag hoses connected to steering control valve. steering shaft.
STEP 5 STEP 8
BD06G262 BD06G246
Disconnect hoses from steering control valve, cap or Remove the steering wheel from the shaft.
plug the fittings and hoses, turn off the vacuum
pump.
STEP 9
STEP 6
BD06G247
Remove the six mounting screws from the instrument

BD06G244
cover.
Remove the center cap from the steering wheel.
5001-4
STEP 10 STEP 13
BD06G248 BD06G258
Remove the five mounting screws for the left and Remove the two mounting screws from the lower
right hand trim. trim.
STEP 11 STEP 14
BD06G249 BD06G259
Disconnect the ignition switch, remove the right and Pull floor mat away from the column and remove the
left hand trim pieces from the column. lower trim from the column.
STEP 12 STEP 15
BD06G257 BD06G260
Remove the screw from the brace. Remove the two lower mounting screws from the
front vent.
5001-5
STEP 18
BD06G261
Remove the three vents from the front trim, remove

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

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

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

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

BD06G258 left and right hand trim.
Install the lower trim onto the column, instal and
tighten the two mounting screws mounting the lower
trim, place the floor mat into position.
5001-7
STEP 27 STEP 30
BD06G247 BD06G262
Install and tighten the six mounting screws for the Start the vacuum pump, remove the caps and plugs
instrument cover. the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
STEP 28 removal, remove and discard the tags.
STEP 31
Remove the vacuum pump from the reservoir, install
and tighten the reservoir fill cap.
STEP 32
Start and run the machine at low idle, turn the wheel
to full left and then to full right, stop the machine and
check for leaks.
STEP 33
BD06G245
Install the skirts onto the cab or canopy.
Install the steering wheel, install and tighten the
mounting nut and washers. STEP 34
Check fluid level in hydraulic reservoir. Add oil as
STEP 29 required. See Section 1002 for specifications.
BD06G244
Install the center cap on the steering wheel.

5001-8
AUXILIARY STEERING PRIORITY VALVE

Removal Installation
1. Park loader on level ground and lower bucket to 1. Connect and hand tighten fitting (5) to the elbow
ground. Put transmission in NEUTRAL, apply in the steering priority valve.
parking brake, and shut down engine, 2. Install cap screws, washers and nuts (6).
2. Put master disconnect switch in OFF position. 3. Tighten pressure tube fitting (5).
3. Remove all dirt and grease from auxiliary 4. Tighten the nuts (6).
steering priority valve and adjacent area. See
5. Connect and tighten pressure hose (7).
illustration on page 9.
6. Connect and tighten steering pressure hose (9).
4. Remove hydraulic reservoir fill cap.
7. Connect and tighten steering load sensing hose
5. Connect a vacuum pump to hydraulic reservoir. (1).
6. Start vacuum pump. 8. Connect and tighten load sensing hose (2).
7. Tag and disconnect suction hose from the 9. Connect electrical connector to the pressure
suction port (4) from auxiliary steering pump and switch (3).
motor. Install a cap on the fitting and a plug in the
hose. 10. Connect electrical connector to the steering
solenoid (8).
8. Tag and disconnect tank return tube (10) from
the priority valve. Install a cap on the elbow and a 11. Start vacuum pump.
plug in the tube. 12. Connect and tighten tank return tube (10).
9. Stop the vacuum pump. 13. Connect and tighten hose to auxiliary steering
10. Tag and disconnect the wiring from the steering pump port (4).
solenoid (8). 14. Stop vacuum pump. Disconnect vacuum pump
11. Tag and disconnect the wiring from the pressure from hydraulic reservoir.
switch (3). 15. Install fill cap on hydraulic reservoir.
12. Tag and disconnect load sensing hose (2) from 16. Put battery disconnect switch in ON position.
auxiliary steering priority valve. Install a cap on Start engine and run at low idle for 30 seconds.
the elbow and a plug in the hose. Stop engine and check for leaks.
13. Tag and disconnect load sensing hose (1) from 17. Check to make sure priority valve operates
the priority valve. Install a cap on the elbow and a correctly. See Section 5002.
plug in the hose.
18. Check fluid level in hydraulic reservoir. Add oil as
14. Tag and disconnect steering pressure hose (9) required. See Section 1002 for specifications.
from priority valve. Install a cap on the fitting and
a plug in the hose.
15. Tag and disconnect pressure hose (7) from
priority valve. Install a cap on the fitting and a
plug in the hose.
16. Loosen fitting (5) connected to elbow installed in
steering priority valve.
17. Support auxiliary steering priority valve. Remove
four nuts (6), cap screws, and washers.
18. Remove auxiliary steering priority valve.
5001-9
1
2
10
4
9
5
6
8 7
BC05M084
1. STEERING LOAD SENSING HOSE TO PRIORITY VALVE 6. CAP SCREWS AND NUTS
2. STEERING LOAD SENSING HOSE TO STEERING VALVE 7. PRESSURE HOSE
3. PRESSURE SWITCH 8. STEERING SOLENOID
4. SUCTION PORT 9. STEERING PRESSURE HOSE
5. PUMP OUT PRESSURE TUBE FITTING 10. TANK RETURN TUBE
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION
5001-10
STEERING PRIORITY VALVE

1. Park loader on level ground and lower bucket to 1. Install bolts with washers (8) through priority
ground. Put transmission in NEUTRAL, apply valve. Install new O-ring on top of priority valve
parking brake, and shut down engine, (not shown). Install priority valve (7) onto low
pressure pump, tighten bolts to37 to 48 Nm
2. Put master disconnect switch in OFF position.
(27 to 35.5 pound feet).
3. Remove all dirt and grease from steering priority 2. Install new O-rings (6) onto high pressure pump
valve (7) and adjacent area. See illustration on discharge tube (5).
page 11.
3. Place tube into position and intsall four split
4. Remove hydraulic reservoir fill cap. flanges (3) and eight bolts (4) with washers,
5. Connect a vacuum pump to hydraulic reservoir. tighten bolts.
4. Connect all hoses as tagged to the steering
6. Start vacuum pump.
priority valve (7).
7. Tag and disconnect all hoses connected to the
5. Stop vacuum pump.
steering priority valve (7).
6. Disconnect vacuum pump from hydraulic
8. Loosen and remove eight bolts (4) and four spit
reservoir.
flanges (3).
7. Install fill cap on hydraulic reservoir.
9. Remove the high pressure pump discharge tube
(5), discard O-rings (6). 8. Put battery disconnect switch in ON position.
Start engine and run at low idle for 30 seconds.
10. Support the steering priority valve (7), remove
Stop engine and check for leaks.
mounting bolts (8).
9. Check to make sure steering priority valve
11. Remove steering priority valve (7).
operates correctly. See Section 5002.
required. See Section 1002 for specifications.
5001-11
4
5
4
3 8
BC05M087
1. LOW PRESSURE PUMP (LOADER PUMP) 5. STEERING PUMP OUTPUT LINE

2. HIGH PRESSURE PUMP (STEERING PUMP) 6. O-RINGS
3. SPLIT FLANGE 7. STEERING PRIORITY VALVE
4. BOLT 8. BOLT
STEERING PRIORITY VALVE ILLUSTRATION
5001-12
AUXILIARY STEERING PUMP AND MOTOR
Removal 7. Connect ground cable (1) to ground stud of

auxiliary steering pump and motor (7) following
1. Park loader on level ground and lower bucket to tag installed during removal.
ground. Put transmission in NEUTRAL, apply
parking brake, and shut down engine, 8. Connect positive cable (2) to B+ stud of auxiliary
steering pump and motor (7) following tag
2. Put master disconnect switch in OFF position. installed during removal.
3. Tag and disconnect two wiring harness (8) from 9. Connect wiring harness wires (8) to auxiliary
auxiliary steering pump and motor (7) solenoid. steering pump and motor (7) following tags
See illustration on page 13. installed during removal.
4. Tag and disconnect positive cable (2) from B+ 10. Put master disconnect switch in ON position.
stud of auxiliary steering pump and motor (7).
11. Start and run engine at low idle and raise bucket
5. Tag and disconnect ground cable (1) from ground 500 mm (20 inches) above ground. Check that
stud of auxiliary steering pump and motor (7). auxiliary steering light on information center is
6. Remove hydraulic reservoir fill cap. OFF.
7. Connect a vacuum pump to hydraulic reservoir. IMPORTANT: In following Step, do not run auxiliary
steering pump and motor continuously for more than
8. Start vacuum pump. 20 seconds at a time without a two minute cool down.
9. Disconnect suction hose (4) from auxiliary 12. With engine at low idle and machine steering
steering pump and motor (7). Install a plug in straight ahead, turn key switch to OFF position to
suction hose and cap on fitting. stop engine and then immediately back to ON
10. Stop vacuum pump. position (not START position). Auxiliary steering
pump and motor should star t operating
11. Loosen fittings on pressure tube (5). immediately. Check that auxiliary steering light
12. Support auxiliary steering pump and motor (7). on infor mation center is ON and auxiliar y
Remove nuts (3), cap screws, and washers steering pump and motor is operating.
securing auxiliary steering pump and motor (7). 13. Turn steering wheel all the way to left and right to
13. Remove pressure tube (5) and auxiliary steering make sure that auxiliary steering pump and
pump and motor (7). motor operates correctly.
14. Restart engine. Check that auxiliary steering
light on information center stays ON and auxiliary
steering pump and motor is operating. After
Installation about three seconds motor should stop operating
1. Position auxiliary steering pump and motor (7) on and auxiliary steering light should go out.
its mounting plate while connecting and hand 15. Let engine run and allow batteries to recharge for
tightening pressure tube (5) to auxiliary steering a minimum of 10 minutes.
priority valve (6). See illustration on page 13.
2. While supporting auxiliary steering pump and
motor (7) have an assistant install cap screws,
washers, and nuts (3) to secure auxiliary steering
pump and motor (7), tighten the nuts.
3. Tighten pressure tube (5) fittings securely.
4. Start vacuum pump.
5. Remove plug from suction hose (4) and cap from
elbow. Connect suction hose to elbow installed in
auxiliary steering pump and motor (7).
6. Stop and disconnect vacuum pump. Install fill
cap in hydraulic reservoir.
5001-13
4
5
BC05M085
1. GROUND CABLE 4. SUCTION HOSE 7. AUXILIARY STEERING PUMP AND MOTOR

2. POSITIVE CABLE 5. PRESSURE TUBE 8. WIRING HARNESS
3. NUT (4) 6. AUXILIARY STEERING PRIORITY VALVE
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
5001-14
STEERING CYLINDER
1. Loosen the fill cap for the hydraulic reservoir to 1. Put steering cylinders (11) in position in machine.
release pressure in the reservoir, then tighten the Make sure that washers (4) are installed between
fill cap. steering cylinder (11) and rear frame. See
2. Disconnect grease hoses (1 and 16) from
steering cylinders (11). See illustration on page NOTE: Install a washer (4) on top and bottom of
15. steering cylinders (11) if possible. If only one washer
(4) can be installed, place washer (4) at bottom of
3. Disconnect hydraulic hoses (2, 3, 9, and 10) from
steering cylinders (11).
2. Make sure washers (14) are installed between
4. Install a plug in each hose (2, 3, 9, and 10) to
steer ing cylinders (11) and front frame of
prevent entry of foreign matter.
machine.
5. Remove locknut (15).
3. Install the pivot pin (5) to secure rear of steering
6. Remove cap screw (13). cylinders (11) to machine frame. Install spacer
(6), washer (7), and cap screw (8) to secure pivot
7. Remove pin (12).
pin (5).
8. Remove washers (14).
4. Tighten cap screw (8).
9. Remove cap screw (8), washer (7), and spacer
5. Install pin (12) in front of steering cylinders (11).
(6) securing pivot pin (5) at rear of steering
Make sure that washers (14) are installed in
cylinders (11).
correct position.
10. Use a suitable driver and drive pivot pin (5) out of
6. Install cap screw (13) and new locknut (15) in
steering cylinder (11).
steering cylinders (11) rod end and pin (12).
11. Remove washer(s) (4) from between steering Tighten locknut (15).
cylinders (11) and rear frame of machine.
NOTE: Cap screw (13) should turn freely in hole
12. Remove steering cylinders (11). after tightening.
7. Connect hose assemblies (2, 3, 9, and 10) to
8. Connect grease hoses (1 and 16) to steering
cylinders (11).
9. Tighten hydraulic reservoir fill cap.
10. Start engine.
11. Turn steering wheel all the way to right and then
to the left several times.
12. Stop the engine. Check fluid level in hydraulic
reservoir. Add oil as required. See Section 1002
for specifications.
5001-15
9 10
8
6
5
3 11
2
1 1 12
13
14
15
11
16
BS03B141
1. GREASE HOSE 5. PIVOT PIN 9. HOSE ASSEMBLY 13. CAP SCREW

2. HOSE ASSEMBLY 6. SPACER 10. HOSE ASSEMBLY 14. WASHER
3. HOSE ASSEMBLY 7. WASHER 11. STEERING CYLINDER 15. LOCKNUT
4. WASHER 8. CAP SCREW 12. PIN 16. GREASE HOSE
STEERING CYLINDER ILLUSTRATION
5001-16
STEERING BACK PRESSURE VALVE
1. Remove the fill cap for the hydraulic reservoir to 1. Install the valve, bolts, spacers and nuts onto the
release pressure in the reser voir, attach a machine, tighten the bolts.
vacuum pump to the reservoir, start the pump.
2. Install new O-rings onto the fittings of the hoses,
2. Disconnect hoses 2 and 6 from the pressure install and tighten the hoses.
valve.
3. Stop the vacuum pump, install and tighten the
3. Remove the nuts, bolts and spacers from the reservoir filler cap.
pressure vale, remove the valve from the
4. Start and run the machine at low idle, turn the
machine.
steering wheel from full left lock to full right lock
holding the steering over relief.
5. Stop the machine and check for leaks.
required. See Section 1002 for specifications.
5001-17
BS06G529
1. STEERING CONTROL VALVE 5. RELIEF VALVE

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

5001-18
NOTES
5002
Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS,

AND TROUBLESHOOTING
5002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Understanding The Results Of The Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5002-3
SPECIAL TOOLS
B785789 B009638
OEM-1239 (CAS-10280) FLOWMETER CAS-1804 PRESSURE TEST FITTING KIT
B797157
CAS-1808 FLOWMETER FITTING KIT
TROUBLESHOOTING THE STEERING SYSTEM

NOTE: The steering hydraulic schematic is included 4. Do the main hydraulic pump test. See Section
in the hydraulic schematic. Refer to the rear pocket of 8002. If the main pump is bad, repair or replace
this manual. the main hydraulic pump.
1. Make sure the oil level in the hydraulic reservoir 5. Test the steering cylinders for leakage, refer to
is correct. Visually inspect the steering system instructions on page 8. If a steering cylinder is
for leakage and damage. leaking, repair or replace the steering cylinder.
2. The loader/steering pump differential pressure 6. If the steering system is noisy test the back
must be properly adjusted. Refer to Section 8002 pressure relief valve, refer to instructions on
Testing and Adjusting the Loader/Steering Pump page 9.
differential Pressure.
3. Do the steering limit valve pressure test. Refer to
page 6. If the pressure is above or below
specifications, adjust the steering limit valve.
5002-4
AUXILIARY STEERING SYSTEM PUMP TEST
Equipment Required
6. Connect the ammeter clamp (1) to the cable as
1. CAS- 10280 Flowmeter in illustration.
2. CAS-1808 Flowmeter fitting kit
Test Procedure
1. Install articulation lock.
BB830300
1. AMMETER CLAMP
7. Make sure that the parking brake is applied and
1 the bucket is on the floor.
BD03A040
8. Make sure that the oil is at operating
temperature.
1. ARTICULATION LOCK
NOTE: When performing this pressure check, 9. Make sure that the load valve for the flowmeter is
always be sure the articulation lock is in place, open (zero pressure).
especially when working in the articulation joint 10. Start and run the engine.
areas.
11. Stop the engine and turn the key back to the On
2. Loosen and remove the outlet hose to the position.
Auxiliary Steering Pump from the Auxiliar y
Steering Priority Valve. 12. Turn the steering wheel, this will activate the
auxiliary steering pump.
3. Install a plug into the Auxiliary Steering Priority
Valve. 13. Turn the load valve on the flowmeter towards
CLOSED until the pressure is 104 bar (1500 psi).
4. Connect the inlet of the flowmeter to the outlet
line of the Auxiliary Steering Pump. 14. Read the flowmeter and ammeter gauges and
record the readings.
5. Install the outlet hose of the flowmeter in the
hydraulic reservoir and hold in place with wire. 15. The flowmeter reading must not be less than
24.6 L/min, (6.5 U.S. gpm). The ammeter reading
must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.
5002-5
AUXILIARY STEERING SYSTEM MOTOR TEST
Test Equipment 5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
1. A 24 volt battery that is fully charged.
6. Turn the load control (8) until the voltmeter (7)
NOTE: A 24 volt battery system (two 12 volt indicates 24 volts. Look at the ammeter (6) in the
batteries in a series) is used for this test. A 12 volt tester. Make a record of the ammeter indication.
battery system will cause damage to the auxiliary
steering motor.
2. A remote starter switch. 6 7
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
System Tester.
8
Test Procedure
1. Remove the connector that is between the
ter minals on the magnetic switch and the
auxiliary steering motor.
B795328
2. Remove the auxiliary steering motor from the
auxiliary steering pump. 6. AMMETER
7. VOLTMETER
3. Remove the drive coupling from the auxiliary 8. LOAD CONTROL
steering motor (3).
7. Hold the tachometer against the armature shaft.
4. Connect the auxiliary steering motor (3), remote Look at the tachometer. Make a record of the
starter switch (1) and tester (2) to the 24 volt indication.
battery system (5) as illustrated.
8. Release the button on the remote starter
switch (1).
2
1
Understanding The Results Of The
Test
4 1. If the ammeter indication in step 6 was 30
3 amperes or less and the tachometer indication in
step 7 was 6950 r/min (r pm) or more, the
auxiliary steering motor is good.
2. If the armature speed was less than 6950 r/min
(rpm) and the ammeter indication was higher
5 than 30 amperes, replace the motor.
B790852
1. REMOTE STARTER SWITCH

2. TESTER
3. AUXILIARY STEERING MOTOR
4. AMMETER CLAMP
5. 24 VOLT BATTERY SYSTEM
5002-6
STEERING PRIORITY VALVE

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

position.
BD03A040 10. Continue holding until the specified temperature
1. ARTICULATION LOCK of the oil is reached.
IMPORTANT: When performing the following
pressure check and adjustment, the articulation lock 12. Start the engine and operate the machine at full
must be installed. Use caution when working in or throttle.
near the articulation area.
13. With the articulation lock still in place, turn and
2. Remove the dust cap from the test port (1). hold the steering wheel for a hard right turn.
14. Continue holding the steering wheel, and read
the pressure gauge.
15. The pressure gauge must indicate 239 to 243
bar (3465 to 3525 psi). If the pressure is not
correct, adjust the steering relief valve.
BD06F148
1. G1 TEST PORT
2. G2 TEST PORT
3. Connect a 345 bar (5000 psi) pressure gauge to
the test port (2).
NOTE: Make sure when you connect the pressure
gauge that you do so in a manner that you can read
the pressure gauge while sitting in the operators
seat.
5002-7
Pressure Setting Adjustment

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

2. LIMIT VALVE
5002-8
STEERING CYLINDER LEAK TEST

NOTE: Make sure all persons are clear of the area 9. Connect the tube to the rod end of the left-hand
of the center pivot. Make sure the center pivot is free steering cylinder.
of any obstructions.
10. Turn the machine all the way to the left.
1. Park the machine on a level surface.
2. Turn the machine all the way to the right.
12. Find the tube that is connected to the rod end of
3. Stop the engine and apply the parking brake. the right-hand steering cylinder. Disconnect the
tube from the right-hand steering cylinder.
4. Find the tube that is connected to the rod end of
the left-hand steering cylinder. Disconnect the 13. Install a plug in the tube.
tube from the left-hand cylinder.
14. Start and run the engine at full throttle.
5. Install a plug in the tube.
15. Turn the steering wheel to the left. Hold the
6. Start and run the engine at full throttle. steering wheel for a full left turn. Have another
person check for leakage at the opening of the
7. Turn the steering wheel to the right. Hold the
rod end of the right-hand steering cylinder.
steering wheel for a full right turn. Have another
person check for leakage from the opening of the 16. If there is constant leakage from the rod end, the
rod end of the left-hand steering cylinder. piston packing in the right-hand steering cylinder
is damaged. Repairs must be made. See Section
8. If there is constant leakage from the rod end, the
5005.
piston packing in the left-hand steering cylinder
is damaged. Repairs must be made. See Section 17. Connect the tube to the rod end of the right-hand
5005. steering cylinder.
5002-9
STEERING BACK PRESSURE VALVE
BS06G529
1. STEERING CONTROL VALVE 5. RELIEF VALVE

2. RETURN HOSE 6. RETURN HOSE TO FILTERS
3. PRESSURE HOSE 7. RETURN MANIFOLD
4. CONNECTOR M27 ORB
5002-10
Pressure Test 4. Turn the steering wheel and observe the

pressure.
1. Disconnect the return hose (2) from the
connector (4). 5. The pressure should be 8 to 10 bar (115 to 145
psi).
2. Install a “T” fitting and connect a pressure gauge
capable of reading 35 bar (500 psi). 6. If pressure is not as specified, replace the relief
valve.
3. Start and run the machine at high idle.
NOTE: The relief valve is not adjustable.
Section
5005
STEERING CYLINDERS
5005
5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5005-3
SPECIFICATIONS
Torque for piston cap screw........................................................................ 810 to 925 Nm (597.5 to 682 pound feet)
Torque for gland............................................................................................. 339 to 475 Nm (250 to 350 pound feet)
STEERING CYLINDER
Disassembly Inspection
1. Fasten tube (18) in a vise. Be careful not to 1. Clean all parts in cleaning solvent.
damage the tube. See illustration on page 4.
2. Check to be sure that piston rod (14) is straight. If
2. Remove gland (1) from tube (18). piston rod is bent, install a new piston rod.
3. Pull piston rod (14) and piston (9) straight out of 3. Inspect inside of tube (18) for deep grooves and
tube (18). other damage. If there is any damage to tube, a
new tube must be used.
4. Fasten piston rod (14) yoke in vise and put a
support below piston rod near piston (9). Put a 4. Remove small scratches on piston rod (14) or
shop cloth between support and piston rod to inside tube (18) with emery cloth of medium grit.
prevent damage to piston rod. Use emery cloth with a rotary motion.
5. Loosen and remove bolt and washer (8) that hold 5. Inspect bushing (17). If bushing requires
piston (9). replacement, remove grease fitting (15) and
retaining rings (16) then press bushing from tube
6. Remove piston (9) from piston rod (14).
end.
7. Remove and discard seal (13), loader ring (12),
wear ring (11), and cast iron ring (10) from piston
(9).
8. Remove gland (1) from piston rod (14).
9. Remove and discard O-ring (7), backup ring (6),
rod wiper (2), rod seal (3), buffer seal (4), and
bearing (5) from gland (1).
5005-4
16 15
17
16
18
8
9
19
13
12
11
10
5
4
3
7
6
14
BC05M089
1. GLAND 6. BACKUP RING 11. WEAR RING 15. GREASE FITTING

2. ROD WIPER 7. O-RING 12. RING LOADER 16. RETAINING RING
3. ROD SEAL 8. BOLT AND WASHER 13. SEAL 17. BUSHING
4. BUFFER SEAL 9. PISTON 14. PISTON ROD 18. TUBE
5. BEARING 10. RING CAST IRON
STEERING CYLINDER ILLUSTRATION
5005-5
Assembly 17. Install bolt and hardened washer (8) in piston (9).
1. Install bearing (5) in gland (1). 18. Install piston (9) on piston rod (14) and start bolt
(8) into piston rod.
2. Install buffer seal (4) in gland (1) so that lips of
seal are toward small end of gland. 19. Tighten bolt (8) to a torque of 810 to 925 Nm
(597.5 to 682 pound feet).
3. Install rod seal (3) in gland (1). Rod seal must be
installed so that lips of seal are toward small end 20. Fasten tube (18) in vise. Be careful not to
of gland. Seal can be difficult to install. Use tools damage tube.
that will not damage seal. See illustration on 21. Apply petroleum jelly to O-rings (7) and backup
page 4. ring (6) on gland (1) and to sealing surface in
4. Install rod wiper (2) in gland (1) with wiper lips tube (18).
toward large end of gland. 22. Lubricate piston (9) and inside of tube (18) with
5. clean hydraulic oil.
6. Install O-ring (7) on gland (1). 23. Push the piston (9) straight into tube (18). Be
careful not to damage cast iron ring (10), wear
7. Install backup ring (6) on gland (1). The backup ring (11), and seal (13) on piston (9).
ring must be toward large end of gland. If backup
ring is not flat on both sides, the side that is not 24. When piston (9) is in smooth part of tube (18),
flat must be toward O-ring (7). start gland (1) into tube (18).
8. Fasten piston rod (14) yoke in vise. 25. If the original parts are being assembled:
9. Lubricate piston rod (15) and bore in gland (1) A. Tighten gland to a torque of 339 to 475 Nm
with clean hydraulic oil. (250 to 350 pound-feet).
NOTE: If a new gland (1) is being installed, write B. Install and tighten self-tapping screw (19) to a
part number of cylinder on gland. torque of 2.3 Nm (20 inch-pounds).
10. Push gland (1) onto piston rod (14) large end C. If, after tightening gland, the self-tapping
first. If necessary, use a soft hammer to drive the screw (19) holes are not aligned, a new hole
gland onto piston rod. for self-tapping screw must be drilled. See
Step 26.
11. Put a support below and near the end of piston
rod (14). Put a cloth between support and piston 26. If a new gland (1) or a new tube (18) are being
rod to prevent damaging piston rod. assembled:
12. Install new cast iron ring (10) on piston (9). A. Tighten gland (1) to a torque of 339 to 475 Nm
13. Install new wear ring (11) on piston (9).
B. Use a No. 27 drill bit and drill a hole half in
14. Install a new loader ring (12) on piston (9). gland (1) and half in tube (18). Drill to a depth
15. Install a new seal (13) over loader ring (12). of 11 mm (7/16 inch). Do not drill within 13 mm
(1/2 inch) of a hole for gland wrench.
16. Clean the threads on the end of piston rod (14)
and threads of bolt (8) using Loctite cleaning C. Install and tighten self-tapping screw (19) to a
solvent. Allow to dry. Apply Loctite 243 to piston torque of 2.3 Nm (20 inch-pounds).
rod threads 6.4 mm (1/4 inch) from open end of 27. If hoses were removed with cylinder, install new
piston rod so that there is 12.7 mm (1/2 inch) of O-rings, if equipped, on hose fittings. Lubricate
Loctite 243 on piston rod threads. DO NOT apply O-rings with clean oil. Install hoses.
Loctite to first 6.4 mm (1/4/inch) of piston rod
threads.
5005-6
NOTES
Section
5006
CENTER PIVOT
5006
5006-2
TABLE OF CONTENTS
SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5006-3
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin .......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for bearing retainers and lower pivot pin...........................................................124 Nm (91 pound-feet)
M12 bolts for lower pin plate .......................................................................128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals ............................................................................... Case AKCELA molydisulfide grease
Steering cylinder rod eyes............................................................................. Case AKCELA molydisulfide grease
SPECIAL TOOLS
CAS10219 ....................................................................................................................... Hand pump (hydraulic ram)
CAS10512 ....................................................................................................................................... 10 ton ram (long)
CAS10592 ........................................................................................................... Puller set, includes 24827 leg ends
CAS10600 ................................................................................ Bearing cup and seal puller, includes 24850 adapter
CAS10193 .............................................................................................................................. Vacuum pump (12 volt)
CAS2029 ................................................................................... *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from CAS10592)
BC06A174
CAS2029 DRIVER SET
5006-4
CENTER PIVOT
Disassembly 19. Disconnect the supply hose.
1. Remove all dirt and grease from the area of the 20. Install a cap on the hose and a plug in the fitting.
center pivot. Park the machine on a level surface. 21. Stop the vacuum pump.
2. Lower the bucket until the bucket is flat on the 22. Loosen and remove the self-locking nut and bolt
floor. that hold the pivot pin for the steering cylinder rod
3. Stop the engine and apply the parking brake. eye.
4. Remove the covers from both sides of the 23. Remove the pivot pin from the rear frame and the
machine. steering cylinder rod eye.
5. Disconnect the front wiring harness from the cab 24. Remove the washer from the rear frame. Move
floor. the steering cylinder out of the way.
6. Remove any tie straps that fasten the front wiring 25. Repeat steps 22, 23 and 24 for the other steering
harness to the chassis near the center pivot. cylinder.
7. Loosen and remove the nut and washer that 26. Loosen and remove the Ferry head screws and
fasten the chassis ground wire and cab ground retainers that fasten the drive shaft to the front
wire to the studs. yoke. Move the drive shaft out of the way.
8. Loosen and remove the bolt, lock washer, and 27. Place two stands below and in contact with the
nut that fasten the clamp on the front wiring front frame.
harness to the bracket on the rear frame. Move 28. Install blocks between the rear axle and the rear
the front wiring harness out of the way. frame on both sides of the machine to prevent
9. Loosen and remove the fill cap for the hydraulic the rear frame from tipping.
reservoir. 29. Put a jack in contact with both sides of the rear
10. Connect a vacuum pump to the hydraulic frame near the center pivot area. Use another
reservoir. Start the vacuum pump. jack at the rear of the machine to prevent the rear
frame from tipping.
11. Disconnect the brake hose from the backside of
front brake line bracket. 30. Loosen and remove the bolt (1), washer (2), and
spacer (3) that fasten the upper pivot pin (4) to
12. Install a plug in the tube and a cap on the fitting. the rear chassis (5).
13. Disconnect the hoses for the steering cylinder. 31. Use a prybar to remove the upper pivot pin (4).
14. Install caps on the fittings and plugs in the hoses. 32. Loosen and remove the bolts (1) and washers (2)
15. Loosen and remove the bolts, lock washers, and that fasten the lower pin plate (15) to the lower
self-locking nuts that fasten the mounting bracket pivot pin (10).
for the hoses to the bracket on the front frame. 33. Loosen and remove the bolts (1) and washers (2)
16. Loosen and remove the bolts, flat washers, and that fasten the lower pin plate (15) to the bottom
self-locking nuts that fasten the bracket for the of the rear chassis (5).
hoses to the rear frame. 34. Use the ram and hand pump to remove the lower
17. Disconnect the return hose. pivot pin (10).
18. Install the cap on the hose and a plug in the 35. Install the puller on the bottom spacer (14), see
fitting. Special Tools in this section.
5006-5
1 2
3
4
5
1
6
2
7
5
8
10
6 9
16 12 11
6
8
13
6
2
14
1
8
15 2
2
1
1
BS03B152
1. BOLT 5. REAR CHASSIS 9. UPPER PIVOT BEARING 13. BEARING RETAINER

2. WASHER 6. SEAL 10. LOWER PIVOT PIN 14. BOTTOM SPACER
3. SPACER 7. BEARING RETAINER 11. LOWER BEARING SPACER 15. LOWER PIN PLATE
4. UPPER PIVOT PIN 8. SHIM 12. LOWER PIVOT BEARING 16. FRONT CHASSIS
CENTER PIVOT ASSEMBLY
5006-6
36. Remove the bottom spacer (14). Assembly
37. Release the parking brake. 1. Pack the bearing cones with grease. Be careful
38. Use prybars to turn the left rear wheel backwards not to mix the bearing cones.
and the right rear wheel forward to move the front 2. Lubricate the bore in the top pivot with grease.
of the rear frame to the left for access to the
bearings. Install blocks under the wheels to 3. Install a bearing cup (20) in the top pivot (22).
prevent the rear frame from moving. 4. Install the bearing driver (17) and plate (21).
17 18 19
40. Hold the bearing retainer (13) in place and
loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (13) and shims
(8) to the bottom of the rear pivot.
41. Remove the bearing retainer (13) and shims (8).
42. Remove the lower bearing spacer (11) from the
top of the lower pivot.
20
43. Loosen and remove the bolts (1) and washers (2)
21 22
that fasten the bearing retainer (7) and shims (8)
to the top of the top pivot. BC06A118
44. Remove the bearing retainer (7) and shims (8). 17. BEARING DRIVER 20. BEARING CUP
18. NUT 21. PLATE
45. Use the puller to remove the seal (6) from the top 19. SREW 22. TOP PIVOT
of the bottom pivot.
5. Tighten a nut (18) on the screw (19) until the
46. Use the puller to remove the seal (6) from the bearing cup (20) is seated in the bore of the top
bottom of the top pivot. pivot (22). Remove the bearing driver (17) and
plate (21) from the top pivot (22).
47. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the upper pivot 6. Install a bearing cone (25), spacer (24), the other
bearing (9) from the top pivot. See Special Tools bearing cone (23), and the remaining bearing
in this section. cup (26) in the top pivot (22).
NOTE: The spacers are matched to the bearing 7. Install the bearing driver (17) and plate (21).
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.
bearing cup (26) is seated against the spacer
48. Use an acceptable driver, the hydraulic ram, and (24). Remove the bearing driver (17) and plate
the hand pump to remove the lower pivot bearing (21) from the top pivot (22).
(12) from the bottom pivot. See Special Tools in
this section. 17 18 19
23
NOTE: The spacers are matched to the bearing 26
sets. Do not mix the spacers. Do not use the old 24
spacers if new bearing sets are being installed.
49. Use an acceptable driver to press the seal (6) out
of each bearing retainer (7 and 13).
25
21 22
BC06A119
23. BEARING CONE 25. BEARING CONE

24. SPCAER 26. BEARING CUP
5006-7
9. Put the bearing retainer (7) in place on the upper 18. Use an acceptable driver to install the seal (6) in
pivot bearing assembly (9). the bottom of the top pivot.
10. Install the bearing driver (17) and plate (21). 19. The bottom of the seal (6) must be even with the
bottom of the top pivot.
bearing retainer (7) is tight against the upper
pivot bearing assembly (9).
17 18 19 27
7
BC06A125.
21 22 20. Apply grease to the upper pivot pin (4).

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

bearing cup (28) is seated in the bore in the
BC06A121 bottom pivot (29).
17. Fill the other seal (6) for the top pivot with grease.
27. Remove the bearing driver (17) and plate (21)
from the bottom pivot (29).
28. Install a bearing cone (25), spacer (24), the other
bearing cone (23), and the remaining bearing
cup (26) in the bottom pivot (29).
29. Install the bearing driver (17) and plate (21).
5006-8
40. Install the seal (6) in the bearing retainer (13).
21 18 19 The bottom of the seal (6) must be even with the
25 bearing retainer (13).
24
29
23 26
17
BC06A124

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

17 bottom spacer (14).
BC06A125 43. Apply grease to the lower pivot pin (10).
44. Install the lower pivot pin (10) in the bottom pivot.
bearing retainer (13) is tight against the lower
pivot bearing assembly (12). 45. Hold the bottom spacer (14) in place and
lubricate the bottom pivot until grease is forced
35. Measure the gap (30) between the bearing
out of the seal (6).
retainer (13) and the bottom pivot (29). Make a
record of the measurement. Subtract 0.0762 to 46. Rotate the lower pivot pin (10) to check the
0.1016 mm (0.003 to 0.004 inch) from the bearing assembly. The lower pivot pin (10) must
measurement. Select shims (8) equal to that rotate smoothly, but not easily.
value.
47. Remove the lower pivot pin (10) and the upper
36. Remove the bearing driver (17), plate (21) and pivot pin (4).
bearing retainer (13) from the bottom pivot.
48. Remove the bottom spacer (14).
37. Install the shims (8), the bearing retainer (13),
washers (2) and bolts (1).
38. Tighten the bolts (1) to 124 Nm (91 pound-feet).
39. Fill the seal (6) for the bearing retainer (13) with
grease.
5006-9
CONNECTING THE FRONT FRAME TO THE REAR FRAME

1. Release the parking brake. 26. Align the hole in the pivot pin with the holes in the
2. Move the rear frame into alignment with the front steering cylinder rod eye, and install the pivot pin.
frame. 27. Install the bolt and self-locking nut that hold the
3. Move the steering cylinders as required to move pivot pin.
the rear frame into alignment with the front 28. Repeat steps 25, 26 and 27 for the other steering
frame. cylinder.
4. Apply the parking brake. 29. Start the vacuum pump.
5. Apply grease to the upper pivot pin (4). 30. Connect the return hose.
6. Install the upper pivot pin (4), spacer (3), washer 31. Connect the supply hose.
(2) and bolt (1). Be careful not to damage the 32. Put the bracket for the hoses in position on the
seal (6). rear frame. Install the bolts, flat washers, and
7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184 self-locking nuts that fasten the bracket to the
pound-feet). rear frame.
8. Apply grease to the lower pivot pin (10). 33. Put the bracket for the hoses in position on the
9. Install the lower pivot pin (10) in the frames. Be front frame.
careful not to damage the seal (6). 34. Install the bolts, flat washers, and self-locking
10. Use the ram and hand pump to install the bottom nuts that fasten the bracket to the front frame.
spacer (14). See Special Tools in this section. 35. Connect the hoses for the steering cylinders.
11. Install the lower pin plate (15), three inner bolts 36. Connect the brake hose for the front brakes at
(1), and washers (2) that fasten the lower pin the front bracket.
plate (15) to the lower pivot pin (10). 37. Stop the vacuum pump.
12. Tighten the bolts (1) to 69 Nm (51 pound-feet). 38. Connect the front wiring harness to the rear
13. Measure the gap between the lower pin plate wiring harness.
(15) and the bottom pivot. Make a record of the 39. Put the clamp on the wiring harness in position
measurement. Subtract 0.0762 to 0.1016 mm on the bracket. Install the bolt, lock washer, and
(0.003 to 0.004 inch) from the measurement. nut that fasten the clamp on the wiring harness to
Select shims equal to that value. the bracket.
14. Loosen the bolts (1) that fasten the lower pin 40. Put the ground wire in position on the stud. Install
plate (15) to the lower pivot pin (10). the washer and nut that fasten the ground wire to
15. Start the six outer bolts (1) into the lower pin the stud.
plate (15) and the bottom pivot. 41. Install a tie strap to fasten the wiring harness to
16. Install the shims (8). the tube.
17. Tighten the six outer bolts (1) to 128 to 136 Nm 42. Disconnect the vacuum pump from the hydraulic
(94 to 100 pound-feet). reservoir.
18. Tighten the three inner bolts (1) to 124 Nm (91 43. Check the fluid level in the hydraulic reservoir.
pound-feet). Add oil as required.
19. Remove the jacks from the rear frame. 44. Install the fill cap in the hydraulic reservoir.
20. Remove the blocks from the rear axle. 45. Bleed air from the front axle bleed screws. Refer
21. Remove the stands from the front frame. to Section 7002 for complete brake bleeding
instructions.
22. Put the drive shaft in position on the front yoke.
46. Lubricate the pivot pins for the steering cylinder
23. Install new Ferry head screws that fasten the rod eyes.
drive shaft to the front yoke.
47. Install the covers on both sides of the machine.
24. Tighten the Ferry head screws to 61 to 81 Nm
25. Put the steering cylinder rod eye in position in the
frame. Install the washer between the steering
cylinder rod eye and the rear frame.
5006-10
NOTES
Section
5008
AUXILIARY STEERING MOTOR AND PUMP
5008
5008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5008-3
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Motor ...........................................................................................................................................................24 volts
Auxiliary steering pump
Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)
5008-4
AUXILIARY STEERING MOTOR AND PUMP
Disassembly Assembly
NOTE: Refer to Section 5001 for removal and 1. Lubricate all parts with clean hydraulic oil before
installation of the auxiliary steering motor and pump. assembly.
NOTE: The pump is the only component that is 2. Lubricate and install a new seal (4) and retaining
disassembled. The switch (8) and motor (1) are ring (3) on the plate (17). Refer to the illustration
replaced as units and are not serviced. Refer to the on page 5.
3. Lubricate and install a new backup ring (5) and a
1. Make an alignment mark on the pump assembly new seal (6) on the plate (17).
and motor (1).
4. Lubricate and install new O-rings (7) on the body
2. Loosen and remove the two screws (15) and lock (18).
washers (14) that hold the pump assembly to the
5. Lubricate and install the pins (22), drive gear
motor (1).
(20), driven gear (19) and wear plates (23) on the
3. Remove and discard the mounting gasket (13), body (18).
retaining ring (3) and seal (4) from the pump
6. Lubricate and install a new backup ring (5) and a
assembly.
new seal (6) on the end plate (21).
4. Loosen and remove the four bolts (2) that hold
7. Align the marks, made during disassembly, on
the pump assembly together.
the end plate (21), body (18) and plate (17) and
5. Remove the end plate (21) from the body (18). install the four bolts (2). Tighten the four bolts (2).
6. Remove and discard the seal (6) and backup ring 8. Install a new gasket (13) on the pump assembly.
(5) from the end plate (21).
9. Align the marks, made during disassembly, on
7. Remove the wear plate (23), drive gear (20) and the pump assembly and the motor (1).
driven gear (19) from the body (18).
10. Install the lock washer (14) and screw (15).
8. Remove the body (18) from the plate (17). Torque the screw (15) to 35 to 39 Nm (312 to 348
pound-inches).
9. Remove and discard the O-rings (7) from the
body (18).
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup ring
(5) from the plate (17).
NOTE: The only serviceable items on the pump
assembly are the seals (6), backup rings (5), O-rings
(7), seal (4), retaining ring (3) and gasket (13). If any
of the other items are damaged, replace the pump
assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.
5008-5
10 8
9
11
12 16
13
3 17
4 14
15
5
6
23
19
7
22
18
22
7
20
23
6
5
21
2
BS01C121
1. MOTOR 7. O-RING 13. GASKET 19. DRIVEN GEAR

2. BOLT 8. SWITCH 14. LOCK WASHER 20. DRIVE GEAR
3. RETAINING RING 9. CABLE 15. SCREW 21. END PLATE
4. SEAL 10. SCREW 16. WIRE 22. PINS
5. BACKUP RING 11. LOCK WASHER 17. PLATE 23. WEAR PLATE
6. SEAL 12. WASHER 18. BODY
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
5008-6
NOTES
Section
5009
JOYSTICK STEERING SYSTEM

(JSS)
5009
5009-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
JOYSTICK STEERING SYSTEM (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of the JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F-N-R Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Procedures for Turning the JSS On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Kick-down Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustration of the valve PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Illustration of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEERING VALVES PVG32 AND PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
JSS HYDRAULIC PRESSURE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Steering Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
STEERING SPEED CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5009-3
SAFETY RULES
WARNING
This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully
read the message that follows and be alert to the possibility of machine damage, serious injury, or death.
M171C
WARNING
Be cautious when turning with joystick steering. Abrupt movements of the joystick to the left or right could cause
the machine to turn more sharply than acceptable. Take necessary precautions. Do not use the joystick for primary
steering. It is intended for short repetitive operations. Failure to comply could result in machine damage, death or
serious injury.
M1336
WARNING
If hydraulic pilots are disengaged, the joystick steering still remains active. Always disengage joystick steering
when not in use. Failure to comply could result in machine damage, death or serious injury.
M1348
WARNING
Do not use joystick steering when loading or unloading the machine from a truck or trailer. Always use the primary
steering wheel when loading or unloading the machine from transport. Failure to comply could result in machine
damage, death or serious injury.
M1345
WARNING
Use caution when moving about in the operator’s compartment when joystick steering is active. An inadvertent
movement against the joystick steering control could cause the machine to turn or move abruptly. Failure to
comply could result in machine damage, death or serious injury.
M1347
WARNING
Do not use joystick steering when traveling on a public road or highway. The left arm rest must be raised and in a
locked position. Use the primary steering wheel if travel on a public road or highway is required. Failure to comply
could result in machine damage, death or serious injury.
M1346
WARNING
Do not use joystick steering if operating at speeds over 20 km/h (12.4 mph). Always use the primary steering
wheel at higher speeds for optimum control of the machine. Failure to comply could result in machine damage,
death or serious injury.
M1349
5009-4
JOYSTICK STEERING SYSTEM (JSS)
Description of the JSS Preliminary check
The JSS is mounted in parallel with the standard Preset condtion must be met by:
steering system. The standard steering system ● left armrest completely lowered
always has priority. If during joystick operation, the ● gear lever in neutral
primary steering wheel is moved, steering will revert
● equipment locking switch disenabled
to primary steering. Joystick steering is designed for
short, repetitive machine operations. ● pilot pressure switch on
● joystick steering switch in neutral
WARNING ● machine is stationary.
Do not use joystick steering if operating at speeds
over 20 km/h (12.4 mph). Always use the primary System efficiency check
steering wheel at higher speeds for optimum control
● with the JSS off, the pilot pressure must be less
of the machine. Failure to comply could result in
than or equal to 8 bar (115 psi).
machine damage, death or serious injury.
● the software monitors the armrest position switch.
M1349
When the JSS is turned on and during operation,
the switch position is checked. If the position of the
3 armrest is raised or the switch is shorted, the
system will deactivate.
After all conditions have been met, the JSS will be

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

necessary that the machine meet specific conditions
prior to activation. The software will run a preliminary
test to verify the machine is in the preset conditions
and check the condition of the JSS system.
5009-5
ALARM ● In order to activate the JSS F-N-R switch, it is

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

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

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

status
JSS / AUX F-N-R (JSS) AUX F-N-R JSS / AUX F-N-R JSS (AUX) F-N-R
disabled enabled disabled enabled
Activation JSS activation signal JSS activation signal Auxiliary F-N-R F-N-R enable signal
signal enabling signal or JSS enable signal
JSS safety Equipment locking Equipment locking

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

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

conditions JSS F-N-R = neutral. JSS F-N-R = neutral. Main F-N-R gear Main F-N-R gear
lever = neutral; lever = neutral;
AUX F-N-R = AUX F-N-R =
neutral. neutral.
Resulting JSS F-N-R Enabled JSS F-N-R Enabled AUX F-N-R JSS F-N-R
F-N-R Stays enabled. Stays enabled. Enabled Enabled
within 8 seconds
status
release parking
brake and engage
F or R to maintain
enabling.
F-N-R If JSS F-N-R not in If JSS F-N-R not in If AUX F-N-R not in
conditions neutral. neutral. neutral.
not met
F-N-R JSS / AUX F-N-R JSS / AUX F-N-R JSS / AUX F-N-R
alternative disabled. disabled. disabled.
status
5009-7
ERROR CODES
Errors for the JSS will only be displayed if the switch is in the ON position.
The errors can be reset by turning the JSS system OFF and On. The following two errors will not reset:
● 1821r Power Supply Failure ● 1830y Activation Switch failure.
The errors will always be shown on the display once they are present. To reset these errors the engine must be
turned off.
ERROR CODES TABLE
Error
Item Error Message
1 1812 JSS Failure Armrest Switch- short to battery or ground
2 1816 JSS Activation Button Failure – mechanical defect
3 1820 JSS Power Supply Failure – check JSS relay, valve, or joystick
4 1821 JSS Short to ground or power on relay, or activation switch
failure
5 1823 JSS Relay Ground Failure
6 1824 JSS Activation Switch Short to Battery
7 1830 JSS Activation Switch failure
8 1831 JSS Error JSC – wrong operation, controller internal fault
9 1832 JSS Signal Input Error JSC – controller out of limits
10 1833 JSS Signal Output Error JSC – controller out of limits
11 1834 JSS JSS controller, JSC output, short to BAT power
12 1835 JSS Valve Failure Power Supply
13 1836 JSS JSS controller, board temperature out of limts
14 1837 JSS JSS controller, switched power out of limits
15 1838 JSS Neutral switch out of range
16 1839 JSS Joystick steering is not calibrated
17 1841 JSS Valve Alarm
18 1842 JSS Valve Alarm Open Circuit
19 1843 JSS Pilot Pressure is High
20 1844 JSS Pilot Pressure Switch Short to Ground
21 1845 JSS Pilot Pressure is Low
22 1846 JSS Failure on LS Pressure Switch
23 1847 JSS JSC model type not available
24 1850 JSS Joystick Failure - Neutral Switch / Power Supply
25 1852 JSS Error in Ground Connection
26 1860 JSS CAN timeout of C5.E detected by JSC
27 1861 JSS CAN timeout of AIC detected by JSC controller
28 1863 JSS Internal malfunction transmission controller
29 9134 JSS CAN communication failed
30 9135 JSS CAN communication failed
5009-8
210 bar
3
211.6 bar
1
210 bar
2
W190-4R091
ILLUSTRATION OF THE VALVE PVFC
Connections
Port 1 - to the steering priority valve
Port 2 - to the auxiliary steering valve
Port 3 - to the LS port of the valve PVG32
5009-9
TO
T
LX
PP
A T2
B
P
W190-4R092
ILLUSTRATION OF THE VALVE PVG32
Connections
Ports A / B to the steering cylinder on the stem Port PP pilot pressure switch 8 bar
side and bottom side 350 bar, 65 l/min Port T outlet 25/40 bar
LS port to port 3 of the valve PVFC Port T2 not used
Port P to the steering priority valve 350 bar, 65 Port TO LX not used
l/min
5009-10
2
6
9
11
4
3
8
10
1
5
W190-4R099
EXPLODED VIEW OF THE VALVE PVG32
1. Valve PVPV 7. Screws

2. Valve PVM 8. Seal
3. Valve PVB 9. Seal
4. Shuttle PVBS 10. Seal
5. Valve PVES 11. Seal
6. Shuttle PVSI
5009-11
ELECTRICAL SYSTEM
Removal STEP 4
STEP 1
Park loader on level ground and lower bucket to 1
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down engine. Put the master
disconnect switch in the OFF position.
STEP 2 11
Remove all dirt and grease from the steering system
valves and adjacent area.
IMPORTANT: Tag all connections prior to
disassembly. 9
10
STEP 3
1
W190-4R072
3 Remove nut (11) from the stud (9) to release the
chassis grounding cable (1).
2
STEP 5
4
7
2
8
5
6
W190-4R071
Disconnect the chassis harness (1) from the valve

PVG32 (2). Disconnect connector (3) from the pilot
pressure switch, connector (4) from the proportional
valve, connector (5) from the solenoid valve. From
the PVFC valve (6) disconnect connector (7) and 1
remove strap (8).
W190-4R073
Open the access panel on the right-hand side of the
cab to access the fuse and relay compartment.
Disconnect the connector from the chassis harness
(1) from the joystick cable (2). Remove the chassis
frame cable (1).
5009-12
STEP 6 STEP 8
5
2
3 8
2
W190-4R074
Disconnect the joystick harness (2) from the cab
wiring harness (3). W190-4R076
Disconnect the joystick cable (2) from the steering

STEP 7 control module (5) by detaching the sixteen-position
connector (6). Disconnect connector (7) from the
transmission switch and the cab harness connector
(8).
3 STEP 9
1
10
2
W190-4R075
9
Disconnect the connector (1) from the joystick 5
harness (2). Disconnect the armrest harness (3) from
the six-position connector (4). 12
11
W190-4R077
Remove the steering control module (5) from the

supporting plate (9) by removing the three nuts (10),
capscrews (11) and washers (12).
5009-13
STEP 10
6 2
3
4
W190-4R078
Detach the joystick harness (1) from the mounting
brackets on the fuse and relay panel (2). Remove the
two connectors (3) by removing the two nuts (4),
washers (5) and capscrews (6). Remove the joystick
harness (1).
STEP 11
W190-4R080
To remove the armrest harness (9), see page 33.
5009-14
STEP 12
1
3
4 12
7
14
13
16
15
8 W190-4R083
5 Open the access panel on the right-hand side of the
cab to access the fuse and relay compartment. Install
6
the steering control module (12) on the supporting
W190-4R071
plate (13) by installing the three nuts (14), capscrews
Connect the chassis harness (1) to PVG32 valve (2),
(15) and washers (16). Tighten the capscrews.
connect connector (3) to the pilot pressure switch
connector (4). Connect connector (5) to the solenoid
valve. Connect connector (7) to the pressure switch
on valve PVFC (6) and secure the harness with strap STEP 15
(8) on the valve.
4
STEP 13 1
5
1
11 6
7
10
W190-4R088
Connect the chassis harness (1) to the grounding
stud (9), install and tighten the nut (11).
W190-4R084
Connect the joystick harness (1) to the steering
control module (4) with connector (5). Connect
connector (6) to the cab harness connector (7).
5009-15
STEP 16 STEP 18
12 9
8 10
11
2
W190-4R085
Mount the joystick cable (1) to the fuse and relay
panel (9) by installing the two nuts (10), washers (11)
and capscrews (12). Tighten the capscrews.
1
STEP 17
W190-4R073
Connect connector (1) to the joystick harness (2).
14 STEP 19
13
1
W190-4R086
3
Connect the joystick harness (1) to the cab harness
(13) with connector (14).
W190-4R082
To install the armrest cable (3), see page 39.
5009-16
STEP 20
3 4
W190-4R087
Connect interface connector (4) of the joystick

harness (2), connect the armrest harness (3) to
connector (5).
5009-17
8
14
D
C 20
12 11 10 19
27
28
15 29
F
E
Detail E
Detail C 16 view from F
13 view from D
18 1. Plate 20. CAN Module

1 2. Steering control device 21. Relays
3. Cab/joystick cable 22. Diode
4. Chassis cable 23. 8 bar pressure switch
21 5. Washer 24. 60 bar pressure switch
2 9 6. Screw 25. Steering valve PVFC
22 7. Nut 26. Steering valve PVG32
23
A 8. Joystick Steering System switch 27. Armrest position switch
3 9. Nylon strap 28. F-N-R switch
26
10. Screw 29. Kick-Down switch
7 6 5 11. Washer 30. Solenoid valve
12. Nut
24 13. 10A fuse in position ECA-F2
14. Cab
30 15. Stud pin on rear chassis frame
25 16. Cable terminal with eyelet
17 17. Metal cable clamp
4
View from A 18. Armrest cable
19. Control joystick
721E-4R001
ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM

5009-18
20
21
21
19 27
8
88
22
22
88
29 22
22
22
21
21
28
13
13
26
24
24
25
16
23
23 22
84419913sht
84419913 sht13
13
WIRING DIAGRAM
WIRING DIAGRAM OF
OF THE
THE JOYSTICK
JOYSTICK STEERING
STEERING SYSTEM
SYSTEM
5009-19
STEERING VALVES PVG32 AND PVFC
Removal STEP 3
STEP 1
Clean all dirt and grease from the steering valves
and adjacent areas.
STEP 2
4
2
3
W190-4R003
1 Tag and disconnect the hose (4) and (5) from valve
PVFC (2). Plug hoses and cap fittings.
2
STEP 4
W190-4R002
Loosen and remove the LS (3) tube from valve
PVG32 (1) and valve PVFC (2).
W190-4R004
Tag and disconnect the hose from the steering
priority valve to valve PVG32.
5009-20
STEP 5 STEP 8
W190-4R005
Tag and disconnect the outlet hose.
STEP 6
1 4
3
W190-4R008
Remove the steering valve PVG32 (2) from the
support bracket (1) by removing the four capscrews
(3) and washers (4).
W190-4R006
Tag and disconnect the supply hose to the steering STEP 9
cylinder line.
STEP 7 1
3
2
5
4
W190-4R009
Remove the mounting bracket (1) from the rear
chassis removing three nuts (2), washers (3),
W190-4R007 capscrews (4) and washers (5).
Tag and disconnect the supply hose to the steering
cylinder line.
5009-21
STEP 10 STEP 13
1
14
14
2
W190-4R010
Remove the mounting bracket (1).
W190-4R013
Unscrew the fittings (14) from the steering valve
STEP 11 PVFC (2).
1 8
STEP 14
7
1
9
10
6
2
W190-4R011
Remove the steering valve PVFC (6) from the
mounting bracket (1) by removing the two nuts (7),
W190-4R014
washers (8), capscrews (9) and washers (10). Remove the pilot pressure switch (1) with seal (2)
from the steering valve PVG32.
STEP 12
STEP 15
12
13
3
11
2 W190-4R015
Remove the reduction fitting (3).
W190-4R012
Unscrew the pressure switch (12) with seal (13) from
the “T” fitting (11).
5009-22
STEP 16 STEP 19
4
W190-4R016
Unscrew the union (4) from the “LS” port of the
steering valve PVG32.
W190-4R019
STEP 17 Remove joint (7) from port “T”.
W190-4R017
Remove the two fittings (5) from ports “A” and “B”.
STEP 18
W190-4R018
Remove the fitting (6) from the port “P”.
5009-23
NOTE: Before assembling the steering valves, clean
the parts using solvent and dry them. 3
1. Inspect each part for defects.
2. Replace all damaged or deformed parts with new
ones.
STEP 20
1
W190-4R022
Install the two fittings (3) into ports “A” and “B”.
Tighten the fittings to 100 N m (75 pound feet).
STEP 23
W190-4R020
Install the joint (1) into port “T” of the steering valve
PVG32. Tighten the joint to 310 N m (230 pound
feet).
1
STEP 21
W190-4R023
2 Install the firing (1) into port “LS”. Tighten the fitting to
45 N m (33 pound feet).
STEP 24
W190-4R021
Install fitting (2) into port “P”. Tighten the fitting to 170 2
N m (125 pound feet).
W190-4R024
Install the reducer (2) for the pilot pressure switch on
the port “Pp”. Tighten the reducer to 45 N m (33
pound feet).
5009-24
STEP 25 STEP 27
3 10
2 11
4
9
W190-4R025
Install the pilot pressure switch (3) with seal (4) into
the reducer (2).
W190-4R027
STEP 26 Install the pressure switch (10) with seal (11) into the
“T” fitting (9).
STEP 28
6 1 4
3
7
8
5
5 6
2
W190-4R026
Install fitting (6) into port “1” of the steering valve W190-4R028
PVFC (5), “T” fitting (7) into port “2” and fitting (8) into Mount the steering valve PVFC (2) onto the mounting
the port “3”. Tighten all the fittings to 45 N m bracket (1) using two capscrews (3), washers (4),
(33 pound feet). nuts (5) and washers (6).
STEP 29
W190-4R010
Position the mounting bracket (1) for the steering
valves into the LH side rear chassis.
5009-25
STEP 30 STEP 32
9
1
11 10
7 8
W190-4R029 W190-4R007
Install three capscrews (7), washers (8), nuts (10) Connect the stem side steering cylinder supply hose
and washers (11). Tighten the nuts to 110 N m onto the fitting. Tighten the hose to 60 N m (44 pound
(80 pound feet). feet).
STEP 31 STEP 33
12
W190-4R006
Connect the bottom side steering cylinder hose.
Tighten to a torque of 60 N m (44 pound feet).
STEP 34
1 14
13
W190-4R030
Install the steering valve PVG32 (12) onto the
mounting bracket (1) using the four capscrews (13)
and washers (14). Tighten the screws to a torque of
W190-4R005
Connect and tighten the outlet hose to 125 N m (92
pound feet).
5009-26
STEP 35 STEP 37
W190-4R004
Connect the suction hose of the steering priority
valve. Tighten the pipe to a torque of 60 N m
(44 pound feet). 5
STEP 36 4
W190-4R032
Connect the line for the “LS” (5) on the valve PVG32
(4) and on the valve PVFC (1). Tighten the line
2
1
W190-4R031
Connect the hose (2) and hose (3) to valve PVFC (1).
Tighten to 14 N m (10 pound feet).
5009-27
26 10
30 16
View from “B” 27 13 10
E 33
See table 2
18 31
25 C
12 8
6 8
27 2
5 23 22
22 24
17
1
15
20 19
19 21
Detail “A”
B 34
F 3 4
See table 2 A View from “C”
W190-4R033
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERINGSYSTEM - Table 1
5009-28
9
28
29
11
10
10
13
Detail J
35
J
11
13
36
16 D
30
9. Joint
30 10. Steering cylinder line pipes
Detail D view from H 11. Joint
14 13. Outlet pipe of valve PVG32
14. Joint
16. Priority valve suction pipe
28. Steering cylinder line pipe (bottom side)
Detail E 29. Steering cylinder line pipe (stem side)
30. LS priority steering valve pipe
Detail F view from G 35. Hydraulic pump
36. Steering priority valve
W190-4R034
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERINGSYSTEM - Table 2
5009-29
26 13
34 10 10
27
30
* E 33 16
View from B
18
* D
7
31
25 C 12 8
22 24
8
6
2
5 23
17 27
* 22
G
1
15
20 19
21 19
F *
1. Steering valve support 22. Washer
2. Steering valve PVG32 23. Nut
3. Washer 24. Screw
4. Screw 25. 60 bar pressure switch
B 5. Steering valve PVFC 26. 8 bar pressure switch
6. Joint 27. Seal
7. Steering LS pipe 30. LS priority steering valve pipe
8. Joint 31. Joint
10. Steering cylinder line pipes 33. Reduction
12. Joint 34. Power steering valve
13. Outlet pipe of valve PVG32
15. Joint
16. Priority valve suction pipe
A 17. Joint
7 6
18. Flexible pipe LS of power steering line
19. Washer
4 20. Nut
View from C
3 21. Screw
* See table 2
W190-4R119
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERINGSYSTEM - Table 1
5009-30
34
Detail J
9
28
29
18
11
32
13
10 Detail D
36
11 J
Detail E 32
16
9. Joint
10. Steering cylinder line pipes
11. Joint
13. Outlet pipe of valve PVG32
30 14. Joint
14 16. Priority valve suction pipe
18. Flexible pipe LS of power steering line
28. Steering cylinder line pipe (bottom side)
Detail F 29. Steering cylinder line pipe (stem side)
view from G 30. LS priority steering valve pipe
32. Flexible hose feed of power steering valve
34. Power steering valve
36. Steering priority valve
W190-4R120
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERINGSYSTEM - Table 2
5009-31
9
1 2 19
15 18
16
21
11 YPP
A1
UNLOCK
20
P
T X1
LOCK
8 16B
MX
16A B1
20D
12 T 20A
280 bar
14
16C
20C
R R1 F
4 13A 13
2 20B
X 13F
16D
3
1
13E
5 P
2 B A
3 13D 16E
13B 1
T1
T1'
N B
240±8% L/min
240±8% L/min
280±8% L/min
20±8% L/min
B1 280±8% L/min
OPTION
22K
BOOM
BUCKET
22K
a3
a2
6 13C
T2
868050
868050
ø0.8
ø2.0
ø2.0
ø0.8
pst
22A
0.6
R2
a1
A1
A3
A2
B3
B2
P
17
765876
LS
Mp
1.2
Pst
22F
11
R901075585
898999
7
528789
528789
528789
30 bar
22C
T
22C )( 22H
22C
22G
847160
TP11: REAR BRAKE TO AXLE 10
224±3 bar
R901007569
R901075587
859551
TP10: FRONT BRAKE TO AXLE 22J
22D
8-10.8 bar
329140
TP6: FRONT BRAKE ACCUMULATOR
MT1
22B
S1
TP7: REAR BRAKE ACCUMULATOR
TP3: STEERING LOAD SENSE
737012
290 bar
290 bar
936718
936718
290 bar
290 bar
936718
936718
TP2: IMPLEMENT LOAD SENSE
936725
TP5: STEERING PUMP PRESSURE
22D
TP1: UNLOADING PUMP PRESSURE 22E 22E 22D 22E
22E
S2
TP9: PILOT PRESSURE SUPPLY
22
A2
280±8% A1
b1
B2
899039
868050
ø2.0
ø2.0
ø0.8
ø0.8
L/min
45C
M2 P
22K 22K
b2
b3
45B
44 45A
45
43
42 234
M2 162 bar IN bar
35 LS EF LS IMPL 24
23cc 234
M1 TANK CF
bar .64
L
.8 24A
P 24B
46
45B 45D
Note 2 T 24C
35A T 30 LS 23
M1 LS SLS ST CF 32
G1
0.7
35B 35C 27
G2 X2
R
34 X1 30A 2
33 T
240 bar 0.31 1 46
0.31
34A 33A 30B
36 29
R L
34B 33B 3
30C
40 28
Note 1 0.75 LS
23cc 34C 33C T P
P T
28A
41 P
34D 33D
1.8
28B 28C
L1 L2 S1 S2 L4 L3 p
31 26
39 11 cc
T
25
38
37 37
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM - 821F (Note: Joystick steering section the same for 921F)
5009-32
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM - 821F

5009-33
JOYSTICK STEERING SYSTEM ARMREST
Removal STEP 3
STEP 1
3
1 6
4
W190-4R037
Remove the four locking screws (6) from the armrest

W190-4R036 (3) and support (4). Remove the armrest (3).
Unscrew and remove the knob (1) and the washer (2)
for armrest adjustment. STEP 4
STEP 2 8
7
4
W190-4R101
W190-4R035
Disconnect connector (7) from the “Kick-Down”
Remove the cover (3), support (4) from the armrest button (8) from the armrest cable connector (9).
adjustment (5).
5009-34
STEP 5 STEP 7
3
8 7 12
1
9 10
W190-4R102 11
From the inside and bottom of the armrest cover (1)
unscrew the threaded washer (2) and remove the W190-4R038
“Kick-Down” button (3). Remove the two nuts (8), washers (9), screws (10)
and washers (11) from the PVRES joystick (7).
STEP 6 Disconnect the connector (12) from the valve (7).
STEP 8
5
5 4 6 7
1
3
1
2
6
W190-4R040
Disconnect the connector (2) from the CAN module

(1). Release the armrest cable (3) from the mounting
4
bracket by removing the nut (4) and the washer (5),
capscrew (6) and the washer (7).
W190-4R103
Disconnect the connector (4) from the “F-N-R” switch

(5) from the armrest cable (6). Remove the switch (5)
from the armrest (1).
5009-35
STEP 9 STEP 11
12
1
10
2
W190-4R039
Detach the CAN module (1) from the support (8).
STEP 10
13
11
9
W190-4R041
Unscrew and remove the knob (10) for height

adjustment of the armrest and spacer (11). Raise
and remove the armrest (12) from the support (13).
W190-4R042
STEP 12
Disconnect the connector (9) from the armrest
positioning switch. Remove the armrest cable. 1
3 5
4 4
2 6
W190-4R043
Remove the armrest height / angle adjustment (2)

from the support assembly (1) by removing the nut
(3), washers (4), capscrew (5) and two nylon
bushings (6).
5009-36
STEP 13 STEP 14
10 8 2
7 11
3
4
9
2 7
5 6
W190-4R104
W190-4R044
Remove the locking bracket (7) with pin (8) from the Unscrew the knob (2) from the suppor t (1) and
armrest height/angle adjustment (2). Unscrew the extract the armrest height/angle adjustment pin (3).
two nuts (9), capscrews (10) and the washers (11). Remove the plate (4) from the suppor t (1) by
Remove the pin (8) from inside the seat of the removing the four capscrews (5) with washers.
bracket (7). Remove the armrest position switch (6) from the
inside of the support (1) by removing the two screws
(7) and washers.
STEP 15
8 9
W190-4R045
Disconnect the wiring harness from the operator’s
seat (if equipped with air seat). Remove the four
capscrews (8), washers (9) from the base of the seat.
Remove the seat.
5009-37
STEP 16 STEP 19
13
12
10 11
1
W190-4R046 W190-4R049
Remove the suppor t fastening the seat belt by
Raise while slowly rotating the seat cushion
removing nut (10), washer (11), capscrew (12) and
support plate (1).
washer (13).
STEP 20
STEP 17
4
14
3
W190-4R050
W190-4R047
Unhook the rod (4) from the support (3) and remove
Remove the four screws (14) and washers from the
the seat cushion plate (1).
seat cushion.
STEP 21
STEP 18
1 5
7
2
6
W190-4R051
W190-4R048
Turn the knob of the support (3) clockwise and move
Pressing down on the seat cushion support plate (1), plate (5) forward until the four sliding blocks (6) are in
slightly tilt the aluminium tongue (2) to release the slots (7). Remove the plate (5).
support (1) and allow raising/rotating the front. Use
caution when releasing aluminium tongue (2) to
avoid breaking it.
5009-38
STEP 22 STEP 23
2 3
4 5
8
W190-4R052
Remove the plate (1) of the seat by removing the four

retaining bolts (2) and washers (3). Slide the plate (1) W190-4R053
forwards to gain access to the two front nuts (4) and Remove the armrest support plate (8).
washers (5) inside the two guides (6) under the plate
(1) of the seat. Repeat the procedure for the two rear
screws (7) by sliding the plate (1) back.
5009-39
STEP 24
8
6
3 4
8
W190-4R054
Position the armrest support plate (8) on the seat

runners (6).
STEP 25 5 6
W190-4R056
2 Push the seat plate (1) forward. From the top, insert
1 the two front capscrews (3) and washers (4). From
the seat runners (7) install nuts (5) and washers (6).
Tighten the nuts to a torque of 32 Nm. Repeat the
W190-4R055
procedure for the two rear capscrews.
Position the seat plate (1) on the seat support plate
(2).
5009-40
STEP 27 STEP 30
9 10
4
3
1
W190-4R057 W190-4R059
Install the seat plate (9). Turn the locking support (10) Install the seat cushion (3) onto plate (1) and secure
clockwise and at the same time push the plate (9) it with four screws (4) and washers.
toward the rear of the seat to locking it.
STEP 31
STEP 28
13 11 6
5
9 7 8
12
W190-4R060
Install the seat belt, install capscrew (5) and washer
W190-4R058
(6), nut (7) and washer (8). Tighten the nut to a
Insert the two lugs for the seat cushion plate (11) torque of between 47 and 68 Nm. Check that the
inside the two openings on the seat plate (9). Hook seat belt mounting hardware is tight and the seat belt
the rod (13) to the catch (12). Slowly lower the seat is not cut or frayed.
cushion support plate (11).
STEP 32
STEP 29
9 10
2
W190-4R061
W190-4R048
Lock the seat cushion support plate (1) by bending Put the seat in the cab. Connect the wiring harness
the aluminium tongue (2) into position. Use caution to the operator’s seat (if equipped with air seat).
when bending the aluminium tongue (2) to avoid Install the seat on the base and secure it with the four
breaking it. capscrews (9) and washers (10). Tighten the screws
to a torque of between 73 and 87 Nm.
5009-41
STEP 33 STEP 34
5 11 8
9 12
4
6
13
3 10
7 2
W190-4R105
W190-4R062
Install the armrest position switch (2) on the support Insert the armrest locking pin (8) in the bracket (9).
(1) using the two screws (3) and washers. Insert the install it on the armrest height/angle adjustment (10)
adjuster pin (4) inside the support (1) and screw the using the two capscrews (11), washers (12) and nuts
knob (5) on it. Install the plate (6) on support (1), (13). Tighten the nuts to 7 Nm.
secure it using four capscrews (7) and washers.
STEP 35
W190-4R106
Insert, rotate and secure the armrest locking pin (8)
as shown.
5009-42
STEP 36 STEP 38
1
11
6 4
5 5
2 3 W190-4R065
Connect the positioning switch connector (11).

W190-4R063
Install the armrest height/angle adjustment (2) on the STEP 39

support assembly (1), insert the two nylon bushings
(3), capscrew (4), washers (5) and nut (6).
STEP 37
1
7
2
9 W190-4R066
Install the CAN module (1) in the seat (2) on the
armrest.
STEP 40
8 7 5 6
8 1
10
W190-4R064
Insert the armrest (7) inside the support (8), Install

the knob (9) for armrest height adjustment with 3
spacer (10).
W190-4R067
Connect the connector (3) to the CAN module (1).

Secure the cable (4) to the mounitng bracket using
capscrew (5), washer (6), nut (7) and washer (8).
5009-43
STEP 41 STEP 43
2
14 9 10
12
11 1
13 3
W190-4R068
Connect connector (10) to the PVRES Joystick (9).

Mount the Joystick to support (11), install the two
capscrews (12), four washers (13) and two nuts (14).
Position the valve (9) so the letter “A” stamped on it is
on the left-hand side of the armrest.
W190-4R108
STEP 42
Connect connector (1) of the “Kick-Down” button (2)
to the cable (3).
16
STEP 44
15
5
17
4
W190-4R107
Insert the “Kick-Down” button (16) on the armrest

(15) and secure it with the nut (17).
7
W190-4R109
Insert the “F-N-R” switch (5) in the armrest (4),
connect connector (6) to the cable (7).
5009-44
STEP 45 STEP 46
4 1
2
4
9
8
3
W190-4R069
Put the armrest (4) on the support (8), secure it with

the four capscrews (9).
W190-4R070
Position armrest (1) with support (2) onto the armrest

adjustment (3) and inatll knob (4) with washer (5).
5009-45
JSS HYDRAULIC PRESSURE ADJUSTMENTS

NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to
Section 8002 Testing and Adjusting the Loader/Steering Pump Differential Pressure.
Pressure Setting Test 4. Make sure that the temperature of the hydraulic
oil is at least 54° C (129° F).
1. Install articulation lock (1). 5. To measure the temperature of the oil using the
instrument panel:
DANGER

that need to be monitored.
WARNING
1 7. Start and run the engine at full throttle.
8. Lower the lift arms and hold the control lever in
the FLOAT position.
9. Hold the bucket control lever in the rollback
position.
BD03A040
10. Continue holding until the specified temperature
of the oil is reached.
IMPORTANT: When performing the following 11. Operate the machine at full throttle.
pressure check and adjustment, the articulation lock 12. With the articulation lock still in place, turn and
must be installed. Use caution when working in or hold the steering wheel for a hard right turn.
near the articulation area.
13. Continue holding the steering wheel, and read
2. Remove the dust cap from the test port (1). the pressure gauge.
14. The pressure gauge must indicate 239 to 243
bar (3465 to 3525 psi). If the pressure is not
correct, adjust the steering relief valve.
NOTE: See section 8002 for pump 1 high pressure
pump differential pressure testing.
2 15. With the engine at low idle, with all the controls in
neutral, JSS NOT active, a differential reading of
28 to 30 bar (405 to 435 psi) should be obtained.
1 16. With the engine at low idle, with all the controls in
neutral, JSS ON and joystick in neutral, a
BD06F148
differential reading of 28 to 30 bar
1. G1 TEST PORT (405 to 435 psi) should be obtained.
2. G2 TEST PORT
17. With the engine at low idle, with all the controls in
3. Connect a 345 bar (5000 psi) pressure gauge to neutral, JSS ON and joystick in full left or right
the test port (2). turn, a differential reading of 28 to 30 bar
NOTE: Make sure when you connect the pressure (405 to 435 psi) should be obtained.
gauge that you do so in a manner that you can read NOTE: If the setting is not correct, verify that the
the pressure gauge while sitting in the operators hydraulic connection from the hydraulic steering
seat. valve PVFC that manages the LS signals connected
or is not kinked.
5009-46
Pressure Setting Adjustment Steering Times

1. Turn the adjusting screw clockwise to increase IMPORTANT: When performing the following
the pressure setting. Turn the adjusting screw procedure check that the articulation of the unit is
counterclockwise to decrease the pressure NOT locked.
setting. The speed of steering is not constant but depends on
2. Repeat pressure test procedure. the speed reached by the vehicle. On reaching 20
km/h the steering sensitivity is reduced by 80%
3. If necessary, adjust the limit valve again until compared to the normal speed of steering.
within the specified range. The JSS can be set on three different levels of
4. Stop the engine before removing the pressure steering speed.
gauge. The three speed levels are:
1. from 4.5 to 5.5 sec.*
2. from 3.2 to 4.5 sec.*
3. from 2.8 to 3.2 sec.*
*(time to take the unit from full right to full left turn).
1 The purpose of these settings is to make steering the
unit similar to the standard steering system.
1. With the engine at low idle, with all the controls in
1 neutral and JSS ON, steer the unit completely to
the left.
2. Set a speed level (e.g. 1, 2 or 3).
3. Move the joystick to the right, time the steering
BD06F147
rate from full left to full right. Compare the time
with the time specified in the table of speed
1. STEERING PRIORITY VALVE
2. LIMIT VALVE
levels.
4. Move the joystick to the left, time the steering
rate from full right to full left. Compare the time
with the time specified in the table of speed
levels.
5. If the times are not in the range shown in the
table, calibrate the system, see page 47.
6. Repeat tests 1 through 4 with the engine at high
idle.
5009-47
STEERING SPEED CALIBRATION PROCEDURE

STEP 1 STEP 4
Before running the unit calibration the following
procedures must be completed:
- Start the engine;
- Set the unit in a straight position;
- Activate the Joystick Steering System;
- Slightly lift the bucket off the ground;
- Release the parking brake.
STEP 2
1
521E-4R005
Press the enter button (2) within two seconds to

confirm the calibration procedure. If you do not press
any buttons after two seconds, the screen will show
“Calibration”, “Timeout”, “Cancelled”. Repeat Step
2 reenter the calibration procedure.
STEP 5
2
521E-4R003
At the same time press the Joystick Steering

activation switch (1) and the enter button (2).
STEP 3
521E-4R006
If the enter button is pressed longer than two

seconds, the main menu screen appears.
521E-4R004
Keep pressed until the screen shows “Calibration?”.

5009-48
STEP 6 STEP 9
521E-4R010
521E-4R007
The display will show a screen with the wording Afterwards, the display will automatically read “Joyst
“Steer. Straight?” Press the enter button to confirm. Full Right” “Release when WL starts moving”.
Move the Joystick lever completely to the right. As
STEP 7 soon as machine movement is noticed release the
lever.
STEP 10
521E-4R008
The display will read “Joyst Full Left” “Release

when WL starts moving”. Move the Joystick lever
521E-4R009
completely to the left. As soon as mahcine After this operation, the display will read “O. K.”. The
movement is noticed release the lever. display will automatically read “Joyst Full Right”
“Release when WL starts moving”. Move the
STEP 8 Joystick lever completely to the right. As soon as
machine movement is noticed release the lever.
STEP 11
521E-4R009
After this operation, the display will read “O. K.” The
display will automatically read “Joyst Full Left”
“Release when WL starts moving”. Move the 521E-4R011
Joystick lever completely to the left. As soon as The display will read “Calibration Successful”
mahcine movement is noticed release the lever. indicating calibration is complete.
6001
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN

COMPONENTS
6001-2
TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6001-3
TRANSMISSION
Removal STEP 7
STEP 1
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 2
position.
STEP 3
Refer to Section 9007 and remove ROPS cab or BD01D315
ROPS canopy. Disconnect transmission wiring harness connector

from control valve connector. Remove socket head
STEP 4 bolt securing wiring harness clamp. Move wiring
harness away from transmission.
Refer to Section 8001 and remove the hydraulic
pump.
STEP 8
STEP 5
Put a 25.5 liter (27 quar ts) container under
transmission drain plug. Remove drain plug and drain
transmission oil. Install drain plug after oil has
drained.
STEP 6
BD01D317
Just above where clamp was installed, tag and

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

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

wiring harness clamps.
6001-4
STEP 10 STEP 13
BD01D312 BD03A165
Identify, tag, and disconnect transmission wiring Identify, tag, and disconnect parking brake hose from
harness connectors from engine speed sensor, parking brake. Plug hose and cap fitting to prevent
intermediate speed sensor, and turbine speed entry of foreign matter into hydraulic system. Move
sensor. Move transmission wiring harness away from hose away from transmission. Remove four bolts and
transmission. two straps securing center drive shaft to transmission
output flange. Disconnect center drive shaft from
STEP 11 transmission.
STEP 14
BD01D316
Remove socket head bolt securing wiring harness

clamp. Move wiring harness away from transmission. BD03A161
Remove four bolts and two straps securing rear drive

STEP 12 shaft to transmission output flange. Disconnect rear
drive shaft from transmission.
BD01D314
Identify, tag, and disconnect transmission wiring

harness connectors from filter maintenance switch
and output speed sensor. Move transmission wiring
harness away from transmission.
6001-5
STEP 15 STEP 18
BD03A160 BD01D342
Remove two bolts. Remove fill tube, with cap and oil In area between the transmission and the engine,
gauge assembled, two seals, and metal strainer. remove four bolts and two straps. Use pry bar to
Discard seals. disconnect engine drive shaft from transmission.
Using 3/4 inch drive socket, extensions, and impact
STEP 16 wrench, remove four bolts and washers securing
transmission to top mounting bracket.
STEP 19
IMG_2114.PNG
Identify, tag, and disconnect cooler hoses from

fittings installed in thermo bypass valve located on
the left hand side of transmission. Install plugs in BD03A163
hoses. Remove and discard O-ring face seals from Remove bolts and washers securing RH and LH
fittings. mounting brackets to rear chassis.
STEP 17
BD01D343
Connect lifting equipment to transmission lifting eyes.

Take up all slack in lifting equipment.
6001-6
STEP 20 STEP 22
BD01D361
BD03A164
If top mounting bracket requires removal, remove bolt
Raise transmission just enough to enable removal of
and washer then remove bracket.
RH and LH mounting brackets. Remove two bolts
and washers securing RH and LH mounting brackets
to transmission. Remove RH and LH mounting
brackets.
STEP 21
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 removal. Remove
transmission from loader.
6001-7
Transmission Mounting
3 4
C 1
1
4
3
2
2
2
1 1 5
5 5
7
1 6
5 1
2
BS03B153
1. ISOLATOR BOLT 6. MOUNTING BRACKET

2. WASHER 7. TOP MOUNTING BRACKET
3. BOLT A. REAR CHASSIS TRUNNION
4. BOLT B. BRACKET (6 OR 7)
5. BOLT C. SMALLER PIECE ON TOP
6001-8
STEP 23
Check isolators for deterioration, tears, deformation,
or other damage. Replace as necessary: refer to
mounting illustration.
STEP 24
BD03A164
Install RH and LH mounting brackets on transmission

using two washers and bolts. Do not tighten bolts.
STEP 27
BD01D361
If top mounting bracket was removed, put bracket on

rear chassis trunnion and secure using washer and
bolt. Do not tighten bolt.
NOTE: Mounting hole use is based upon 4-speed or
5-speed installation. The 5-speed transmission
installation uses rear mounting hole.
STEP 25
BD03A163
Loosely install washers and bolts to secure RH and

LH mounting brackets to rear chassis. Tighten bolts
securing RH and LH mounting brackets to
transmission to a torque of 481 to 590 Nm (355 to
435 pound feet).
BD01D345
Move transmission into position above loader. Slowly

lower transmission into loader.
6001-9
STEP 28 STEP 30
NOTE: In this step, new straps and bolts securing
the drive shaft must be installed whenever these
parts are removed. Bolts have a nylon patch to
maintain torque which requires new bolts.
BD01D343
Disconnect lifting equipment from transmission lifting

eyes.
BD01D342
STEP 31
Using 3/4 inch drive socket, extensions, and impact Remove plugs in thermo bypass valve ports.
wrench, install four washers and bolts to secure top
mounting bracket to transmission. Then tighten bolts STEP 32
to a torque of 251 to 319 Nm (185 to 235 pound feet).
If bracket had been removed, tighten bolt to a torque
of 890 to 1000 Nm (655 to 735 pound feet). Connect
engine drive shaft to transmission. Install two new
straps and four new bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet).
STEP 29
IMG_2114.PNG
Install new O-ring face seals in fittings on thermo

bypass valve. Connect cooler hoses to fittings
following tags installed during removal. Remove and
discard tags.
BD03A163
Tighten bolts securing RH and LH mounting brackets

to a torque of 890 to 1000 Nm (655 to 735 pound
feet).
6001-10
STEP 33 STEP 36
BD03A160 BD01D314
Position fill tube, two new seals, and metal strainer Connect transmission wiring harness connectors to
on transmission; metal strainer is installed between output speed sensor and filter maintenance switch
seals. Secure using two bolts. Tighten bolts to a following tags installed during removal. Remove and
torque of 17 to 33 Nm (12 to 24 pound feet). discard tags.
STEP 34 STEP 37
BD03A161 BD01D316
Connect rear drive shaft to transmission then install Install socket head bolt to secure wiring harness
two straps and four bolts. Tighten bolts to a torque of clamp.
STEP 38
STEP 35
BD01D312
BD03A165 Connect transmission wiring harness connectors to

Connect center drive shaft to transmission and install turbine speed sensor, intermediate speed sensor,
two straps and four bolts. Tighten bolts to a torque of and engine speed sensor following tags installed
61 to 81 Nm (45 to 60 pound feet). Connect parking during removal. Remove and discard tags.
brake hose to parking brake following tag installed
during removal. Remove and discard tag.
6001-11
STEP 39 STEP 42
BD01D310 BD01D306
Install two socket head bolts to secure transmission At brake valve, install new O-ring face seals in
wiring harness clamps. fittings. Connect brake to hydraulic reservoir hose
and brake pump pressure hose following tags
STEP 40 installed during removal. Remove and discard tags.
STEP 43
BD01D317
Connect transmission wiring harness connector to

temperature sensor following tag installed during BD03A177
removal. Remove and discard tag. Check that transmission drain plug is tight.
STEP 41 STEP 44
Fill transmission with Standard Multi-G Hydraulic oil
until oil level is up to the arrow in sight glass.
STEP 45
Refer to Section 8001 and install the hydraulic pump.
STEP 46
Refer to Section 9007 and install ROPS cab or ROPS
canopy.
STEP 47
BD01D315
Start and run engine at idle speed with transmission
Install socket head bolt to secure wiring harness in neutral. If transmission oil level is at or below
clamp. Connect transmission wir ing har ness bottom of crosshatch region, put articulation lock in
connector to control valve connector. LO CKED po sition a nd ad d Stan da rd M ulti- G
Hydraulic oil until oil level is up to crosshatch region.
Shut down engine and put ar ticulation lock in
OPERATING position.
6001-12
FRONT AXLE
Removal STEP 4
STEP 1
BD03A167
Remove four bolts and two straps securing front drive

BD03A040
shaft to front axle.
Park machine on level surface. Have assistant put
articulation lock in LOCKED position. STEP 5
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.
STEP 2
BD03A166
Remove clamp securing lubrication hose to machine

and nut securing opposite end of hose. Remove four
bolts and two straps securing center drive shaft to
front drive shaft. Use a pry bar to separate drive
shafts. While supporting center bearing and front
BD03A092 drive shaft, remove four nuts and bolts and eight
Raise bucket and have assistant install safety link. washers. Lower center bearing and front drive shaft
Lowe r loa der ar ms slowly until sa fety link is from mounting plate and remove from machine.
supporting loader arms.
STEP 3
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
6001-13
STEP 6 STEP 8
BD03A168 IMG_1998 RESIZED.JPG
For machines without brake damping accumulators, Disconnect differential lock hose.
disconnect brake hose from elbow. Remove and
NOTE: Locking front differential is available on 721F,
discard O-ring face seal from elbow.
821F and 921F machines equipped with heavy duty
NOTE: 721F machines with heavy duty axles and all axles.
821F/921F machines are equipped with brake
damping accumulators. STEP 9
STEP 7
BD01F298
100_0174 RESIZED.JPG
For machines with brake damping accumulators,

disconnect brake line from elbow at axle connection.
Remove and discard O-ring face seal from elbow. To
remove accumulator, also disconnect brake line and
hose from accumulator. Unbolt accumulator from
machine frame.
NOTE: 721F heavy duty axles and all 821F/921F
axles have brake damping accumulators.
BD01D392
Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand
under machine.
STEP 10
Repeat Step 9 to raise other front axle tire from
ground.
6001-14
STEP 11 STEP 13
IMG_2121.PNG BD01F296
Use an acceptable jack to hold front axle. Remove eight nuts bolts, and washers securing front
axle to machine.
STEP 12
STEP 14
Carefully lower front axle and remove from under
machine.
821FXR-8818.PNG
Remove wheel nuts/bolts and washers from front

wheels. Remove both wheels from front axle.
NOTE: 721F and 821F (pictured) heavy duty axles
and all 921F axles have wheel studs on the axles and
use wheel nuts.
6001-15
Front Axle Mounting
FRONT AXLE MOUNTING.PNG
1. BOLT 4. NUT
2. WASHER 5. FRONT AXLE
3. WASHER
6001-16
Installation
STEP 15
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 16
84324413205.TIF
821F Torque Pattern
BD01F296
Apply one drop of engine oil to threads prior to

assembly. Install eight washers, bolts, washers, and
nuts to secure front axle to machine. Tighten bolts to
a torque of 765 to 865 Nm (565 to 630 pound feet).
STEP 17
0R0R201007RCIL10WHL288BAL[1].TIF
921F Torque Pattern

821FXR-8818.PNG
Install both wheels on front axle and secure. Tighten STEP 18

wheel nuts/bolts to a preliminary torque of 278 Nm
(205 lb ft.) in sequence indicated; then tighten to a
torque of 640 to 720 Nm (475 to 530 pound feet) in
same sequence.
use wheel nuts.
NOTE: 821F units (pictured) use a 16 hole mounting
pattern. 921F units use a 20 hole mounting pattern.
IMG_2121.PNG
Remove jack from front axle.

6001-17
STEP 19 STEP 22
100_0174 RESIZED.JPG
BD01D298
For machines with brake damping accumulators,
install a new O-ring face seal and connect brake line
to elbow at axle connection. If accumulator has been
removed, bolt accumulator to machine frame and
connect brake line and hose to accumulator.
STEP 23
BD01D392
Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.
STEP 20
Repeat Step 19 to remove other jack stand from
under machine. IMG_1998 RESIZED.JPG
Connect differential lock hose.

STEP 21 NOTE: Locking front differential is available on 721F,
821F and 921F machines equipped with heavy duty
axles.
BD03A168
Install a new O-ring face seal in elbow. Connect

brake hose to elbow.
NOTE: 721F machines with heavy duty axles and all
821F/921F machines are equipped with brake
damping accumulators.
6001-18
STEP 24 STEP 26
If necessary, fill axle with Standard Multi-G Hydraulic
oil.
STEP 27
Refer to Section 7002 and bleed brakes.
STEP 28
Star t engine and raise bucket. Have assistant
remove safety link. Lower bucket to ground and stop
engine.
BD03A166 STEP 29
Position and support center bearing and front drive Put articulation lock in OPERATING position.
shaft and install eight washers and four bolts and
nuts. Tighten bolts to a torque of 99 to 128 Nm (73 to
94 pound feet). Install two straps and four bolts.
Tighten bolts to a torque of 61 to 81 Nm (45 to 60
pound feet). Secure lubrication hose to machine
using clamp; secure opposite end of hose using nut.
STEP 25
BD03A167
Secure drive shaft to front axle using two straps and

four bolts. Tighten bolts to a torque of 61 to 81 Nm
(45 to 60 pound feet).
6001-19
REAR AXLE
Removal STEP 5
STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and for th at least 30 times to release any
pressure from hydraulic circuit.
STEP 2
BD03A169
Disconnect brake hose from elbow. Remove and

discard O-ring face seal from elbow.
STEP 6
BD03A040
Put articulation lock in LOCKED position.
STEP 3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting. BD01F299
Using an acceptable hydraulic jack, raise one tire

STEP 4 from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.
STEP 7
BD03A162
Remove four bolts and two straps. Use a pry bar to

disconnect rear drive shaft from rear axle.
IMG_2124.PNG
Use an acceptable jack to hold rear axle.

6001-20
STEP 8 STEP 9
821FXR-8818.PNG IMG_2133.PNG
Remove nuts/bolts and washers from rear wheels. At front of trunnion, remove three Allen head bolts
Remove both wheels from rear axle. and washers. Remove front cap: if necessary use
two M12 by 32 mm (1.25 inches) bolts in puller holes
(A); tighten bolts evenly to pull cap from axle and
trunnion. Remove and discard O-ring from cap.
use wheel nuts.
Repeat this step at rear of trunnion except remove
and retain shim(s) after removal of rear cap. Remove
pivot shaft using acce ptable sle eve or rod if
necessary.
6001-21
Rear Axle Mounting
5
4
3
2
1
5 7
1
2 8
7 9
6
4
REAR AXLE MOUNTING.PNG
1. O-RING 4. WASHERS 7. SHIM(S)

2. SEAL 5. BOLTS 8. PIVOT PIN
3. FRONT CAP 6. FRONT CAP 9. REAR AXLE
6001-22
NOTE: If shim(s) (7) have been lost or pivot pin (8)
has been replaced, do Step 12 to determine required
shim(s) otherwise go to Step 13. A
STEP 12
5 5
B
8
3
6
PIVOT BUSHING 2.PNG
A B
INSTALL PIVOT PIN.PNG
Install pivot pin (8) and caps (3 and 6) in trunnion (B)

without rear axle or shim(s). Install washers (4) and
bolts (5). Tighten bolts securely. Push assembled
pivot pin and caps to rear of machine as far as
possible. Measure and record gap (A) between rear
cap (6) and trunnion. Select shims from the following:
PIVOT BUSHING.PNG
NOTE: Shims are available in following sizes: 0.50
mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm Clean front (A) and rear (B) pivot area of rear axle
(0.059 inch). where seals will be installed.
MEASURED SHIM(S) REQUIRED STEP 14

GAP (mm) (mm)
0.07 to 0.55 None A
0.56 to 1.09 0.50
2
1.10 to 1.59 1.0
3
1.60 to 2.09 1.50
6
2.10 to 2.59 0.50 plus 1.50
2.60 to 3.02 1.0 plus 1.50
2
PIVOT PIN SEAL.PNG
Lubricate two new seals (2) and new O-rings (1)

using Molydisulfide Grease. Install seals, smooth
side out, into front and rear of axle housing (A) until
flush with housing. Install an O-ring in each cap (3
and 6).
STEP 15
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.
6001-23
STEP 16
7
A 4 5
5 6
8 B
INSTALL PIVOT PIN 2.PNG
Lubricate pivot pin (8) using Molydisulfide Grease. At

rear of trunnion (B), install pivot pin into trunnion and
axle (A). Install shim pack (7), rear cap (6) with
O-ring installed, and two washers and bolts (4 and
5). At front of trunnion install front cap (4) with O-ring 84324413 205.TIF
installed, and two washers and bolts (4 and 5). 821F Torque Pattern
Tighten bolts (5) to a torque of 651 to 678 Nm (480 to
500 pound feet).
STEP 17
821FXR-8818.PNG
Install both wheels on rear axle and secure. Tighten

wheel nuts/bolts to a preliminary torque of 278 Nm
(205 lb ft.) in sequence indicated; then tighten to a 0R0R201007RCIL10WHL288BAL[1].TIF
torque of 640 to 720 Nm (475 to 530 pound feet) in 921F Torque Pattern
same sequence.
use wheel nuts.
NOTE: 821F units (pictured) use a 16 hole mounting
pattern. 921F units (pictured) use a 20 hole mounting
pattern.
6001-24
STEP 18 STEP 20
821FXR-8818.PNG BD03A162
Remove hydraulic jack supporting rear axle and jack Connect rear drive shaft to rear axle. Install two
stands supporting loader. straps and four bolts. Tighten bolts to a torque of 61
to 81 Nm (45 to 60 pound feet).
STEP 19
STEP 21
If necessary, fill axle with Standard Multi-G Hydraulic
oil.
STEP 22
Refer to Section 7002 and bleed brakes.
STEP 23
Place articulation lock in OPERATING position.
BD03A169
Install a new O-ring face seal in elbow. Connect

brake hose to elbow.
6002
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Clutch Calibration (4-Speed Transmission Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Pedal Transmission Declutch (4-Speed Transmissions Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 20
6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi)
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm)
Transmission oil operating temperature..........................................................................80 to 120 °C (176 to 248 °F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)
6002-4
4 1
3 2
5 12
9
6
11
14
13 7
10
BS01A190
1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR
2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR
5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE
6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH (APPLIES TO 4-SPEED
TRANSMISSION ONLY)
7. TRANSMISSION 14. PLUG
COMPONENT LOCATIONS SYSTEMS

6002-5
12
11
1
2
10
9
4
5
15
6
14
8
13 7
BS03A262
1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP
2. POWER TAKE OFF 10. INPUT FLANGE
3. CLUTCH SHAFT KV 11. CONVERTER
4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED
5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K4
6. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE
7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K1
8. OUTPUT SHAFT
COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6
2 2
2
2
1 3
4
BS01A191
3. OUTPUT FLANGE CONVERTER
1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK
SIDE
2. TRANSMISSION SUSPENSION BORES 4. OIL DRAIN PLUG
COMPONENT LOCATIONS FRONT VIEW

6002-7
1
2
3
10
6
7
BS01A192
1. CONVERTER BELL HOUSING 6. OUTPUT FLANGE REAR
2. BREATHER 7. OIL DRAIN PLUG
3. TRANSMISSION CASE COVER 8. OUTPUT FLANGE CONVERTER SIDE
4. FILTER HEAD 9. TRANSMISSION CASE
5. FILTER 10. PARKING BRAKE
COMPONENT LOCATIONS SIDE VIEW

6002-8
2
1
1
7 3
4 4
BS01B048
1. LIFTING LUGS 5. OUTPUT FLANGE REAR
2. POWER TAKE OFF 6. FILTER
3. TRANSMISSION CONTROL VALVE 7. FILTER HEAD
4. TRANSMISSION SUSPENSION BORES
COMPONENT LOCATIONS REAR VIEW

6002-9
TRANSMISSION OPERATION
General Transmission ECM Tasks

The transmission is equipped with a Transmission The Transmission ECM performs a variety of tasks in
ECM (Electronic Control Module). This module the overall system. The Transmission ECM:
controls modulation and shifting that were normally
A. Determines which clutches to engage in the
a s s o c i a t e d w i t h hy d r a u l i c a l l y m o d u l a t e d
transmission.
transmissions, providing smoother shifts and
enhanced clutch life. B. Protects the engine and transmission turbine
from overspeed conditions dur ing
The Transmission ECM relies on signals from several
downloading.
sensors that are incorporated into the design. These
sensors measure the speed of several components, C. Receives speed information from the engine
as well as other sensors that measure temperature. speed sensor, the turbine speed sensor, the
These solenoids and sensors are further defined in intermediate shaft speed sensor and the
the following paragraphs. transmission output shaft speed sensor.
T h e s e s p e e d s e n s o r s a r e c h e ck e d t o
In a d d i t i o n , th e t ra n s m i s s i o n i n c o r p o ra t e s a
deter mine if nor mal sensor operation is
two-piece transmission case for ease of transmission
present. The data is also used to control
maintenance, helical cut gears that help reduce
modulation during shifting and to determine
noise, and all external hoses have been eliminated
the appropriate shift patterns.
(all oil passages are internal).
D. Detects system failures and determines the
Transmission ECM appropriate alternative actions.
Modulation and shifting are controlled by the E. Provides various diagnostic messages to the
Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e Information Center.
(Transmission ECM). This module replaces the oil F. Provides other information to the information
and springs that are found in hydraulically modulated center, which in turn displays engine speed,
transmissions. wheel speed, gear shift selection, and actual
T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h gear selection.
e n g a g e m e n t , p r ov i d i n g s m o o t h e r s h i f t s a n d G. Provides a method to calibrate the
enhanced clutch life, whether the transmission is set transmission clutch control.
to the automatic or manual shift mode.
H. Establishes clutch modulation pressure during
The Transmission ECM also informs the Information transmission shifts.
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.
Electrical Shift Solenoids

Electrical Shift Solenoids control the modulation of
the clutches, eliminating the need for a modulation
valve, and providing a smooth shift while maintaining
constant control over clutch engagement as follows:
A. A temperature sensor relays the oil
temperature to the Transmission ECM.
B. The Transmission ECM times the rate the
solenoid energizes and de-energizes.
C. As the transmission changes gears, there is
reduced hesitation from one gear to the next.
6002-10
Transmission Sensor Data Clutch Modulation Substitute Mode

Collection In this mode, the transmission clutch modulation is
The Transmission ECM collects and uses information time dependant rather than load dependant. The
from four sensors to accurately shift the transmission transmission will go into the Clutch Modulation
and determine if any clutches are slipping. These Substitute Mode if any of the four speed sensors fail.
sensors are: If the output speed sensor is working and the
Engine (Speed) Sensor - monitors engine speed to transmission is in gear, the shift points in Automatic
determine the load on the engine for shift points and mode will be speed dependant but the modulation
sends the engine rpm to the Transmission ECM, will be a predetermined amount of time.
which sends the information to the tachometer in the If the output speed sensor is not working and the
Information Center. transmission is in gear, the shift points will be load
Turbine (Speed) Sensor - assists the engine speed d e p e n d a n t bu t t h e m o d u l a t i o n w i l l s t i l l b e a
sensor in deter mining the load going into the predetermined amount of time.
transmission and helps determine shift points. If the transmission is shifted from neutral into a
Intermediate (Shaft Speed) Sensor - determines direction in the Clutch Modulation Substitute Mode in
differential gear speed in the transmission to check automatic, the transmission will shift into 4th gear
for clutch slippage. and shift down until it gets the correct output speed
from the turbine.
Output (Speed) Sensor - monitors transmission
output shaft speed to help determine the load on the Limp-Home Mode
transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM In this mode, the transmission will go into second
which sends the information to the speedometer in gear, forward or reverse, no matter what gear is
the Information Center. selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
T h e t ra n s m i s s i o n E C M a l s o r ev i ew s vo l t a g e
g e a r s u n t i l a n o p e r a b l e g e a r i s fo u n d . T h e
infor mation from the shifter and transmission
transmission will go into the Limp Home Mode if
solenoids to determine if there are any short circuits
there is a fault on one clutch, a fault on one clutch
or open circuits in the system.
valve, or a fault on more than one speed sensor.
Automatic Problem Modes Transmission/Transmission ECM

If the Transmission ECM detects an error condition in Shutdown Mode
the transmission system, it will generate a service
code in the Information Center and will enter one of In this mode, the Transmission ECM has detected a
three modes: s e ve r e fa i l u r e t h a t d i s a b l e s c o n t r o l o f t h e
transmission. The transmission will go into Shutdown
A. Clutch Modulation Substitute Mode
Mode if there is a fault on more than one clutch, a
B. Limp-Home Mode fault on the solenoid power supply, or invalid voltage.
C. Transmission/Transmission ECM Shutdown In this mode, the Transmission ECM will shut off all
Mode solenoid valves and the power supply and the
transmission shifts into and stays in neutral.
If the Transmission ECM generates a code, the
wren ch over th e se r vice m anual ico n will be
displayed on the Information Center.
6002-11
Transmission Clutch Calibration Gear Selections

(4-Speed Transmission Only) The 4 speed transmission provides 4 forward and 3
The Transmission ECM has the capability to find the reverse gear selections. The 5 speed transmission
optimal adjustment of the clutch filling parameters for provides 5 forward and 3 reverse gear selections.
each individual transmission, providing the ability to The transmission ratios were designed to give
individually adjust the optimum fill time for the optimized speed and torque for each gear selection.
individual transmission in the machine. Clutch Filling The torque conver ter is a single stage torque
Parameter Calibration is performed on each machine converter (one locking unit in the torque converter).
at the plant and should be repeated at the first 250 The 5-speed transmissions locku-up.
hours of use and every 1000 hours thereafter.
Automatic/Manual Modes
Before doing the following transmission clutch
calibration procedures make sure of the following: The automatic/manual switch is located on the right
control panel. The transmission is in automatic mode
1. The machine is running and the transmission oil
when the top of the automatic/manual switch is
is warm.
depressed. The Transmission Display Center
2. Engine low idle speed is correct. indicates when the machine is in the automatic
mode.
3. The transmission is in neutral.
4. The park brake is applied. Upshifting in Automatic Mode
5. If steps 1 through 4 have been accomplished, Upshifting is determined by machine speed and the
calibrate the transmission clutches as follows: torque on the transmission.
A. Press and hold the enter key for 2 to 3 The transmission will shift from first or second gear
seconds and the monitor will change to up to the highest gear selected as the accelerator is
SELECT. depressed, machine speed increases, and required
B. Use the down arrow and high light “CONFIG”, torque is reduced.
press the enter key. If the machine speed is increasing, but the operator
C. Press the down arrow and high light “CALIB is not depressing the accelerator (such as when
G/B”, press the enter key. going down a hill), the transmission will not upshift.
D. Monitor will state “CALIB G/B” “CONFIRM As the operator depresses the accelerator and the
PLEASE”, press the enter key. torque on the transmission is lowered, the
transmission will upshift.
E. If the conditions are not correct for clutch
calibration the monitor will display the problem
that needs to be corrected.
Downshifting in Automatic Mode
F. Clutch calibration status will be displayed on Downshifting is determined directly by machine
the monitor, “ADJUST K1, K2, K3, K4, KV, speed and transmission torque. The transmission will
KR”. downshift to first or second gear as machine speed
decreases and transmission torque increases. For
G. After completing the Clutch Calibration example, if the unit begins to climb a hill in forth gear
procedure, turn the machine OFF for 15 and the machine speed decreases, as the torque
seconds. This sets the calibration in the requirement increases, the transmission will
controller. downshift into third, then second, and down to first
gear, if necessary.
6002-12
Upshifting in Manual Mode B. The shifter is moved into neutral and then into
forward or reverse.
In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the C. The autoshift switch is recycled.
operator selects another gear or direction. The
transmission can be upshifted without reducing Manual Mode
engine speed or machine speed.
In the manual mode, the downshift button toggles
If the gear selected is two or more gears higher than between 1st and 2nd gear. The manual mode is
the present gear, the transmission will shift up useful in short haul operations. In this mode, the
through the gears at 2.5 second intervals until the downshift button functions in two ways in 1st and 2nd
selected gear has been reached. gear.
When the operator is in 2nd gear and pushes the
Downshifting in Manual Mode downshift button, the transmission instantly shifts into
The transmission can be downshifted in the manual 1st gear. When the operator pushes the downshift
mode without reducing engine speed or machine button again, the transmission upshifts into 2nd gear.
speed. If the machine is in 2nd gear and the downshift
If 1st gear is selected from 3rd or 4th gear, the button is pushed, the transmission instantly shifts into
transmission will downshift into 2nd gear for 1.2 1st gear. When the operator shuttles the shifter, the
seconds and then will shift into 1st gear. transmission upshifts back into 2nd gear.
Downshift Button Cold Start Protection System

The downshift button is located on front of the The transmission has a cold start protection system.
joystick control lever in machines with a single lever When the transmission sump temperature is minus
configuration, and on top of the control tower in 10° C (14° F), the Transmission ECM will keep the
machines with two or three lever configurations. transmission in neutral.
With the number of different ways the downshift When the transmission sump temperature warms up
button functions, the operator can tailor the use of the to minus 10° C (14°F) (within approximately one
machine to the application at hand. minute), the machine will operate in all gears.
Automatic Mode
In the Automatic Mode, the downshift button only
shifts down. The downshift button allows the operator
to downshift through the entire range of gears. This is
useful in long haul applications or roading.
Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then
from 3rd to 2nd, and then from 2nd to 1st.
The transmission will automatically downshift and
then upshift, as needed, to the last gear that was
selected with the downshift button.
Example: If the downshift button was used to shift
from 4th to 3rd gear, the transmission will
automatically shift from 3rd down and then back up to
3rd again. It will not shift into 4th until the
transmission has been returned to the full range
automatic mode.
The transmission will retur n to the full range
automatic mode when:
A. Another gear is selected.
6002-13
Brake Pedal Transmission

Declutch (4-Speed Transmissions
Only)
A transmission declutch feature concentrates more
engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and
starts. Total disconnection of the transmission from
the engine is prevented. This feature will function in
1st, 2nd, or 3rd gear only. It will not function in 4th
gear.
When the transmission declutch switch is in the on
p o s i t i o n a n d t h e b ra ke p e d a l i s p u s h e d , t h e
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.
6002-14
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

DESIGNATION ON
No. IDENTIFICATION/LOCATION CONNECTION
VALVE BLOCK
Measuring Points for Pressure Oil and Temperature
51 Before the Converter - Opening Pressure 8 bar (116 psi) M10x1 H
52 Behind the Converter - Opening Pressure 2.5 bar (36 psi) M14x1.5
53 Clutch Forward 16+2 bar (232 + 29 psi) KV M10x1 B
55 Clutch Reverse 16+2 bar (232 + 29 psi) KR M10x1 E
56 Clutch 16+2 bar (232 + 29 psi) K1 M10x1 D
57 Clutch 16+2 bar (232 + 29 psi) K2 M10x1 A
58 Clutch 16+2 bar (232 + 29 psi) K3 M10x1 C
60 Clutch 16+2 bar (232 + 29 psi) K4 M10x1 F
63 Behind the Converter Temperature 100° C, Short Time 120° C M14x1/5
65 System Pressure 16+2 bar (232 + 29 psi) M10x1 K
Measuring Points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16” - 12 UNF-2B
16 Connection from the Heat Exchanger 1 5/16” - 12 UNF-2B
Inductive Transmitter and Speed Sensor
21 Inductive Transmitter for Turbine Speed M18x1.5
34 Output Speed Sensor
47 Inductive Transmitter for Central Gear Train Speed M18x1.5
48 Inductive Transmitter for Engine Speed M18x1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 System Pressure M16x1.5 G
69 Pilot Pressure M16x1.5 J
NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.
6002-15
4-SPEED TRANS. ͻPRESSURE REGULATOR UNDER VOLTAGE 5-SPEED TRANS. ͻPRESSURE REGULATOR UNDER VOLTAGE
FORWARD REVERSE NEUTRAL FORWARD REVERSE NEUTRAL
CLUTCH PRESSURE REGULATOR 1 2 3 4 1 2 3 CLUTCH PRESSURE REGULATOR 1 2 3 4 5 1 2 3
KV Y5 ͻ ͻ ͻ KV Y5 ͻ ͻ ͻ
KR Y2 ͻ ͻ ͻ KR Y2 ͻ ͻ ͻ
K1 Y3 ͻ ͻ K1 Y3 ͻ ͻ
K2 Y6 ͻ ͻ K2 Y6 ͻ ͻ ͻ
K3 Y4 ͻ ͻ ͻ K3 Y4 ͻ ͻ ͻ
K4 Y1 ͻ K4 Y1 ͻ ͻ
BC01B047
MEASURING POINTS AND CONNECTIONS
6002-16
CHART FOR RECORDING PRESSURE READINGS

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

6002-17
PRESSURE TEST RESULTS
All or Most Pressures Low and/or Not Enough Power

Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
3. Oil operating temperature high.
A. Check engine and fuel system for problem.
4. Screen for suction tube plugged.
B. Check that torque converter installation is
5. Suction tube or gaskets leak. correct.
6. Main pressure valve, springs, or valve bore. 3. Engine RPM above Stall Test specified RPM.
7. Reduction valve, springs, or valve bore. (Refer to Section 2002 for specifications.)
8. Charge pump seals or gaskets leak. A. Check converter pressures and flow.
9. Charge pump worn. B. Check that torque converter installation is

correct.
10. Oil supply flange not sealing correctly.
Machine Stops or Hesitates While
Some Pressures Low Shifting - Intermittent
Possible causes include:
Possible causes include:
1. Circuit isolation does not correct low pressure.
1. Check orifice and O-ring. (See Section 6007 for
A. Control valve or gasket. replacing.)
B. Channel plate or gasket. 2. Check for foreign material plugging orifices or
sticking valves.
2. Circuit isolation corrects low pressure.
3. Check for reduced pressure at test pressure
A. Clutch shaft or seals.
points.
B. Clutch drum or piston.
4. See Electrical Troubleshooting in this Section for
electrical system problem.
6002-18
CONVERTER OUT PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge.
0 to 28 bar (400 psi) gauge with hose long enough to 4. Heat the oil to an operating temperature of 80 to
take readings in the cab and CAS-2324 Special 100° C (176 to 212° F).
Adapter. 5. While in the cab, put the transmission in
NEUTRAL. Run the engine at full throttle. Record
Test Procedure the reading in the chart on page 16. Pressure
must be a minimum of 3.5 to 6.5 bar
1. Block the machine tires. (51 to 96 psi).
2. Apply the parking brakes.
LUBRICATION PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 16. Pressure must
be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
Test Equipment Required 3. Heat the oil to an operating temperature of 80 to

100° C (176 to 212° F).
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter. 4. Remove the filter and install the CAS-2702
adapter.
Flowmeter Test Procedure 5. Install the flowmeter between the adapter and
the filter.
1. Block the machine tires.
2. Apply the parking brakes. Put the transmission in NEUTRAL and record the
flow measurement. The correct flow is 80 L/min
(21 U.S. gpm) at 2000 rpm.
CONSUMPTION TEST PROCEDURE

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

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

Transmission ECM Transmission Transmission Transmission Trans/Cab
Clutch # Wire #
Function ECM Pin # Valve Valve Pin # Pin #
A1P1 56 Y1 K4 1 25K 16
A1P2 10 Y2 KR 2 25L 17
A1P3 32 Y3 K1 3 25M 18
A1P4 55 Y4 K3 4 25N 19
A1P5 9 Y5 KV 5 25P 20
A1P6 51 Y6 K2 6 25J 21
VPSI 12,13 all Y all K 7 25S 22
TEMP 39 TEMP none 8 36T 5
TEMP 46 TEMP none 9 36R 12
6002-21
NOTES
6002-22
Section
6003
6003
4 & 5 SPEED TRANSMISSION
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.0 Electro-hydraulic control and oil filter (replaceable filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.0 Inductive sensor Hall effect sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . 9
3.0 Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring
point “63” after the converter as described in the specifications, pressure checks and troubleshooting section
of the manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.0 Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.0 Removal of input shaft, output shaft, pump shaft (PTO -shaft) and clutches . . . . . . . . . . . . . . . . . . . . 15
7.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.0 Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches . . . . . . . . . . . 66
10.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.0 Reassembly: Engine connection, oil pressure pump, converter back-pressure valve and temperature sen-
sor (measuring point “63” after the converter as described in the specifications, pressure checks and trouble-
shooting section of the manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12.0 Reassembly - Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13.0 Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . 81
14.0 Reassembly Electro-hydraulic control with proportional valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6003-3
SPECIAL TOOLS
CAS2885 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
380001560 TRANSMISSION
INPUT/OUTPUT SHAFT SEAL CAS2869 TRANSMISSION
INSTALLATION TOOL OUTPUT SHAFT SEAL
380001559 TRANSMISSION INSTALLATION TOOL
TORQUE CONVERTER SEAL (521 AND 621
INSTALLATION TOOL MODELS ONLY)
BS02C093 THRU 096

CAS40075 TRANSMISSION TOOL KIT
CAS2802 ALIGNMENT
380001556 CLUTCH PACK DOWEL SET
H0LDER AND SPRING
COMPRESSOR TOOLS
CAS2801 TRANSMISSION
CAS2796 NESTING MOUNTING BRACKETS
PLATE
CAS2868 CLUTCH SPRING

COMPRESSOR
(521 AND 621
380001557 CLUTCH CAS2797 LIFTING MODELS ONLY)
ASSEMBLY HOLDING EYEBOLT SET
CAS2798 GEAR KNOB SET
PULLER COLLET SET
BS02C097 THRU 104
CAS40079 TRANSMISSION OVERHAUL KIT
6003-4
SPECIAL TORQUES
Oil pipes
Studs ............................................................................................................................... 9 Nm (80 pound inches)
Socket head bolt................................................................................................................. 23 Nm (17 pound feet)
Screw plug.......................................................................................................................... 51 Nm (38 pound feet)
Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches)
Plugs........................................................................................................................................ 25 Nm (18 pound feet)
Output shaft
Output shaft bolts (apply Loctite 243 to threads) ............................................................... 23 Nm (17 pound feet)
Housing cover bolts (apply Loctite 574 to threads) ............................................................ 46 Nm (34 pound feet)
Output flange bolts ............................................................................................................. 34 Nm (25 pound feet)
Oil feed housing and transmission pump
Transmission pump bolts.................................................................................................... 46 Nm (34 pound feet)
Oil feed housing bolts......................................................................................................... 25 Nm (18 pound feet)
Engine connection and converter
Input shaft bolts................................................................................................................ 115 Nm (85 pound feet)
Converter housing bolts ..................................................................................................... 68 Nm (50 pound feet)
Cover................................................................................................................................... 23 Nm (17 pound feet)
Converter cover.................................................................................................................. 46 Nm (34 pound feet)
Input flange ......................................................................................................................... 34 Nm (25 pound feet)
Duct plate
bolts.................................................................................................................................... 25 Nm (18 pound feet)
bolt plug.............................................................................................................................. 30 Nm (22 pound feet)
Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches)
Filter
Filter head bolts.................................................................................................................. 25 Nm (18 pound feet)
Oil distribution cover bolts .................................................................................................. 25 Nm (18 pound feet)
Speed sensor and inductive transmitter
Speed sensor bolt .............................................................................................................. 23 Nm (17 pound feet)
Inductive transmitter ........................................................................................................... 30 Nm (22 pound feet)
Cover plate ......................................................................................................................... 23 Nm (17 pound feet)
bolt plug.......................................................................................................................... 140 Nm (103 pound feet)
SPECIFICATIONS
Clutch KV and KR plate clearance ..................................................................... 2.65 to 2.95 mm (0.104 to 0.116 in)
Clutch K1plate clearance.................................................................................... 2.35 to 2.65 mm (0.092 to 0.104 in)
Clutch K2 and K3 plate clearance ...................................................................... 1.75 to 2.05 mm (0.069 to 0.081 in)
Clutch K4 plate clearance................................................................................... 1.35 to 1.65 mm (0.053 to 0.065 in)
6003-5
DISASSEMBLY
1.0 Electro-hydraulic control and oil filter STEP 2
(replaceable filter)
STEP 1
1.1 Removal of filter
1
BILD-02
Remove and properly discard filter (1).
STEP 3
2
1
BILD-01
Fasten transmission on assembly stand CAS2801 or

similar tool. Drain oil prior to starting disassembly.
WARNING: Dispose of oil according to legal
requirements.
BILD-03
Remove Torx bolts (2) and separate filter head (1)

from transmission. Remove and discard O-rings.
6003-6
STEP 4 STEP 6
1.2 Removal of electronic gear-shift control
2
3
1
1
4
BILD-06
Remove differential pressure switch (1) from fine filter

BILD-04
duct plate (4).
1. Switch with O-ring
Remove gear-shift control (1). Remove Torx bolts (2)
and separate gear-shift control housing from 2. Piston
intermediate plate.
3. Compression spring.
NOTE: For version with torque converter lock-up
clutch Solenoid valve, go to Steps 20 thru 22. STEP 7
STEP 5
2
S
1
1 BILD-07
Remove hex nuts and Torx bolts. Separate the duct

BILD-05 plate (1) and seal (2) from rear housing.
Remove gear-shift control assembly (1) and sealing
plate (2). Adjusting bolts M6 (S).
6003-7
STEP 8 STEP 11
2 3
1
BILD-11
Separate duct plate (1) and sealing plate (2) from

valve block (3).
BILD-08
Remove converter safety valve (1) out of the housing STEP 12

hole.
1
STEP 9
2
1
BILD-12
Remove retaining clamp (1).
BILD-09
STEP 13
Mark installation position of wiring harness (1)
towards the valve block (2). 1
STEP 10
2
1
3
BILD-13
Remove Torx bolts (1) and cover (2). Repeat the

procedure on the opposite end cover (3).
BILD-10
Remove Torx bolts (1).

6003-8
STEP 14 STEP 17
2 S
3
BILD-14 BILD-17
Remove wiring harness (1). Remove cylindrical bolts Loosen the adjusting bolts (S) equally releasing the
(3), securing plates and pressure controllers (2). valve’s spring pressure. Remove the housing.
STEP 15 STEP 18
1 2
BILD-18
BILD-15
Remove cylindrical bolts, securing plates and Remove individual parts including pressure reducing
pressure controllers (1) on opposite side. valve (1), vibration dampers (2), follow-on slide (3).
STEP 16 STEP 19
1 S
3 2
BILD-19
BILD-16
Remove two Torx bolts (1) and temporarily attach Remove individual parts of opposite side including
housing using 380001577 adjusting bolts (S). main pressure valve (1), vibration dampers (2),
(Housing is spring-loaded.) Remove remaining Torx follow-on slide (3).
bolts.
6003-9
STEP 20 STEP 22
1.3 Version with torque converter lock-up clutch
solenoid valve
1 1
5
4 4
3
2 2
3 BILD-20
Mark installation position of connecting housing (4)

towards valve block (5). Remove cylinder bolts (1)
BILD-32
and lock-up clutch valve. Remove bolt neck (2) and
Loosen nuts (1 and 2) and remove system pressure
discard O-rings. Remove Torx bolts (3), and the
pipe (3) from lock-up clutch valve to lock-up clutch.
connecting housing.
Remove screw-in sleeve (4).
NOTE: For further disassembly, go back to Steps 15
STEP 21 thru 19.
2.0 Inductive sensor Hall effect sensor,
breather, oil filler and oil drain plug
STEP 1
1 3 4
2 5
3 6
BILD-31
Remove hollow bolt (1) and O-ring. Loosen bolt nut

(2). Remove system pressure to lock-up clutch valve
pipe and O-rings.
NOTE: For further disassembly, go back to steps 4
to 8.
2
1
BILD-01
Attach transmission to assembly stand CAS2801.

Remove oil drain plug (1), oil filler tube with oil
dipstick (2), breather (3), inductive sensor - n central
gear chain (4), inductive sensor - n turbine (5),
inductive sensor - n engine (6).
6003-10
STEP 2 STEP 2
BILD-02 BILD-04
Remove cylindrical bolt (1) and remove Hall effect Separate cover from converter bell housing using a
speed sensor - n output and O-ring (2). suitable lifting device.
3.0 Engine connection, oil pressure
STEP 3
pump, converter back-pressure valve
and temperature sensor (measuring
point “63” after the converter as
described in the specifications, pressure
checks and troubleshooting section of
the manual)
STEP 1
3.1 Engine connection (remote mount)
1
2 BILD-05
Remove output flange.
STEP 4
BILD-03
Remove hex bolts (1) and washer. Loosen the

cover/converter bell housing bolts (2).
NOTE: Mark radial installation position of
cover/converter bell housing with center punch.
BILD-06
Press input shaft and converter out of cover (ball

bearing).
6003-11
STEP 5 STEP 8
3.2 Oil pressure pump
1
2
2
1
BILD-07
Remove retaining ring (1) and ball bearing (2).

BILD-10
Loosen bolted connection (1) between converter bell

STEP 6 housing and oil feed housing. Remove converter bell
housing (2).
1 2
STEP 9
1 21
BILD-08
Remove hex bolts (1) and flex plate (2) from

converter.
BILD-11
STEP 7 Remove the Torx bolts (1) from the oil feed housing
and front transmission housing. Remove cylindrical
bolts (2) from the oil pressure pump and front
2
transmission housing.
1 3
NOTE: Separate oil feed housing together with oil
pressure pump from front transmission housing.
BILD-09
Remove hex bolts (1) and flex plate (2) from input
shaft (3).
6003-12
STEP 10 STEP 12
2
1
1
BILD-12 BILD-14
Separate oil pressure pump (1) from oil feed housing Check oil gear pump for wear. In case of wear marks
(2). on the pump housing, cover, inner rotor, or outer
rotor; replace the oil pressure pump.
STEP 11 1. Cover
2. Inner rotor
3. Outer rotor
1 4. Pump housing
2
STEP 13
BILD-13
Remove O-ring (1) and cylindrical bolts (2).
BILD-15
Remove shaft seal (1) from the pump housing (2).

6003-13
STEP 14 STEP 16
3.3 Converter back-pressure valve
1
BILD-18
Remove temperature sensor (1).

BILD-16
With a screwdriver, release the converter safety valve

(1) pressure and remove the locking plate (2). STEP 17
STEP 15
1
2
3
1 2
BILD-19
Remove stator shaft (1). If applicable, remove the

pressure relief valve (2) out of the housing hole.
BILD-17
Remove individual parts of converter safety valve NOTE: The pressure relief valve is not mounted on
which are released. all versions. Versions concerned, see the
corresponding spare parts list.
1. Pressure plate
2. Compression spring
3. Piston
6003-14
4.0 Emergency steering pump STEP 2
STEP 1 1
4.1 Version without emergency steering pump
2
2
1
BILD-02
Pull off output flange (1) and remove shaft seal (2).
5.2 Output flange on output side with parking
BILD-01 brake FSG-88
Remove hex bolts (1), cover (2) and seals.
STEP 3
5.0 Outputs and closure parts pump
shaft (PTO-shaft)
5.1 Output flange on converter side (Standard 2 1
version)
STEP 1
BILD-11
Connect a hand-operated pump at port (see arrow)

and apply approximately 80 bar (1160 PSI) pressure
to the hydraulically actuated parking brake (1) until
the brake disc (2) can be rotated by hand.
BILD-01
STEP 4
Remove hex bolts (1), washer and O-ring.
BILD-12
Remove hex nut with open end wrench.

6003-15
STEP 5 6.0 Removal of input shaft, output shaft,
pump shaft (PTO -shaft) and clutches
2
STEP 1
1 1 2
BILD-13
Remove hex bolts (2) and parking brake (1).
STEP 6 BILD-01
Force out both cylindrical pins (1). Loosen bolted

connection (2) between front and rear transmission
housings. Separate housing sections using a suitable
2 1 lifting device.
STEP 2
BILD-14
Remove hex bolts (1) of bolted brake disc/output

flange connection and remove brake disc (2).
STEP 7
3 BILD-02
2 Loosen bolted connection (1) of oil screen sheets.
1
BILD-15
Remove hex bolts (1), washer and O-ring. Remove

output flange (2) and shaft seal. Remove cylinder
bolt with washer (3).
6003-16
STEP 3 STEP 6
1 2
BILD-03 BILD-06
Remove output shaft (1) and lower oil screen sheet Secure all clutches K1, K2, K3 and K4 by using
(2) from housing. 380001557 handle (1).
WARNING: Clutches KV, KR and input shaft (2) are
STEP 4 only secured by the gear chain. Care must be taken
to ensure these non-secured components do not
detach.
2
NOTE: Due to the installation conditions, the
1 removal of single clutches without using the special
tool is not possible.
STEP 7
BILD-04
Remove all rectangular rings (1) from the clutches

and all O-rings (2) from the oil tubes.
STEP 5 1
3
1 4
2
BILD-07
Separate rear housing section including clutches

from front housing section using a suitable lifting
device and attach it to the assembly truck.
1. Clutch KV
2. Input shaft
3. Clutch KR
2 4. Pump shaft
BILD-05
WARNING: Clutches KV, KR and input shaft are only
Use a suitable lifting device to lower rear housing secured by the gear chain. Care must be taken to
section (1) into contact position with front housing ensure these non-secured components do not
section (2). detach.
6003-17
STEP 8 STEP 10
BILD-08 BILD-10
Remove cylindrical bolts of oil tubes (1) from the front Remove bearing outer rings (arrows) from the front
housing. housing.
NOTE: If contrary to recommendation, the tapered
STEP 9 roller bearings of clutches, input and output are not
replaced, the technician must ensure the previous
pairing (bearing outer ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be
marked.
2
STEP 11
BILD-09
NOTE: The suction tube (1) and the lubrication lines

(2) are rolled in and difficult to remove. In case of
damage, use special tools 380001285 (EU) or 2
380001286 (EU) for fitting or replacing these
components. North American Dealers contact 1
special tools.
BILD-11
Disengage retaining ring (1) and remove pump shafts

(2).
6003-18
STEP 12 STEP 14
1
2
BILD-12 BILD-14
Press ball bearing (1) off the pump shaft. Snap out Remove bearing outer rings (arrows) from the rear
rectangular ring (2). housing.
NOTE: If contrary to recommendation, the tapered
STEP 13 roller bearings of clutches, input and output are not
replaced, the technician must ensure the previous
7 pairing (bearing outer ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be
6 marked.
2 STEP 15
5
3
4 1 1
2
BILD-13
Lift the clutches out of the housing in numerical order

as described in the legend.
1. K1 clutch
2. K2 clutch
3. K3 clutch (Version with emergency steering BILD-15
pump) NOTE: The lubrication lines (1 and 2) are rolled in

and difficult to remove. In case of damage, use
4. K4 clutch
special tool 380001285 (EU) for fitting or replacing
5. KR clutch these components. North American Dealers contact
special tools.
6. KV clutch
7. Input shaft
6003-19
7.0 Clutches KV/KR/K1/K2/K3/K4 input STEP 3
and output shaft.
STEP 1
2 6
4 5
3
1
BILD-03
7 Pull tapered roller bearing off the shaft using special

tool CAS2798.
BILD-01
1. K1 clutch STEP 4
2. K2 clutch
1
3. K3 clutch
4. K4 clutch
5. KR clutch
6. KV clutch
7. Input shaft.
STEP 2
7.1 KV clutch
BILD-04
1 2 Snap out retaining ring (1).
STEP 5
BILD-02
1
Remove stud bolt (1) and snap out piston ring (2).
BILD-05
Pull clutch (1) off the shaft.

NOTE: For disassembly of clutch see Steps 11-16.
6003-20
STEP 6 STEP 9
1 2
BILD- 06 BILD-09
Secure idler gear (1) using a cut-off device and pull it Turn shaft (2) 180 degrees and snap out piston ring
off the clutch shaft. (1).
STEP 7 STEP 10
BILD-07 BILD-10
Snap retaining ring (1) out of the idler gear (2) and Pull tapered roller bearing off shaft with special tool
remove ball bearing (3). CAS2798.
STEP 8 STEP 11
1
1
BILD-08 BILD-11
Remove needle cage (1) from the shaft (2). Unsnap snap ring (1).
6003-21
STEP 12 STEP 15
1
2
BILD-12 BILD-15
Remove end shim (1) and disc set (2) from the disc Using compressed air, remove the piston (1) from the
carrier (3). disc carrier.
STEP 13 STEP 16
1 2
BILD-13 BILD-16
Preload compression spring with special tool Remove both O-rings (1 and 2).
380001556 and unsnap L-ring (1).
STEP 1
STEP 14 7.2 KR clutch
1 1 2
BILD-14
BILD-01
Remove support shim (1), compression spring (2)
and washer (3).
6003-22
STEP 2 STEP 5
BILD-02 BILD- 05
Pull tapered roller bearing off the shaft with special Secure idler gear (1) using a cut-off device and pull it
tool CAS2798. off the clutch shaft.
STEP 3 STEP 6
1 1
BILD-03 BILD-06
Snap out retaining ring (1). Snap retaining ring (1) out of the idler gear (2) and
remove ball bearing (3).
STEP 4
STEP 7
1
BILD-04
Pull clutch (1) off the shaft. BILD-07
NOTE: For disassembly of clutch see Steps 10-15. Remove needle cage (1) from the shaft (2).
6003-23
STEP 8 STEP 11
1
1
BILD-08 BILD-11
Turn shaft (2) 180 degrees and snap out piston ring Remove end shim (1) and disc set (2) from the disc
(1). carrier (3).
STEP 9 STEP 12
BILD-09 BILD-12
Pull tapered roller bearing off shaft using special tool Preload compression spring with special tool
CAS2798. 380001556 and unsnap L-ring (1).
STEP 10 STEP 13
1
1
2
BILD-10 BILD-13
Unsnap snap ring (1). Remove support shim (1), compression spring (2)
and washer (3).
6003-24
STEP 14 STEP 2
BILD-14 BILD-02
Using compressed air, remove the piston (1) from the Pull tapered roller bearing off the shaft with special
disc carrier. tool CAS2798.
STEP 15 STEP 3
BILD-15 BILD-03
Remove both O-rings (1 and 2). Snap out retaining ring (1).
STEP 1 STEP 4
7.3 K1 clutch
1
1 2
BILD-04
Remove axial bearing assembly (1).

BILD-01
6003-25
STEP 5 STEP 8
BILD-05 BILD-08
Take off idler gear (1), remove needle cage (2) and Pull tapered roller bearing off the shaft with special
axial bearing assembly (3). tool CAS2798.
STEP 6 STEP 9
BILD-06 BILD-09
Pull clutch (1) off the shaft. Unsnap snap ring (1).
STEP 10
STEP 7
1
1
2
3
BILD-10
Remove end shim (1) and disc set (2) from the disc
BILD-07
carrier (3).
Turn shaft (2) 180 degrees and snap out piston ring
(1).
6003-26
STEP 11 STEP 14
1 2
BILD-11 BILD-14
Preload cup springs using special tool 380001556 Remove both O-rings (1 and 2).
and unsnap L-ring (1).
STEP 1
STEP 12 7.4 K2 clutch
1 2
1
BILD-12
BILD-01
Remove cup spring package (1).
STEP 13 STEP 2
BILD-13
BILD-02
Using compressed air, remove the piston (1) from the
Pull tapered roller bearing off the shaft using special
disc carrier.
tool CAS2798.
6003-27
STEP 3 STEP 6
1
BILD-03 BILD-06
Snap out retaining ring (1). Pull clutch (1) off the shaft.
STEP 4
1 STEP 7
BILD-04
Remove axial bearing assembly (1).

BILD-07
Turn shaft (2) 180 degrees and snap out piston ring
STEP 5 (1).
STEP 8
1
3
2
BILD-05
Remove idler gear (1), needle cage (2) and axial

bearing assembly (3).
BILD-08

tool CAS2798.
6003-28
STEP 9 STEP 12
1
1
BILD-09 BILD-12
Unsnap snap ring (1). Remove cup spring package (1).
STEP 10 STEP 13
1
2
BILD-10 BILD-13
STEP 11 STEP 14
2
1
BILD-11 BILD-14
Preload cup springs using special tool 380001556 Remove both O-rings (1 and 2).
6003-29
STEP 1 STEP 4
7.5 K3 clutch
1
1
3
BILD-04
Take off idler gear (1), remove needle cage (2) and
BILD-01
axial bearing assembly (3).
Snap out piston ring (1).
STEP 5
STEP 2
BILD-05
BILD-02
tool CAS2798. NOTE: For disassembly of clutch see Steps 8-13.
STEP 3 STEP 6
1 2
1
BILD-03 BILD-06
Remove axial bearing assembly (1). Remove stud bolt (1) and snap out piston ring (2).
6003-30
STEP 7 STEP 10
BILD-07 BILD-10
Pull tapered roller bearing off the shaft using special Preload cup springs using special tool 380001556
tool CAS2798. and unsnap L-ring (1).
STEP 8 STEP 11
1 1
BILD-08 BILD-11
Unsnap snap ring (1). Remove cup spring package (1).
STEP 9 STEP 12
1
2
BILD-09 BILD-12
6003-31
STEP 13 STEP 3
1
1
BILD-13 BILD-03
Remove both O-rings (1 and 2). Snap out retaining ring (1).
STEP 1 STEP 4
7.6 K4 clutch
1
2
BILD-04

BILD-01
Remove stud bolt (1) and snap out piston ring (2). NOTE: For disassembly of clutch see Steps 9-14.
STEP 2 STEP 5
1
BILD-02 BILD-05
Pull tapered roller bearing off the shaft using special Remove axial bearing assembly (1) and idler gear
tool CAS2798. (2).
6003-32
STEP 6 STEP 9
2 1
BILD-06 BILD-09
Remove needle cage (1) and axial bearing assembly Unsnap snap ring (1).
(2).
NOTE: The gear (3) cannot be removed, it is a STEP 10
shrink fit.
1
STEP 7
1 2
2 BILD-10
Remove end shim (1) and disc set (2) out of the disc
carrier (3).
BILD-07
Turn shaft (2) by 180 degrees and snap out piston STEP 11
ring (1).
STEP 8
BILD-11
Preload cup springs using special tool 380001556

BILD-08

tool CAS2798.
6003-33
STEP 12 STEP 1
7.7 Input shaft
2
1
BILD-12
Remove cup spring package (1).

BILD-01
Snap out piston ring (1). Turbine wheel shaft and

STEP 13 drive gear (2) are secured by a snap ring.
NOTE: When separated, the snap ring will be
destroyed.
1 STEP 2
BILD-13
Using compressed air, remove the piston (1) from the

disc carrier.
STEP 14
BILD-02
Pull tapered roller bearing off drive gear using special

tool CAS2798.
1
BILD-14
Remove both O-rings (1 and 2).

6003-34
STEP 3
BILD-03
Pull tapered roller bearing off drive gear using special

tool CAS2798.
NOTE: It is not possible to separate the input shaft
and gear (1). It is a shrink fit.
STEP 1
7.8 Output shaft
BILD-01
Pull tapered roller bearing off of output shaft using

special tool CAS2798 and remove oil sheet (1).
STEP 2
BILD-02
Turn output shaft 180 degrees and pull off tapered

roller bearing using special tool CAS2798.
6003-35
REASSEMBLY
8.0 Clutches KV/KR/K1/K2/K3/K4 input STEP 3
and output shaft
1
STEP 1
8.1KV Clutch
BILD-03
Mount bearing cage (1) onto the shaft and oil it.
STEP 4
BILD-01
Heat bearing to approximately +120° C (+248° F).

3
STEP 2 2
2
1 1
BILD-04
Install ball bearing (2) into the idler gear (1) until
contact occurs and secure it using retaining ring (3).
STEP 5
BILD-02
Mount bearing (1) until contact is made. Adjust

bearing after it cools. Fit rectangular ring (2).
WARNING: Always wear protective gloves to
prevent burning your hands when handling heated
parts. 1
BILD-05
Press pre-assembled idler gear (1) onto the shaft

until contact occurs.
6003-36
STEP 6 STEP 9
4
3
1
2
1
1 S
BILD-06 BILD-09
Place both O-rings (1 and 2) into the piston grooves Mount inner installer (S) onto the disc carrier. Install
and oil them. disc (1), compression spring (2), support shim (3)
and L-ring (4).
NOTE: Check function of the drain valve (see arrow).
The ball must not jam. NOTE: For installation position of support shim and
L-ring see Step 11. (S) Inner installer, see Step 10.
STEP 7
STEP 10
1
S1
S2
BILD-07
Place piston (1) into the disc carrier. BILD-10
Preload compression spring using special tool

NOTE: Observe installation position.
380001556 (S1) and pressure piece (S2), until
L-Ring has engaged into the annular grove.
STEP 8
NOTE: Always use a new L-ring.
BILD-08
Use special tool 380001556 (S) to place piston into

the disc carrier.
6003-37
STEP 11 STEP 12
1 2 3
6 2
3
7
4 1
BILD-11 BILD-12
Disc carrier with piston retraction: Install outer and inner discs into the disc carrier (4).
1. Washer 1. Friction disc - coated on one side (1 pcs)
2. Compression spring 2. Outer discs (10 pcs)
3. Support shim 3. Inner discs (10 pcs)
4. L-Ring NOTE: Make sure that the uncoated (blank) side of
the friction disc (1) is showing towards the piston.
5. Disc carrier
Number of friction surfaces is 20.
6. Drain valve (piston)
NOTE: Different clutch disc arrangements with
7. Piston with O-Rings relevant disc clearance can be installed depending
on the parts list version.
NOTE: The actual installed clutch and disc
arrangement must be taken from the corresponding
spare parts list. The spare parts list is binding.
STEP 13
1
2
BILD-15
Mount end plate (1) and secure disc package using

snap ring (2) e.g. thickness = 2.65 mm (0.104 in.)
/recommended value.
6003-38
STEP 14 STEP 16
BILD-16 BILD-18
Press on end plate with F (approximately 100 N = 10 Heat clutch to approximately +120° C (+248° F).
kg) and set dial indicator to “zero”.
STEP 17
STEP 15
L R
F
BILD-19
BILD-17 Install clutch until contact is made. Mount inner discs

Then press end plate against the snap ring onto the inner disc carrier using shor t left/right
(upwards) and read disc clearance. Disc clearance rotations.
should be: 2.65 to 2.95 mm(0.104 to 0.116 in.).
NOTE: In cases of deviation, the disc clearance prevent burning your hands when handling heated
must be corrected with the appropriate snap ring. parts.
Optional thicknesses range from 2.1 to 4.2 mm
(0.083 to 0.165 in.). STEP 18
BILD-20
Secure clutch (1) using retaining ring (2).

6003-39
STEP 19 STEP 22
BILD-21 BILD-24
Heat bearing inner ring to approximately +120° C Check clutch operation using compressed air at the
(+248° F). hole (see arrow). Closing and opening of the clutch
must be clearly audible.
STEP 20
STEP 23
1 1
BILD-22
Mount bearing (1) until contact is made. Adjust BILD-25
bearing after it cools. Install sealing cap on orifice (1).

WARNING: Always wear protective gloves to NOTE: Wet contact surface with Loctite (Type No.
prevent burning your hands when handling heated 262).
parts.
NOTE: The sealing cap is not mounted on all
versions. For versions concerned, see corresponding
STEP 21 spare parts list.
2
1
BILD-23
Mount stud bolt (1), torque to 17 Nm (150 pound

inches). Fit rectangular ring (2).
6003-40
STEP 1 STEP 4
8.2 KR Clutch
3
BILD-04
Install ball bearing (2) into the idler gear (1) until
BILD-01
contact occurs and secure it using retaining ring (3).
STEP 5
STEP 2
2
1
BILD-05
BILD-02
Press in pre-assembled idler gear (1) onto the shaft
until contact occurs.
WARNING: Always wear protective gloves to STEP 6
parts.
STEP 3
1
1
3
BILD-06
Place both O-rings (1 and 2) into the piston grooves

and oil them.
NOTE: Check function of the drain valve (3). The ball
BILD-03
must not jam.
Mount needle bearing (1) onto the shaft and oil it.
6003-41
STEP 7 STEP 10
1 S1
S2
BILD-07 BILD-10
Place piston (1) into the disc carrier. Preload compression spring using special tool
assembly 380001556 (S1) and pressure piece (S2),
until L-Ring has engaged the annular grove.
STEP 8 NOTE: Always use a new L-ring.
STEP 11
1 2 3
S
5
6
7
4
BILD-08

the disc carrier. BILD-11
Disc carrier with piston retraction:

STEP 9 1. Washer
4 2. Compression spring
3 3. Support shim
2 4. L-Ring
5. Disc carrier
1 6. Drain valve (piston)
S 7. Piston with O-Rings.
BILD-09
Mount inner installer (S) onto the disc carrier. Install

disc (1), compression spring (2), support shim (3)
and L-ring (4).
NOTE: Installation position support shim and L-ring
see Step 11. (S) Inner installer, see Step 10.
6003-42
STEP 12 STEP 14
3 2
4 1
BILD-12 BILD-16
Install outer and inner discs into the disc carrier (4). Press on end plate (F) approximately 100 N = 10 kg
and set dial indicator to “zero”.
1. Friction disc - coated on one side (1 pcs)
2. Outer discs (10 pcs) STEP 15
3. Inner discs (10 pcs)
NOTE: Make sure that the uncoated (blank) side of F
relevant disc clearance can be installed depending
STEP 13 BILD-17
Press end plate against the snap ring (upwards) and

read disc clearance. Disc clearance should be 2.65
1 to 2.95 mm (0.104 to 0.116 in.).
2 NOTE: In cases of deviation, the disc clearance
must be corrected with an appropriate snap ring.
(0.083 to 0.165 in.).
BILD-15

snap ring (2) e.g. thickness = 2.65 mm(0.104
in.)/recommended value.
6003-43
STEP 16 STEP 19
BILD-18 BILD-21
Heat clutch to approximately +120° C (+248° F). Heat bearing to approximately +120° C (+248° F).
STEP 17 STEP 20
L R 1
BILD-19 BILD-22
Install clutch until contact is made. Mount inner discs Mount bearing (1) until contact is made. Adjust
onto the inner disc carrier using shor t left/right bearing after it cools.
rotations.
WARNING: Always wear protective gloves to prevent burning your hands when handling heated
prevent burning your hands when handling heated parts.
parts.
STEP 21
STEP 18
2
2 1
BILD-23
BILD-20 Mount stud bolt (1) and torque to 17 Nm (150 pound

Secure clutch (1) using retaining ring (2). inches). Fit rectangular ring (2).
6003-44
STEP 22 STEP 1
8.3 Clutch K1
BILD-24
Check clutch operation by using compressed air at

BILD-01
the hole (see arrow). Closing and opening of the
clutch must be clearly audible.
STEP 2
STEP 23
2
1 1
BILD-02
BILD-25
Install sealing cap on orifice (1). Mount bearing (1) until contact is made. Adjust
NOTE: Wet contact surface with Loctite (Type No.
262). WARNING: Always wear protective gloves to
NOTE: The sealing cap is not mounted on all parts.
versions. Versions concerned, see corresponding
spare parts list.
6003-45
STEP 3 STEP 6
2
1
1
3
2 S
BILD-03 BILD_06
Place both O-rings (1 and 2) into the piston grooves Mount inner installer (S) onto the disc carrier. Install
and oil them. cup spring package (1) and L-ring (2).
NOTE: Check function of the drain valve (3). There NOTE: For installation position of cup spring
must be no jamming of the ball. package and L-ring see Step 8. (S) Inner installer,
see Step 7.
STEP 4
STEP 7
S2 S1
BILD-04
Place piston (1) into the disc carrier. BILD-07
Preload cup spring package using special tool

L-Ring has engaged the annular grove.
STEP 5
BILD-05

the disc carrier.
6003-46
STEP 8 STEP 10
1 2
1
3 2
BILD-08 BILD-11
Disc carrier with piston retraction: Mount end plate (1) and secure disc package using
1. Cup spring package
2. L-Ring
3. Disc carrier STEP 11
4. Piston with O-rings
STEP 9 F
3 2
BILD-12
Press on end plate (F) approximately 100 N = 10 kg

and set dial indicator to “zero”.
4 1
BILD-09
Install outer and inner discs into the disc carrier (4).
2. Outer discs (9 pcs)
NOTE: Make sure that the uncoated (blank) side of
6003-47
STEP 12 STEP 14
F
1
BILD-13 BILD-15
Press end plate against the snap ring (upwards) and Install clutch (1) until contact is made.
to 2.65 mm(0.092 to 0.104 in.).
NOTE: In cases of deviation, the disc clearance parts.
Optional thicknesses range from 2.1 to 4.2 mm STEP 15
(0.083 to 0.165 in.).
STEP 13 2 3
BILD-16
Mount running disc (1), axial cage (2) and axial

washer (3) and oil it.
BILD-14
NOTE: Install chamfer (see arrow) of running disc
Heat clutch to approximately +120° C (+248° F).
(1) showing towards the axial cage.
STEP 16
BILD-17
Mount needle bearing (1) and oil it.

6003-48
STEP 17 STEP 20
L
R
BILD-18 BILD-21
Install (1) idler. Mount inner discs onto the inner disc Heat bearing to approximately +120° C (+248° F).
carrier (idler) by using short left/right rotations.
STEP 21
STEP 18
3 1
2
BILD-22
BILD-19 Mount bearing (1) until contact is made. Adjust

Mount axial washer (1), axial cage (2) and running bearing after it cools.
disc (3) and oil it.
NOTE: Install chamfer (see arrow) of running disc prevent burning your hands when handling heated
(3) showing towards the axial cage. parts.
STEP 19 STEP 22
2 1 2
BILD-20 BILD-23
Secure idler gear (1) and single par ts by using Mount stud bolt (1) and torque to 17 Nm (150 pound
retaining ring (2). inches). Fit rectangular ring (2).
6003-49
STEP 23 STEP 2
2
1
BILD-24 BILD-02
Check clutch operation by using compressed air at Mount bearing (1) until contact is made. Adjust
the hole (see arrow). Closing and opening of the bearing after it cools. Fit rectangular ring (2).
STEP 1 parts.
8.4 Clutch K2
STEP 3
BILD-01
Heat bearing to approximately +120° C (+248° F). BILD-03

and oil them.
NOTE: Check function of the drain valve (3). There
must be no jamming of the ball.
6003-50
STEP 4 STEP 7
1
S2 S1
BILD-04 BILD-07
Place piston (1) into the disc carrier. Preload cup spring package using special tool
STEP 5 NOTE: Always use a new L-ring.
STEP 8
1 2
S
3
BILD-05

the disc carrier. BILD-08
Disc carrier with piston retraction:

STEP 6 1. Cup spring package
2 2. L-Ring
3. Disc carrier
1
BILD_06

cup spring package (1) and L-ring (2).
NOTE: For installation position cup spring package
and L-ring see Step 8. (S) Inner installer, see Step 7.
6003-51
STEP 9 STEP 11
2
3
4 1
BILD-09 BILD-12
Install outer and inner discs into the disc carrier (4). Press on end plate with (F) approximately 100 N = 10
kg and set dial indicator to “zero”.
2. Outer discs (7 pcs) STEP 12
NOTE: Make sure that the uncoated (blank) side of F
STEP 10 BILD-13
Press end plate against the snap ring (upwards) and

to 2.05 mm (0.069 to 0.081 in.) see Step 9.
1
2 NOTE: In cases of deviation, the disc clearance
(0.083 to 0.165 in.).
BILD-11

6003-52
STEP 13 STEP 16
BILD-14 BILD-17
Heat clutch to approximately +120° C (+248° F). Mount needle bearing (1) and oil it.
STEP 14 STEP 17
L R
1
BILD-15 BILD-18
Mount clutch (1) until contact is made. Install (1) idler. Mount inner discs onto the inner discs
carrier (idler) by using short left/right rotations.
parts. STEP 18
3
STEP 15
2
3
2 1
BILD-19
Mount axial washer (1), axial cage (2) and running

disc (3) and oil it.
BILD-16
Mount running disc (1), axial cage (2) and axial NOTE: Install chamfer (see arrow) of running disc
washer (3) and oil it. (3) showing towards the axial cage.
NOTE: Install chamfer (see arrow) of running disc
(1) showing towards the axial cage.
6003-53
STEP 19 STEP 22
2 1 2
BILD-20 BILD-23
Secure idler gear (1) and single parts using retaining Mount stud bolt (1) and torque to 17 Nm (150 pound
ring (2). inches). Fit rectangular ring (2).
STEP 20 STEP 23
BILD-21 BILD-24
Heat bearing to approximately +120° C (+248° F). Check clutch operation by using compressed air at
STEP 21 clutch must be clearly audible.
STEP 1
1 8.5 Clutch K3
BILD-22

bearing after it cools.
WARNING: Always wear protective gloves to BILD-01
prevent burning your hands when handling heated Heat bearing to approximately +120° C (+248° F).
parts.
6003-54
STEP 2 STEP 4
3 2
1 1
BILD-02 BILD-04
Mount bearing (1) until contact is made. Adjust Place piston (1) into the disc carrier.
bearing after it cools. Fit rectangular ring (2). Mount
stud bolt and torque to 17 Nm (150 pound inches).
WARNING: Always wear protective gloves to STEP 5
parts.
STEP 3
S
3
2 BILD-05

the disc carrier.
BILD-03 STEP 6
and oil them. 2
must be no jamming of the ball.
1
BILD_06

NOTE: For installation position of cup spring
package and L-ring see Step 8. For inner installer
(S), see Step 7.
6003-55
STEP 7 STEP 9
2
S2 S1
3
4 1
BILD-07 BILD-09
Preload cup spring package using special tool Install outer and inner discs into the disc carrier (4).
STEP 8 NOTE: Make sure that the uncoated (blank) side of
1 2 Number of friction surfaces is 14.
3
4 arrangement must be taken from the corresponding
STEP 10
BILD-08
Disc carrier with piston retraction: 1

1. Cup spring package 2
2. L-Ring
3. Disc carrier
4. Piston with O-rings.
BILD-11

snap ring (2) e.g. thickness = 2.65 mm (0.104
6003-56
STEP 11 STEP 13
BILD-12 BILD-14
Press on end plate with (F) approximately 100 N = 10 Heat clutch inner diameter to approximately +120° C
kg and set dial indicator to “zero”. (+248° F).
STEP 12 STEP 14
F
1
BILD-13 BILD-15
Press end plate against the snap ring (upwards) and Mount clutch (1) until contact is made.
to 2.05 mm (0.069 to 0.081 in.).
NOTE: In cases of deviation, the disc clearance parts.
(0.083 to 0.165 in.).
6003-57
STEP 15 STEP 18
3 3
2 2
1 1
BILD-16 BILD-19
Mount running disc (1), axial cage (2) and axial Mount axial washer (1), axial cage (2) and running
washer (3) and oil it. disc (3) and oil it.
NOTE: Install chamfer (see arrow) of running disc NOTE: Install chamfer (see arrow) of running disc
(1) showing towards the axial cage. (3) showing towards the axial cage.
STEP 16 STEP 19
BILD-17 BILD-20
Mount needle bearing (1) and oil it. Make sure that the running disc is flush with the shaft
collar (see arrow) to ensure that all inner discs are
STEP 17 mounted on the idler gear teeth.
STEP 20
1
L R
BILD-18
Install (1) idler. Mount inner discs onto the inner disc
carrier (idler) using short left/right rotations. BILD-21

6003-58
STEP 21 STEP 1
8.6 K4 Clutch
2
1
BILD-22

BILD-01
prevent burning your hands when handling heated STEP 2
parts.
STEP 22 2
1
BILD-02

bearing after it cools. Fit angular ring (2).
BILD-23
Check clutch operation by using compressed air at
parts.
6003-59
STEP 3 STEP 5
2 2
1
BILD-03 BILD-05
Cool shaft (1) to approximately -80° C (-112° F), heat Mount lower axial washer (1), axial needle cage (2)
gear (2) to approximately +120° C (+248° F) and and upper axial washer (1) and oil it.
mount until contact is made.
NOTE: Upper and lower axial washer are identical.
prevent burning your hands when handling heated STEP 6
parts.
STEP 4 1
1
BILD-06
Mount needle bearing (1) and oil it.
BILD-04 STEP 7
Secure gear using retaining ring (1).
BILD-07
Mount idler gear (1).

6003-60
STEP 8 STEP 10
3
2
1
1
BILD-08 BILD-10
Mount axial washer (1), axial needle bearing (2) and Place piston (1) into the disc carrier.
running disc and oil it.
NOTE: Mount running disc (3) with the chamfer (see
arrow) pointing to the needle cage. STEP 11
STEP 9
3
2
BILD-11

BILD-09 the disc carrier.
and oil them. STEP 12
must be no jamming of the ball. 2
BILD-12

NOTE: For installation position of cup spring
package and L-ring see Step 14. For inner installer,
see Step 13.
6003-61
STEP 13 STEP 15
3
S2
S1 2
4 1
BILD-13 BILD-15
Preload cup spring package using special tool Install outer and inner discs into the disc carrier (4).
1. Friction disc - coated on one side - (1pcs)
L-Ring has engaged into the annular groove.
STEP 14 NOTE: Make sure that the uncoated (blank) side of
1 2 Number of friction surfaces is 12.
3 relevant disc clearance can be installed depending
4 arrangement must be taken from the corresponding
STEP 16
BILD-14
Disc carrier with piston retraction: 1

2
1. Cup spring package
2. L-ring
3. Disc carrier
BILD-16
Mount end plate (1) and secure disc package using a

snap ring (2) e.g. thickness = 2.65 mm (0.104
6003-62
STEP 17 STEP 19
BILD-17 BILD-19
Press on end plate with (F) approximately 100 N = 10 Heat clutch inner diameter to approximately +120° C
kg and set dial indicator to “zero”. (+248° F).
STEP 18 STEP 20
F L
R
BILD-18 BILD 20
Press end plate against the snap ring (upwards) and Mount clutch (1) until contact is made. Mount inner
read disc clearance. Disc clearance should be 1.35 discs onto the inner disc carrier using short left/right
to 1.65 mm (0.053 to 0.065 in.) see step 15. rotations.
NOTE: In cases of deviation, the disc clearance WARNING: Always wear protective gloves to
must be corrected with an appropriate snap ring. prevent burning your hands when handling heated
Optional thickness range from 2.1 to 4.2 mm (0.083 parts.
to 0.165 in.).
STEP 21
BILD-21
Secure clutch using retaining ring (1).

6003-63
STEP 22 STEP 24
BILD-22 BILD-24
Heat bearing inner ring to approximately +120° C Check clutch operation by using compressed air at
(+248° F). the hole (see arrow). Closing and opening of the
STEP 23
STEP 1
3 8.7 Input shaft
2
1
2
1
BILD-23

bearing after it cools. Fit rectangular ring (2). Mount
BILD-01
stud bolt (3). Torque to 17 Nm (150 pound inches).
Cool input shaft (1) to approximately -80° C (-112° F)
WARNING: Always wear protective gloves to and heat drive gear (2) to approximately +120° C
prevent burning your hands when handling heated (+248° F). Mount until contact is made.
parts.
prevent burning your hands when handling heated or
cooled parts.
6003-64
STEP 2 STEP 5
BILD-02 BILD-05
Secure drive gear using retaining ring (1). Heat bearing to approximately +120° C (+248° F).
STEP 3 STEP 6
BILD-03 BILD-06
Heat bearing to approximately +120° C (+248° F). Mount bearing (1) until contact is made. Adjust
STEP 4 WARNING: Always wear protective gloves to
parts.
1 STEP 7
2
BILD-04

prevent burning your hands when handling heated BILD-07
parts. Install snap ring (1) into the annular groove of the
turbine shaft (2).
6003-65
STEP 8 STEP 1
8.8 Output Shaft
BILD-08
Mount turbine shaft (1) until the snap ring engages

BILD-01
into the input shaft groove. Snap in and interlock
rectangular ring (2).
NOTE: Turbine shaft is axially secured. STEP 2
STEP 9
3 1
BILD-02

BILD-09 bearing after it cools.
Version with lock-up clutch:
Mount turbine shaft (1) until the snap ring engages prevent burning your hands when handling heated
into the input shaft groove. Snap in and interlock parts.
rectangular ring (2 and 3).
NOTE: Turbine shaft is axially secured. STEP 3
BILD-03
Mount screen sheet (1).

6003-66
STEP 4 9.0 Installation of input shaft, output
shaft, pump shaft (power-take off shaft)
and clutches
STEP 1
BILD-04

2
STEP 5
BILD-01
NOTE: If the suction tube (1) in the front housing is

1 to be replaced, a special rolling tool 380001285 (EU)
must be used for assembly. North American Dealers
contact special tools. Secure the tube with cylindrical
bolt (2). Torque to 23 Nm (17 pound feet).
NOTE: Oil cylindrical bolt. It is always necessary to
use new cylindrical bolts.
STEP 2
BILD-05

parts.
1
BILD-02
NOTE: The lubricating oil tube (1) is supplied as a

complete package with the front housing only. Single
parts delivery are available only upon request.
NOTE: Assembly is only possible with special tool
380001286 (EU), North American Dealers contact
special tools.
6003-67
STEP 3 STEP 5
3 3
1 2
1 2
4 4
BILD-03 BILD-05
Mount O-rings into the oil tube annular grooves (1 NOTE: The lubricating oil tubes (1 and 2) are
and 2) and oil them. Then insert tubes into the front supplied as a complete package with the rear
housing. Oil cylindrical bolts (3 and 4) and secure housing. Single parts delivery available only upon
them. Torque to 23 Nm (17 pound feet). request.
NOTE: Always use new cylindrical bolts. NOTE: Assembly is only possible with special
tool380001287 (EU), North American Dealers
STEP 4 contact special tools.
STEP 6
4
3 1
6 8
1 7
5
2
2
BILD-04
Mount O-rings into the oil tube annular grooves (1

and 2) and oil them. Then insert tubes into the front BILD-06
housing. Insert all bearing outer rings into the bearing holes of
both housing sections. Front housing.
1. Input
2. Output
3. Forward clutch
4. Reverse clutch
5. K1 = 1st gear clutch
6. K2 = 2nd gear clutch
7. K3 = 3rd gear clutch
8. K4 = 4th gear clutch.
NOTE: For installation position, see Step 6 and 7.
6003-68
STEP 7 STEP 9
3 1
4
1
8 6
5 7 2
BILD-07 BILD-09
Rear housing legend see Figure 6. Place bearing Slightly lift drive gear (1) and position K4 clutch (2).
outer rings into the bearing holes using assembly
grease. STEP 10
NOTE: If contrary to manufacturer recommendation,
the tapered roller bearings of clutches, input and
output are not replaced, you must ensure the
previous pairing (bearing inner ring/bearing outer
ring) - see disassembly instructions.
1
STEP 8
1
BILD-10
3
Mount K3 clutch (1).
STEP 11
BILD-08
1
Place KR clutch (1), AN input shaft (2) and KV clutch
(3) into the housing rear section at the same time.
WARNING: Risk of injury.
NOTE: Due to installation conditions, the installation
of single clutches without using the special tool is not
possible.
NOTE: Housing rear section will be removed again
later. BILD-11
Position K2 clutch (1).

6003-69
STEP 12 STEP 15
1 7 5
2 2
6
1
3
4
S
BILD-12 BILD-15
Slightly lift K4 clutch (1) and position K1 clutch (2). Secure clutches K1 (1), K2 (2), K3 (3) and K4 (4) by
using a special handle tool 380001557 (S). Check all
STEP 13 rectangular rings, grease and align them centrically.
NOTE: This step shows the installation position of
the individual clutches in the rear housing.
WARNING: Clutches KV (5), KR (6) and input shaft
AN (7) are only secured by the gear chain. Care must
2 be taken to ensure these non-secured components
do not detach.
STEP 16
3
1
BILD-13
Press ball bearing (1) onto the pump shaft (2) until
contact is made. Mount rectangular ring (3). Grease
and centrically align rectangular ring.
STEP 14 3
1
2 4
BILD-16
Pivot rear housing 180 degrees by using a suitable

lifting device.
1. Clutch KV
2. Input shaft
1 3. Clutch KR
4. Pump shaft.
2
WARNING: Clutches KV, KR and input shaft (2) are
BILD-14
only secured by the gear chain. Care must be taken
Mount pump shaft (1) until contact is made. Attach to ensure these non-secured components do not
pump shaft using retaining ring (2). detach.
6003-70
STEP 17 STEP 20
4 2 3 1
BILD-17 BILD-20
Use the suitable lifting device to bring the rear Oil cylindrical bolts (1) and use them to attach screen
housing into contact position with the front housing sheet (1). Torque to 23 Nm (17 pound feet). Mount
by cautiously assembling the clutches. Then remove O-rings (2) into the annular grooves of the oil tubes
handles. and oil them. Mount all rectangular rings (4), grease
and align them centrally. Wet mounting face (3) with
STEP 18 sealing agent Loctite (type No. 574).
NOTE: Always use new cylindrical bolts.
STEP 21
BILD-18
Remove the rear housing again.
STEP 19 BILD-21
Carefully bring the front housing into contact position

with the rear housing by using a suitable lifting
device.
2
NOTE: Be sure that both oil tubes are aligned with
the holes in the rear housing.
BILD-19
Position screen sheet (1). Install pre-assembled

output shaft (2).
6003-71
STEP 22 STEP 24
1 3 1
1 2 1
BILD-22 BILD-24
Fit both cylindrical pins (1) centrically to the mounting Join front and rear housing sections using cylindrical
face bolts (1). Torque to 46 Nm (34 pound feet). Mount
securing plate (2). Mount stud bolts (3) and torque to
STEP 23 15 Nm (133 pound inches).
NOTE: Wet bolt-in thread with Loctite (type No. 243).
S
STEP 25
1 1
BILD-23
Check clearance of the gear drive train. Position

driving element (S) and rotate KV clutch shaft.
Driving element can be fabricated by dealer.
BILD-25
NOTE: If interference of the movable parts (e.g. on The bolt plugs (1) must be mounted with a hydraulic
the screen sheet or on the oil tubes) is found, it must pneumatic pressing tool.
be corrected. Do this step on all clutch shafts.
NOTE: In case of damage the pre-mounted rear
transmission housing must be fully replaced.
6003-72
10.0 Outputs and closure parts pump STEP 3
shaft (PTO-shaft)
STEP 1 1 3
2
10.1 Output flange output side with brake FSG-88
BILD-16
Insert O-ring into the space between output flange

and shaft. Attach output flange (1) using washer (2)
and hex bolts. Oil hex bolts before the assembly.
Torque to 46 Nm (34 pound feet). Mount cylindrical
BILD-14 bolt with washer (3) for stop of the parking brake set
Use driver tool 380001560 (S) to mount shaft seal screw. Tightening torque 48 Nm (35 pound feet).
with the sealing lip showing to the oil sump. Fill space
between sealing lip and dust lip with grease. Wet NOTE: Always use new hex bolts.
outer diameter (rubber-coated) with mineral spirit.
STEP 4
NOTE: Use of specified driver (S) ensures the exact
installation position.
NOTE: For installation position of shaft seal see
Step 4. 2
STEP 2 1
3
1 BILD-17
Secure brake disc (1) at output flange (2) using hex

bolts and washers. Torque to 68 Nm (50 pound feet).
Connect a hand-operated pump at port (see arrow)
and apply approximately 80 bar (1160 PSI) pressure
to the parking brake (3) and bring it in contact
BILD-15
position.
Press screen sheet (1) onto the output flange (2).
Mount output flange (2) until contact is made.
6003-73
STEP 5 STEP 7
2
BILD-18 BLD-20
Attach parking brake (1) on transmission housing Insert setting gauge on both sides between base disc
using the hex bolt - guide pin (2). Torque to 46 Nm and brake disc and hold in its position. Clearance:
(34 pound feet). 0.5 - 1.5 mm (0.02 to 0.06 in), Nominal clearance: 1.0
mm (0.04 in.).
STEP 6 NOTE: For all installation, fitting and maintenance
instructions, functional characteristics and setting
specifications of the parking brake, see
manufacturer’s documentation.
STEP 8
10.2 Output flange on converter side (Standard
versions)
S
BILD-19
Secure hex nut on brake caliper using the open end

wrench insert. Torque to 230 Nm (170 pound feet).
BILD-26
Use driver tool 380001560 (S) to mount shaft seal,

with the sealing lip showing to the oil sump.
NOTE: Use of the specified driver (S) ensures the
exact installation position.
NOTE: Fill space between sealing lip and dust lip
with grease.
NOTE: For installation position shaft seal see Step
34.
6003-74
STEP 9 STEP 11
2 3
1 3
1
4
2
5
BILD-27 BILD-29
1. Shaft seal Insert O-ring into the space between output flange
and shaft. Secure output flange (1) using washer (2)
2. Gearbox housing - rear section
and hex bolts (3). Oil hex bolts before the assembly.
3. Roller bearing Torque to 46 Nm (34 pound feet).
4. Output shaft NOTE: Always use new hex bolts.
5. Screen sheet
STEP 10
2
BILD-28
Press screen sheet (1) onto the input flange (2).

Mount output flange (2) until contact is made.
6003-75
11.0 Reassembly: Engine connection, oil STEP 3
pressure pump, converter back-pressure
valve and temperature sensor
(measuring point “63” after the converter
1
as described in the specifications,
pressure checks and troubleshooting
section of the manual)
STEP 1
11.1 Converter back-pressure valve
1 BILD-03
Mount temperature sensor (1) with O-ring. Torque to

25 Nm (18 pound feet).
2 NOTE: For version without a temperature sensor, fit
5 3
a plug (1) with O-ring and torque to 25 Nm (18 pound
feet).
STEP 4
4 11.2 Oil pressure pump
BILD-01
The Step shows the single parts of the converter 3

back-pressure valve.
1. Oil feed housing
2. Piston 1 2
4. Pressure plate
S S
5. Locking plate.
NOTE: Install pressure plate (4), with the pin (6 mm
diameter) facing towards the locking plate (1).
BILD-04
Insert pressure relief valve (1) into the housing hole

STEP 2 until contact is made. Mount two M8 adjusting bolts
(S) and position gasket (2) and oil feed housing (3).
Use assembly grease.
NOTE: The pressure relief valve is not mounted on
2 all versions. Versions concerned, see the
corresponding spare parts list.
1
BILD-02
Assemble single par ts, preload them with

screwdriver (1) and secure them with the locking
plate (2).
6003-76
STEP 5 STEP 8
1
1
BILD-05 BILD-08
Install two adjusting bolts (S) and mount stator shaft Position control disc and secure it radially using two
(1). cylindrical bolts (1). Place O-ring (2) into the annular
groove and oil it.
NOTE: Pay attention to radial installation position.
NOTE: Do not tighten the cylindrical bolts - only turn
STEP 6 them in until contact is made and then turn them
back by approximately 1/2 a turn. Pay attention to the
installation position of the control disc in figure.
STEP 9
BILD-06
Install outer rotor with the chamfer (see arrow) facing

2
downwards.
NOTE: If there are wear marks in the pump housing
BILD-09
or on the control disc, replace the pump assembly.
With the sealing lip positioned facing downward,
carefully insert the shaft seal (1) into the pump
STEP 7 housing with suitable driver (2) until contact is made.
NOTE: Wet outer diameter of shaft seal with mineral
spirits.
BILD-07
Install inner rotor with the teeth (see arrow) facing

upwards.
6003-77
STEP 10 STEP 13
2 1
1 2
4 2
3
BILD-10 BILD-13
Oil sliding bearing (see arrow) before assembly. Secure oil feed housing (1) equally using Torx bolts
Mount inner installer (S) onto the stator shaft. Mount (2). Torque to 23 Nm (17 pound feet). Secure plate
pre-assembled transmission pump (1). (3) using cylindrical bolts (4). Torque to 34 Nm (25
pound feet).
NOTE: Pay attention to radial installation position.
STEP 14
STEP 11
1
2
BILD-14
BILD-11
Secure converter bell housing (1) using hex bolts (2).
Mount pre-assembled pump with driver (S) until
Torque to 65 Nm (48 pound feet).
contact is made.
STEP 12
2
1
BILD-12
Grease O-rings and fit them to the cylindrical bolts

(1). Secure transmission pump (2) using cylindrical
bolts. Torque to 46 Nm (34 pound feet).
6003-78
STEP 15 STEP 17
11.3 Engine connection (remote mount)
1
2
1
2
3
BILD-20
Install ball bearing (1) and secure it using V-ring (2).

BILD-18
Bolt input shaft (1) to flex plate (2) using hex bolts (3).
Torque to 115 Nm (85 pound feet). STEP 18
NOTE: Wet threads of hex bolts with Loctite (Type
No. 262). S
STEP 16
1 2 1
BILD-21
Put cover (1) onto the converter and press it until

contact is made.
NOTE: Support the pressure sleeve (S) on the
bearing inner ring.
BILD-19
Secure flex plate (1) to converter (3) using hex bolts

(2). Torque to 115 Nm (85 pound feet). STEP 19
NOTE: Wet threads of hex bolts with Loctite (Type
No. 262).
BILD-22
Press screen sheet (1) onto the input flange (2).

6003-79
STEP 20 STEP 22
3
1
BILD-23 BILD-25
Heat flange inner diameter to approximately +120° C Secure input flange (3) using washer (1) and hex
(+248° F). bolts (2). Oil hex bolts before assembly. Torque to 34
Nm (25 pound feet).
STEP 21 NOTE: Always use new hex bolts.
1 STEP 23
BILD-24
2
Mount input flange (1) until contact is made.
WARNING: Always wear protective gloves to BILD-26
prevent burning your hands when handling heated Position converter using a suitable lifting device until
parts. the cover (1) is in contact with the converter bell
housing (2).
6003-80
STEP 24 STEP 2
1 1
2
3
BILD-27 BILD-02
Bolt converter bell housing (1) to cover (2) using Attach cover using hex bolts (1). Torque to 23 Nm (17
cylindrical bolts and hex nuts (3). Torque to 46 Nm pound feet).
(34 pound feet).
NOTE: Pay attention to radial installation position
markings made during disassembly (see arrows).
12.0 Reassembly - Emergency steering
pump
STEP 1
12.1 Version without emergency steering pump
1
S
BILD-01
Install adjusting bolts (S) and assemble seal (1) and

cover (2).
6003-81
13.0 Reassembly: Inductive sensor, Hall STEP 2
sensor, breather, oil filler and oil drain
plug 4
STEP 1
1 2 3 4
2
3 5
1
BILD-02
Mount oil drain plug with O-ring (1) and torque to 80

Nm (59 pound feet). Attach oil level tube (2) with seal
6 to the housing front section and secure it using hex
bolts (3). - torque to 34 Nm (25 pound feet). Fasten
dipstick (4) in oil level tube. Attach identification plate
(5) to the housing front section.
NOTE: Use Loctite (type No. MS 9360).
7
5
9 8
BILD-01
Mount inductive sensors (1,2 and 3) with O-rings and

torque to 30 Nm (22 pound feet).
1. Inductive sensor - turbine speed
2. Inductive sensor - speed/central gear chain
3. Inductive sensor - engine speed.
Mount breather (4) and torque to 12 Nm (106 pound
inces). Mount speed sensor (Hall sensor) - output
speed (5) with O-ring. Secure it using a cylindrical
bolt (6) and torque to 23 Nm (17 pound feet). Mount
plug (7) with O-ring and torque to 80 Nm (59 pound
feet). Attach cover (8) with seal to the housing front
section securing it with hex bolts (9), torque to 23 Nm
(17 pound feet).
6003-82
14.0 Reassembly Electro-hydraulic

control with proportional valves
STEP 1
Main pressure valve 16+2 bar Pressure reducing valve 9 bar Wiring harness
A A
B
B
Cover Cover
Housing Valve block Housing
CHAPTER 14 - FIG. 1.PNG
Electro-hydraulic Control
NOTE: Different versions regarding the wiring
harness position are possible. Please observe the
vehicle manufacturer’s specifications.
The following sketches show the sectional views of
the electro-hydraulic control.
6003-83
STEP 2
Proportional valve P5
Vibration damper
Pressure controller
Follow-on slide
STEP 3
Main pressure valve 16+2 bar Valve block Wiring harness
Pressure reducing valve 9 bar

Duct plate
Main Pressure Valve
STEP 4
14.1 Fitting of electric control
1 1
BILD-04
NOTE: Check all single parts for damage and

replace if required. Ensure free travel of the moving
parts in the valve block before installation. Pistons
can be exchanged individually. Before installation, oil
single parts.
With the concave side facing upward, insert orifice
(1) until contact is made.
6003-84
STEP 5 STEP 7
2
1
3 S
S
2
1
BILD-05 BILD-07
NOTE: See arrows for installation position. Fit adjusting bolts 380001577 (S). Mount seal (1) and
housing (2). Then position housing equally using the
This Step shows the following single parts:
adjusting bolts until contact is made.
1. Pressure reducing valve (1x, piston and
compression spring) STEP 8
2. Vibration damper (3x, piston and compression
spring) 1
3. Follow-on slide (3x, piston and compression
spring)
STEP 6
BILD-08
Bring housing (1) into contact position using the Torx

bolts. This preloads the pistons, allowing removal of
the cylindrical pins (assembly aid).
S
STEP 9
BILD-06
Install the single parts shown in Step 5. Preload 1

compression springs of the follow-on slides and
temporarily secure pistons using 5.0 mm diameter
cylindrical pins (S).
BILD-09
Secure housing using the Torx bolts (1) and torque to

5.5 Nm (49 pound inches).
6003-85
STEP 10 STEP 12
1 3
2 1
BILD-10 BILD-12
Mount pressure controllers with O-ring (1) and Install the single parts shown in Step 11. Preload the
secure them using securing plates (2) and Torx bolts compression springs of the follow-on slides and
(3). Torque to 5.5 Nm (49 pound inches). temporarily fasten the pistons using the 5.0 mm
diameter cylindrical pins (S).
NOTE: Install securing plate with the claw side
facing downward. Pay attention to the radial Install two adjusting bolts (S). Assemble flat gasket
installation position of pressure controllers. (1) and housing cover. Place the housing cover
equally until contact by using the adjusting bolts.
STEP 11
STEP 13
1
1
3 2
BILD-11
Preassemble the opposite side with the following BILD-13
single parts: Preload the pistons with Torx bolts and remove the
cylindrical pins (assembly aid) again. Then secure
1. Main pressure valve (1x, Piston and
the housing cover using Torx bolts (1). Torque to 5.5
compression spring)
Nm (49 pound inches).
2. Vibration damper (3x, Piston and compression
spring)
3. Follow-on slide (3x, Piston and compression
spring).
6003-86
STEP 14 STEP 16
1 1
BILD-14 BILD-16
Mount the pressure regulators with O-ring (1) and Install flat gasket (1) and assemble the plug socket
fasten them using securing plates and cap screws. with the slot facing the lug of the cover until it makes
Torque to 5.5 Nm 49 pound inches). contact. Secure the cover using cap screws and
torque to 5.5 Nm (49 pound inches).
NOTE: Install the securing plate with the neck facing
downward. Observe radial installation position of the
pressure regulators. STEP 17
STEP 15 1
BILD-17
Secure the wiring harness using the retaining clamp

(1). Install the opposite cover.
BILD-15
Assemble the wiring harness (1) and connect the NOTE: For version with torque converter lock-up
pressure regulators. clutch solenoid valve, go to Steps 29 & 30.
NOTE: See Step 1 for installation position of
pressure regulators. Pay attention to the installation STEP 18
position of the wiring harness - see markings made
during disassembly. S
BILD-18
Install two adjusting bolts (S).

6003-87
STEP 19 STEP 21
1 1 1 2
BILD-19 BILD-21
Flush-mount screens (1) into the holes of the sealing Position duct plate (1) and secure it equally using
plate, see arrows. Torx bolts (2). Torque to 10.5 Nm (93 pound inches).
NOTE: Pay attention to the installation position, -
screens should face upwards toward the duct plate. STEP 22
STEP 20
1
2 3
BILD-22
Install bolt plugs with O-rings (1) and torque them to

6 Nm (53 pound inches).
BILD-20
Attach sealing plate (1) and duct plate (2). Screens

(3) should face upward. STEP 23
NOTE: Do not re-assemble the seal plate after
opening the threaded joint shift unit/duct plate. In
case of repair, always mount a new seal plate.
BILD-23
Insert converter safety valve (1) into the housing hole

until contact is made.
6003-88
STEP 24 STEP 26
2 1
1
2
3 4
BILD-24 BILD-26
Mount stud bolts (1) and torque to 15 Nm (133 pound Mount compression spring (4), piston (3) and switch
inches). (2) with new O-ring. Torque to 30 Nm (22 pound feet).
NOTE: Wet bolt-in thread with Loctite (Type No. 1. Filter differential pressure valve
243).
2. Switch with O-ring
Position seal (2) and duct plate (3) on the rear
3. Piston
housing until contact is made.
NOTE: Use assembly grease.
STEP 27
STEP 25
S
2
4
1
3
1
BILD-27
BILD-25
Fit two adjusting bolts (S). Mount sealing plate (1)
Secure duct plate (1) using Torx bolts (2) and hex
and electro-hydraulic control unit (2).
nuts (3). Torque to 23 Nm (17 pound feet). Mount
plug (4) with new O-ring and torque to 30 Nm (22 NOTE: Do not re-assemble the seal plate after
pound feet). opening the threaded joint of the shift unit/gearbox
housing. In the case of repair, a new seal plate must
be mounted.
6003-89
STEP 28 STEP 30
3 1
4
2
BILD-28 BILD-30
Secure electro-hydraulic control unit (1) evenly using Secure pressure controller (1) using cylindrical bolts
Torx bolts (2) and torque them to 9.5 Nm (84 pound (2) and torque to 10 Nm (89 pound inches). Fit bolt
inches). necks (3) with O-ring and torque to 25 Nm (18 pound
feet). Fit plug (4) with O-ring and torque to 10 Nm (89
NOTE: For version with torque converter lock-up
pound inches).
clutch solenoid valve, go to Steps 31 and 32.
NOTE: Go back to Step 18.
STEP 29
14.2 Version with torque converter lock-up clutch STEP 31
solenoid valve Pipe - System pressure to lock-up clutch valve.
3
2 1
BILD-29 BILD-31
Position seal (1) and secure connecting housing (2) Secure pipe (1) with hollow bolt (2) and bolt nut (3).
using Torx bolts (3). Tightening torque 5.5 Nm (49 Fit O-ring on to hollow bolt (2), insert it into the eye of
pound inches). the pipe and torque to 45 Nm (33 pound feet). Attach
bolt nut (3) and torque to 35 Nm (26 pound feet).
NOTE: Pay attention to installation position of
connection housing, see markings applied during
disassembly.
6003-90
STEP 32 STEP 34
Pipe - System pressure from lock-up clutch valve
to lock-up clutch.
3 BILD-34
Install new filter element.

BILD-32 NOTE: Before putting the transmission into
Insert screw-in sleeve (1) and torque to 45 Nm (33 operation, fill it with oil according to operators
pound feet). manual.
NOTE: Wet bolt-in thread with Loctite (Type No.
243).
Secure pipe (2) with nuts (3 and 4). Torque nut (3) to
35 Nm (26 pound feet). Torque nut (4) to 45 Nm (33
pound feet).
STEP 33
14.3 Fitting of filter (pressure filter)
BILD-33
Secure filter head (1) with new O-rings to the rear

housing using Torx bolts (2). Torque to 34 Nm (25
pound feet).
Section
6004
6004
MULTITRAC MT-L 3085 II / 3095 II AXLES
6004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly Multi-disc Differential DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Reassembly Multi-disc Differential DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Reassembly Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6004-3
SPECIAL TOOLS
Planetary bearing puller collet set ............................................................................................................... CAS2881
Brake housing seal installer......................................................................................................................... CAS2880
Differential bearing cone puller collet set..................................................................................................... CAS2871
Differential bearing preload wrench ............................................................................................................. CAS2851
Brake housing inner bearing cup installer ................................................................................................... CAS2877
Brake housing outer bearing cup installer ................................................................................................... CAS2878
Wear ring installer adapter .......................................................................................................................... CAS2874
Wear ring installer adapter ......................................................................................................................... CAS2875
Pinion depth gauge set................................................................................................................................ CAS2872
Pinion depth gauge block ............................................................................................................................ CAS2873
Puller body and screw ................................................................................................................................. CAS2882
Support bracket ........................................................................................................................................... CAS2883
Slide hammer puller adapter ..................................................................................................................... CAS10846
Slide hammer ..............................................................................................................................................OEM4252
Replacer ...................................................................................................................................................... CAS2297
Magnetic base with indicator ................................................................................................................... CAS10066A
Heat gun .................................................................................................................................................... CAS10810
Lifting sling...................................................................................................................................................OEM4106
Engine stand................................................................................................................................................OEM4135
Snap ring pliers............................................................................................................................................OEM6484
Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288
Step plate ............................................................................................................................................................8061
Step plate ............................................................................................................................................................8067
Step plate ............................................................................................................................................................8073
Hexagonal Wrench 105 mm ..............................................................................................................SPX 380003004
6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015
6004-6
LUBRICATION
821F Limited Slip Front Axle
5 4
3
2 1
RH11C095.PNG RH11C096.PNG
1. OIL DRAIN HOLE (AXLE CASING) 3. OIL FILLER HOLE 5. BLEEDER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
821F Locking Differential Front Axle
5 4
2
3
2 1
821F Limited Slip Rear Axle
5 4
2
3
2 1
6004-7
821F/921F Open Differential Rear Axle
5 4
2
3
2 1
6004-8
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a
changed braking behavior.
A wear measurement has to be made on both wheel ends.
Remove plug, actuate brake and determine dimension “X” using a feeler gauge.
If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.
Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).
6004-9
OUTPUT AND BRAKE
Disassembly STEP 3
NOTE: Tools and axle shown in the following images
may appear slightly different than the tools and axle
you may have. The use of the tools and
disassembly/assembly of axle is the same regardless
of appearance.
STEP 1
1-03.PNG
Remove plug and drain oil from outputs.

NOTE: Use a suitable container for collection of oil
and abide by all local environmental laws for proper
handling and disposal.
STEP 4
1-01.PNG
Use a suitable lifting device and attach axle to

assembly stand.
NOTE: Only heavy duty axle version uses wheel
mounting studs.
STEP 2
1-04.PNG
Remove bleeder valve to avoid damage during output

and axle housing separation.
1-02.PNG
Remove plug and drain oil from differential carrier.

6004-10
STEP 5 STEP 8
1-05.PNG 1-08.PNG
Attach load carrying device 380002303 to output Use a lever to remove output shaft cover.
assembly. Remove hex bolts and separate output
from axle housing. STEP 9
WARNING: Attach load carrying device with a wheel
nut.
STEP 6
1-09.PNG
Remove locking bolts and releasing cover.
STEP 10
1-06.PNG
Pull stub shaft and sun gear shaft.

NOTE: Watch for loose shim(s).
STEP 7
1-10.PNG
Use puller and press planetary carrier out of output

shaft profile.
1-07.PNG
Attach output to suitable assembly stand.

6004-11
STEP 11 STEP 14
1-11.PNG 1-14.PNG
Use a suitable lifting device and lift planetary carrier Pull off planetary gears.
out of brake housing.
STEP 15
STEP 12
1-15.PNG
1-12.PNG Lift end plate out of brake housing.

With a suitable puller remove tapered roller bearing
from planetary carrier. STEP 16
STEP 13
1-16.PNG
Lift disk package out of brake housing.

1-13.PNG
Remove retaining rings.

6004-12
STEP 17 STEP 20
1-17.PNG
Remove hex bolts, releasing cover and cup spring.
STEP 18
1-20.JPG
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
1-18.PNG
6. Back-up ring
Mount bleeder valve. Use compressed air to remove
piston from brake housing. 7. Slide ring seal (Metal face seal - HD option only
or combi seal standard version)
STEP 19 8. Output shaft
STEP 21
1-19.PNG
If necessary, remove guide ring, back-up rings and

grooved rings from annular grooves of brake housing 1-21.PNG
(arrows). Use a suitable lifting device. Lift brake housing from
NOTE: For installation position of single parts, see output shaft.
Step 20.
6004-13
STEP 22
1-22.PNG
Depending on version, use a lever to remove slide

ring seal or shaft seal (combi seal version) from
brake housing. If needed, remove both bearing outer
rings.
STEP 23
1-23.PNG
For slide ring seal version, use a lever to remove

slide ring seal from output shaft. For combi seal
version, check screening plate for wear marks. If
required, separate it from output shaft.
STEP 24
1-24.PNG
Use a puller to remove tapered roller bearing from

output shaft.
6004-14
AXLE HOUSING
Disassembly STEP 3
STEP 1
2-03.PNG
Remove screw neck.

2-01.PNG
Secure axle housing to suitable lifting device. STEP 4

Remove hex bolts. Separate axle housing from axle
drive housing
NOTE: Watch out for releasing differential.
STEP 2
2-04.PNG
Pull bearing outer ring from bearing hole and remove

shim. Remove O-ring (see arrow).
2-02.PNG
Loosen threaded connections and remove releasing

brake tube.
6004-15
INPUT
Disassembly STEP 3
STEP 1
3-03.PNG
Remove piston (arrow) from axle housing.

3-01.PNG NOTE: Step is necessary only for DHL version.
Lift differential from axle drive housing using a
suitable lifting device. STEP 4
NOTE: Disassembly of differential is covered in
differential section.
STEP 2
3-04.PNG
Use compressed air to remove piston
3-02.PNG
Pull bearing outer ring (arrow) from housing and

remove shim.
6004-16
STEP 5 STEP 7
3-05.PNG 3-07.PNG
Heat slotted nut with a hot air blower. Remove input flange from pinion. Use a lever to
remove shaft sea.
NOTE: Slotted nut is secured with Loctite (Type no.
262).
STEP 8
parts.
STEP 6
3-08.PNG
Press input pinion from axle drive housing and

remove releasing tapered roller bearing.
STEP 9
3-06.PNG
Remove slotted nut and shim behind it. Use slotted

n u t w r e n c h C A S 2 8 4 2 a n d c l a m p i n g d ev i c e
380001546.
3-09.PNG
Remove spacer ring and pull tapered roller bearing

from input pinion.
STEP 10
6004-17
3-10.PNG
If needed, remove bearing outer rings from axle drive

housing.
6004-18
DIFFERENTIAL
Disassembly Multi-disk Differential STEP 4

Lock DHL-2400
STEP 1
4-04.PNG
Preload housing cover/compression spring using a

press. Disengage retaining ring. Remove sliding
sleeve and compression spring from housing cover.
4-01.PNG
Remove axial roller cage (arrow).

STEP 5
STEP 2 2 3
1 4
4-05.PNG
Remove single parts.

4-02.PNG
Pull both tapered roller bearings from differential. 1. Pressure piece

2. Cage
STEP 3
3. Lever (12x)
4. Disk carrier
5. Disk package
4-03.PNG
Preload differential using a press. Remove hex bolts

and releasing housing cover.
6004-19
STEP 6 STEP 9
4-06.PNG 4-09.PNG
Preload differential using a press. Remove locking Remove both shor t differential axles. Remove
bolts and housing cover. releasing spider gears and thrust washers from
differential housing.
STEP 7
STEP 10
4-07.PNG
Remove axle bevel gear with thrust washers from 4-10.PNG
differential housing. Remove long differential axle, releasing spider gears

and thrust washers from differential housing.
STEP 8
STEP 11
4-08.PNG
Force out both slotted pins. 4-11.PNG
Remove axle bevel gear and shim.
STEP 12
6004-20
STEP 15
4-12.PNG
Press crown wheel from differential carrier. 4-15.PNG
Preload differential using a press. Remove locking

Disassembly Differential D-2400 bolts and housing cover.
STEP 16
STEP 13
4-16.PNG
4-13.PNG
Remove axle bevel gear with thrust washers from
Pull both tapered roller bearings from differential.
STEP 14 STEP 17
4-14.PNG
4-17.PNG
Force out both slotted pins.
6004-21
STEP 18 STEP 21
4-18.PNG 4-21.PNG
Force out both shor t differential axles. Remove Press crown wheel from differential carrier.
releasing spider gears with thrust washers from
differential housing. Disassembly Multi-disc Differential
STEP 19
DL-2400
STEP 22
4-19.PNG
Pull long differential axle. Remove releasing spider

4-22.PNG
gears with thrust washers from differential housing.
Pull both tapered roller bearings from differential.
STEP 20
STEP 23
4-20.PNG
4-23.PNG
Preload differential with a press. Remove locking
screws and housing cover.
6004-22
STEP 24 STEP 27
4-24.PNG 4-27.PNG
Remove axle bevel gear with pressure ring, disc Remove pressure ring, disc package and thrust
package and thr ust washers from differential washers from the differential housing.
housing.
STEP 28
STEP 25
4-28.PNG
4-25.PNG Press crown wheel from the differential carrier.

Remove spider shafts and axle bevel gears from
STEP 26
4-26.PNG
Remove second axle bevel gear.

6004-23
DIFFERENTIAL
Reassembly Multi-disk Differential STEP 3

Lock DHL-2400
STEP 1
5-03.PNG
Insert axle bevel gear.
STEP 4
5-01.PNG
Mount two M16 x 1.5 locating pins (S) and press

heated crown wheel onto differential housing until
contact is made.
parts.
STEP 2
5-04.PNG
I ns e r t s p i d e r g e a r s w i t h t h r u s t wa s he r s i n t o
differential housing. Secure them with long spider
shaft.
NOTE: Thrust washers must be positioned with tabs
(arrow) located in recesses of differential housing.
5-02.PNG
Insert thrust washers into differential housing.

6004-24
STEP 5 STEP 7
1 2
5-05.PNG 5-07.PNG
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto Mount second axle bevel gear.

differential housing. Attach them with two shor t
spider shafts. STEP 8
(1) located in recesses of differential housing. Pay
attention to radial installation position of spider shaft
attaching holes (2).
STEP 6
5-08.PNG
Position thrust washers in housing cover with grease.
STEP 9
5-06.PNG
Secure short spider shafts with slotted pins.

NOTE: Flush mount slotted pins.
5-09.PNG
Mount M16 x 1.5 adjusting bolts and insert housing

cover until contact with differential housing is made.
Preload differential using a press and secure with
new locking bolts. Torque to 400 Nm (295 pound
feet).
6004-25
STEP 10 STEP 12
5-10.PNG 5-12.JPG
Install compression spring onto sliding sleeve. Setting of disc package

Premount single parts according to illustration.
STEP 11
1. Housing cover
2. Pressure piece
3. Cage
4. Lever (12x)
5. Disk carrier
6. Pressure ring
7. Inner discs
8. Outer discs (optional)
9. Snap ring.
NOTE: For number of discs and disc arrangement,
5-11.PNG refer to related spare parts list.
Insert premounted sliding sleeve into housing cover.
Preload compression spring with a press and engage
retaining ring into annular groove of sliding sleeve.
6004-26
STEP 13 STEP 15
5-13.PNG 5-15.PNG
Preload disk package with an axial force of F = 50 +30 Position housing cover onto pressure piece (arrow).
KN. Then check setting dimension “A” = 1.05 +/-0.1 Insert two hex bolts into housing cover to radially
mm (0.041 +/-0.004 in) from collar of differential attach disc package.
cover to plane face of outer disc (also see sketch in
step 14). STEP 16
NOTE: Any deviation from specified setting
dimension must be corrected with a corresponding
outer disk.
NOTE: Special tools pressure piece and load cell
are to be determined. Contact special tools.
STEP 14
5-16.PNG
Use a suitable lifting device. Position premounted

differential onto housing cover and temporarily attach
with hex bolts.
STEP 17
5-14.JPG
A = Setting dimension = 1.05 +/- 0.1 mm (0.041

+/-0.004 in)
B = Contact face.
NOTE: To obtain correct measuring result, housing
cover may only be supported on contact face (B).
Ensure that assembly stand is only supported on
disk package and not on disk carrier.
5-17.PNG
Preload differential with a press and pressure piece.

Final tighten housing cover with hex bolts. Torque to
6004-27
STEP 18 Reassembly Differential D-2400
STEP 20
5-18.PNG
Heat both tapered roller bearings and insert until

contact is made. Adjust tapered roller bearing after 5-20.PNG
cooling down. Mount locating pins and press heated crown wheel
WARNING: Always wear protective gloves to onto differential housing until contact is made.
prevent burning your hands when handling heated WARNING: Always wear protective gloves to
parts. prevent burning your hands when handling heated
parts.
STEP 19
STEP 21
5-19.PNG
Attach axial roller cage to sliding sleeve with grease. 5-21.PNG
Insert thrust washer into differential housing.
STEP 22
5-22.PNG

6004-28
STEP 23 STEP 25
5-23.PNG 5-25.PNG
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto Secure short spider shafts with slotted pins.
shaft.
NOTE: Thrust washers must be positioned with tabs STEP 26
STEP 24
1 2
5-26.PNG
Mount second axle bevel gear.
5-24.PNG STEP 27
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto
differential housing. Secure them with two short
spider shafts.
attention to radial installation position of spider shafts
securing holes (2).
5-27.PNG
Secure thrust washers into housing cover with

grease.
6004-29
STEP 28 STEP 30
5-28.PNG 5-30.PNG
Mount two adjusting bolts and insert housing cover Heat both tapered roller bearings and insert until
until contact with differential housing is obtained. contact is made. Adjust tapered roller bearing after
Preload differential using a press. Secure with new cooling down.
locking bolts. Torque to 400 Nm (295 pound feet).
STEP 29 parts.
Reassembly Multi-disc Differential

DL-2400
STEP 31
5-29.PNG
Attach housing cover and preload differential with a

suitable press. Secure housing cover with hex bolts
and torque to 185 Nm (136 pound feet).
5-31.PNG
Mount two M16 x 1.5 locating pins (S) and press

heated crown wheel onto differential housing until
contact is made.
parts.
6004-30
STEP 32 STEP 34
5-32.PNG 5-34.PNG
Insert thrust washer into differential housing. Install pressure ring.
STEP 33 STEP 35
5-33.PNG 5-35.PNG
Mount outer and inner discs in alternating order Install axle bevel gear until contact is made. Then
starting with an outer disk. install inner discs with teeth.
NOTE: The installation clearance of internal parts is
corrected by mounting outer discs of different STEP 36
thicknesses.
NOTE: The difference in thickness between the left
and right disc package must be less than 0.1 mm
(0.004 in.).
5-36.PNG
Preassemble the differential spider and insert it into

the differential housing/pressure ring.
6004-31
STEP 37 STEP 39
5-37.PNG 5-39.PNG
Install second axle bevel gear. Mount outer and inner discs in alternating order
starting with an inner disc.
STEP 38 NOTE: The installation clearance of internal parts is
corrected by mounting outer discs of different
thicknesses.
NOTE: The difference in thickness between the left
and right disc package must be less than 0.1 mm
(0.004 in.).
STEP 40
5-38.PNG
Install second thrust ring into differential housing.
5-40.PNG
Determine the installation clearance 0.2 to 0.7 mm

(0.008 to 0.028 in.). Measure dimension I from the
mounting face of the differential housing to the plane
face of the outer disc. Dimension I e.g. 44.30 mm
(1.744 in.).
6004-32
STEP 41 STEP 43
5-41.PNG 5-43.PNG
Measure Dimension II, from the contact face of the Mount two M16 x 1.5 adjusting bolts and inser t
outer disc to the mounting face on the housing cover. housing cover until contact with differential housing is
Dimension II e.g. 43.95 mm (1.730 in.) made. Preload differential with a press. Secure with
new locking bolts and torque to 400 Nm (295 lb ft.)
Calculation Example:
Dimension I - 44.30 mm (1.744 in.) STEP 44
Dimension II - 43.95 mm (1.730 in.)
Difference + disc clearance - 0.35 mm (0.013 in.)
NOTE: Any deviation from the required installation
clearance must be corrected with corresponding
outer discs: s = 2.7 mm (0.106 in.), s = 2.9 mm
(0.114 in.), s = 3.0 mm (0.118 in.), s = 3.1 mm (0.122
in.), s = 3.2 mm (0.126 in.), s = 3.3 mm (0.130 in.), s
= 3.5 mm (0.138).
NOTE: Make sure the difference in thickness
between the left and right disc package is less than
0.1 mm (0.004 in.).
5-44.PNG
STEP 42 Heat both tapered roller bearings and insert until

contact is made. Adjust tapered roller bearing after
cooling down.
parts.
5-42.PNG

grease.
6004-33
INPUT
Reassembly Input STEP 3
STEP 1
Determination of shim thickness to
obtain a correct contact pattern
6-03.PNG
221.10
Determine dimension III (bearing width). Dimension
III e.g. 39.10 mm (1.54 in).
Calculation Example “A”:
6-01.PNG Dimension I: 221.10 mm (8.70 in)
R e a d d i m e n s i o n I f r o m a x l e d r i ve h o u s i n g . Dimension II: -181.00 (7.13 in)
Dimension I e.g. 221.10 mm (8.70 in)
Dimension III: -39.10 (1.54 in)
NOTE: If crown wheel or input pinion are damaged,
both parts must be replaced together. When Difference = shim s = 1.00 mm (0.04 in)
installing a complete new bevel gear set, look for
identical mating number of input pinion and crown STEP 4
wheel. Reassembly of input pinion
NOTE: Measuring procedures must be done
accurately. Inaccurate measurements lead to
incorrect contact pattern requiring additional
disassembly and reassembly of input pinion and
differential.
STEP 2
181.0 +/- 0
6-04.PNG
Undercool external bearing and insert it into axle

drive housing until contact is made.
cooled parts.
6-02.PNG
Read dimension II from pinion. Dimension II e.g.

181.00 mm (7.13 in)
6004-34
STEP 5 STEP 7
6-05.PNG 6-07.PNG
Insert shim into housing hole size e.g. s = 1.00 mm Heat tapered roller bearing and insert it into input
(0.04 in). pinion until contact is made.
STEP 6 prevent burning your hands when handling heated or
cooled parts.
STEP 8
Setting of rolling torque of input pinion
bearing without shaft seal 1.5 to 3.0 Nm
(13.3 to 26.6 pound inches)
6-06.PNG
Undercool internal bearing outer ring and bring it into

contact position in housing hole using 380100001
assembly tool.
cooled parts.
6-08.PNG
Insert spacer e.g. s = 8.18 mm (0.32 in)

NOTE: Based on experience, necessary rolling
torque is obtained by reusing the spacer removed
during disassembly e.g. s = 8.18 (0.32 in).
NOTE: A later check of rolling torque is needed.
6004-35
STEP 9 STEP 11
6-09.PNG 6-11.PNG
Insert preassembled input pinion into axle drive Insert input flange and secure it with disk and slotted
housing. Insert heated tapered roller bearing until nut. Torque to 1200 Nm (885 pound feet). Use
contact is made. CAS2842 slotted nut wrench and 380001546
clamping device.
prevent burning your hands when handling heated or NOTE: Temporarily mount slotted nut without
cooled parts. Loctite. While tightening, rotate input pinion several
times in both directions.
STEP 10
STEP 12
6-10.PNG
Press protection plate onto input flange until contact 6-12.PNG
is made. Check rolling torque. It should be 1.5 to 3.0 Nm (13 to

27 pound inches) without a shaft seal.
NOTE: Do not fit shaft seal until contact pattern has
been checked as shown in shown in step 24. NOTE: When installing new bearings try to achieve
upper value of rolling torque.
NOTE: In cases of rolling torque measurement
deviations, correct with a corresponding spacer as
specified - go back to Step 8. For insufficient rolling
torque - install thinner spacer ring. Excessive rolling
torque - install a thicker spacer ring.
6004-36
STEP 13 STEP 15
Determination of shims for setting of
bearing rolling torque (differential
housing) and backlash (bevel gear set)
6-13.PNG
Grease O-rings and insert them into annular grooves

of piston. 101 +/-0
NOTE: Steps 13 and 14 are only need for versions
6-15.PNG
with DHL.
Determine required shims on the basis of read value
(deviation/test dimension) and corresponding
STEP 14 specifications of the following table: (KRS - SET -
RIGHT) (KRS = bevel gear set):
Deviation see crown wheel rear side.
The test dimension “101” is stamped into crown
wheel rear side. If no +/- deviation is indicated, this
value corresponds to actual value “0” in the following
table. According to this value, the required shims are
allocated in table.
Any +/- deviation of test dimension caused by
production is also marked on the crown wheel rear
side (e.g. - 20 or - 10 or 10 or 20). In accordance with
this deviation, required shims are allocated in the
6-14.PNG table.
Inser t piston (arrow) into bearing housing until
contact is made. STEP 16
6-16.JPG
1 = Axle housing
2 = Shim (crown wheel side)
3 = Shim (differential carrier side)
4 = Axle housing
6004-37
Shims for differential D/DL and DHL-2400 in ZF axles MT-L 3085/3095 II

Crown wheel
-20 -10 - 10
marking
Deviation -0.2 -0.1 0 0.1
Shim
Diff. cage side 0.7 0.8 0.9 1.0
Shim thickness
Shim
DHL 2400 84395193 84354725 84354726 84354727
Order no.
Shim
D/DL 2400 84476078 84330538 84330539 84330540
Order no.
Shim
Crown wheel side 1.3 1.2 1.1 1.0
Shim thickness
Shim
D/DL/DHL 2400 84476080 84330542 84330541 84330540
Order no.
STEP 17 STEP 18
6-17.PNG 6-18.PNG
Insert selected shim e.g. s = 0.9 mm (0.04 in) into Cover some drive and coast flanks of crown wheel
hole of axle housing and adjust bearing outer ring with marking ink. Insert premounted differential into
(arrow) until contact is obtained. axle drive housing.
STEP 19
6004-38
STEP 21
6-19.PNG
Insert selected shim e.g. s = 1.1 mm (0.04 in) into 6-21.PNG
hole of axle housing and adjust bearing outer ring Leak test differential lock. Pressurize lock p = 1 bar
until contact is made. (15 psi), close shut-off valve and remove air line. No
noticeable pressure loss should occur within 10
STEP 20 seconds.
NOTE: This operation is only necessary for version
S with DHL.
STEP 22
6-20.PNG
Mount two M20 locating pins (S) and bring axle

housing into contact position with axle drive housing
using a suitable lifting device. Temporarily attach axle
housing with hex bolts. Torque to 560 Nm (413 pound 6-22.PNG
feet). In both directions, several times, rotate input flange
NOTE: Test mount axle housing without O-ring. to roll crown wheel over input pinion. Remove axle
housing and lift differential out of axle drive housing.
Compare obtained contact pattern with contact
pattern examples at the beginning of this section.
NOTE: If tooth contact pattern differs, an incorrect
shim size was selected in Step 5. This must be
corrected.
6004-39
STEP 23 STEP 25
6-23.PNG 6-25.PNG
After contact pattern check, insert differential into Using CAS2841 driver tool, mount shaft seal with
axle drive housing again. seal lip facing oil chamber.
NOTE: Exact installation position of seal is obtained
STEP 24 using specified driver tool.
Reassembly of shaft seal (Step 24 to 26)
NOTE: Wet outer diameter of shaft seal with mineral
spirits just before installation. Fill space between seal
and dust lip with grease.
STEP 26
6-24.PNG
Remove slotted nut and pull input flange from input

pinion. Use CAS2842 slotted nut wrench and
380001546 clamping device.
6-26.PNG
Insert input flange and secure it using disc and

slotted nut. Torque to 1200 Nm (885 pound feet).
USe CAS2842 slotted nut wrench and 380001546
clamping device.
NOTE: Cover threads of slotted nut with Loctite
(Type no. 262).
6004-40
AXLE HOUSING
Reassembly STEP 3
STEP 1
7-03.PNG
Mount fitting and torque to 36 Nm (27 pound feet).

7-01.PNG
Grease O-ring and insert it into axle housing. STEP 4
STEP 2
7-04.PNG
Grease O-ring. Inser t it into annular groove of

7-02.PNG
parking brake tube.
Mount two M20 locating pins and bring axle housing
into contact position with axle drive housing using a STEP 5
suitable lifting device. Secure axle housing using hex
bolts. Torque to 560 Nm (413 pound feet).
WARNING: After axle housing assembly, secure
axle with clamping brackets (S).
7-05.PNG
Mount brake tube with threaded connection and hex

nut (arrow). Torque to 100 Nm (74 pound feet).
6004-41
STEP 6
7-06.PNG
Install plug and new O-ring. Torque to 50 Nm (37

pound feet).
6004-42
OUTPUT AND BRAKE
Reassembly STEP 3
STEP 1
8-03.PNG
Version with slide ring seal shown in Step 3 and 4

8-01.PNG Wet O-ring of slide ring seal and locating hole with
Pull wheel stud into output shaft until contact is mineral spirits. Snap new slide ring seal (part 1) into
made. output shaft.
NOTE: Special tool may only be used for repairs
when exchanging individual wheel studs with STEP 4
mounted output shaft. For new output shaft, use a
press.
NOTE: Only heavy duty axle version uses wheel
mounting studs.
STEP 2
8-04.PNG
Then mount new slide ring seal (part 2) into brake

housing.
NOTE: For installation position of seal, see Step 12.
NOTE: Surface of slide ring seal may not have any
grooves, scratches or other damage. Make sure
sealing surface is parallel to housing face. O-rings
8-02.PNG must be mounted evenly into locating hole and must
Heat tapered roller bearing and insert it onto output not bulge out.
shaft until contact is made.
WARNING: Risk of injury - metal rings have
WARNING: Always wear protective gloves to extremely sharp edges. Wear protective gloves.
cooled parts.
6004-43
STEP 5 STEP 7
8-05.PNG 8-07.PNG
Insert both bearing outer rings (arrows) into brake Heat slide bushing and position it at collar of output
housing until contact is made. shaft. Then position slide bushing with CAS2860
pressure ring.
STEP 6 NOTE: Exact installation position is obtained when
using specified pressure ring.
cooled parts.
STEP 8
8-06.JPG
Steps 6 to 8 are for the Version with combi seal

Illustration shows installation position of combi seal.
1. Output shaft
2. Brake housing
3. Combi seal consisting of: a = Shaft seal, b = 8-08.PNG
Screening plate. Insert shaft seal into brake housing using CAS2880
driver tool.
NOTE: Exact installation position is obtained when
using specified driver tool. Make note of installation
position (Step 6). Wet outer diameter of shaft seal
with mineral spirits before assembly.
6004-44
STEP 9 STEP 11
8-09.PNG 8-11.PNG
Use suitable lifting device and insert premounted Clean annular groove of brake housing with mineral
brake housing over output shaft until contact is made. spirits. Insert guide ring into annular grove (go to step
12). Secure it with Loctite (type no. 415) at its ends
NOTE: Before clamping seal rings (slide ring seal) to
(arrows).
installation dimension, clean sliding surfaces and
apply an oil film. A leather cloth soaked in oil is NOTE: Full circumference of guide ring must be in
recommended for this step. an exact contact position.
WARNING: Upon installation, orifice of guide ring
STEP 10 must show upwards - 12 o’clock position.
8-10.PNG
Insert back-up rings and grooved rings into annular

grooves of brake housing (arrows).
NOTE: For installation position, go to Step 12.
6004-45
STEP 12 STEP 14
8-14.PNG
Insert piston into brake housing and install with

fabricated fixing device until contact is made.
NOTE: Sufficiently oil seal surface of piston/back-up
rings, grooved rings and guide ring (W-10 oils are to
be used).
STEP 15
8-12.JPG
1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
8-15.PNG
STEP 13 Insert disk and cup spring with convex side facing
upwards into piston.
STEP 16
8-13.PNG
Flush-mount slotted pins into holes of piston.
8-16.PNG
Insert cover and secure it by means of hex bolts.

6004-46
STEP 17 STEP 20
2
3
1
4
8-17.PNG 8-20.PNG
Insert outer and inner disks. Insert cylindrical roller bearing into planetary gear. To
do this, press cylindrical roller bearing (1) through
NOTE: For number of disks and disk arrangement,
packaging sleeve (2) until snap ring (3) engages into
refer to related spare parts list.
annular groove of planetary gear (4).
STEP 18 NOTE: Use packaging sleeve to facilitate assembly.
STEP 21
8-18.PNG
Insert end plate.

8-21.PNG
STEP 19 Heat bear ing inner r ings. Inser t premounted

planetary gears with large radius facing planetary
carrier (downwards) until contact is made. Secure
planetary gears using retaining rings.
1 2 NOTE: Adjust bearing inner rings after cooling.
cooled parts.
8-19.JPG
Press stop bolt (1) into planetary carrier (2) until

contact is obtained.
6004-47
STEP 22 STEP 24
8-22.PNG 8-24.PNG
Heat tapered roller bearing and install it on planetary Align disk package centrally and radially. Insert
carrier until contact is made. planetary carrier into teeth of output shaft using a
suitable lifting device.
parts. STEP 25
STEP 23
1 2
8-25.PNG
Bring planetary carrier into contact position with

c ove r a n d o l d l o ck i n g b o l t s r e m ove d d u r i n g
8-23.PNG
disassembly. Then remove locking bolts.
Wet contact face of bearing inner ring (1) and profile
teeth (2) in output shaft with anti-corrosive agent.
6004-48
STEP 26 STEP 29
8-26.PNG 8-29.PNG
Pivot output 90 degrees. Insert disk and secure Set axial play of sun gear shaft to 0.5 to 2.0 mm (0.02
planetary carrier with new locking bolts. to 0.08 in). Determine dimension I, distance from
mounting face of brake housing to front face of stop
NOTE: Tighten locking bolts successively with a
bolt.
tightening torque of 200 Nm (148 pound feet). Then,
retighten with a torque of 500 Nm (369 pound feet). Dimension I e.g. 19.75 mm (0.78 in).
STEP 27 STEP 30
8-27.PNG 8-30.PNG
Install O-ring on cover. Insert stub shaft into teeth of axle bevel gear until
contact is made.
STEP 28 NOTE: Be aware of installation position. Mount stub
shaft side with long teeth towards differential.
8-28.PNG
Install cover into output shaft until fully seated.

6004-49
STEP 31 STEP 33
8-31.PNG 8-33.PNG
Insert sun gear shaft until contact is made. Insert sun gear shaft into planetary carrier.
STEP 32 STEP 34
8-32.PNG 8-34.PNG
Measure dimension II, from front face of sun gear Insert shim(s) e.g. s = 1.60 mm (0.06 in) with grease
shaft to mounting surface of axle housing. into sun gear shaft.
Dimension II e.g. 17.15 mm (0.68 in)
STEP 35
CALCULATION EXAMPLE:
Dimension I: 19.75 mm (0.78 in)
Dimension II: 17.15 mm (0.68 in)
Difference: 2.60 mm (0.10 in)
Required axial play e.g.: 1.00 mm (0.04 in)
Difference = shim e.g. s = 1.60 mm (0.06 in)
8-35.PNG
Insert O-ring with grease into countersink of brake

housing.
6004-50
STEP 36 STEP 39
8-36.PNG 8-39.PNG
Grease O-ring and install it in axle housing. Check brake hydraulics for leakage. Before starting
test bleed brake hydraulics. Pressurize brake
STEP 37 temporarily 5 times with a max pressure of p = 100
bar (1450 psi).
High-pressure test:
Build up test pressure p = 100-10 bar maximum and
close connection to pump via shut-off valve. A
maximum pressure drop of 2% or 2 bar (29 psi) is
permissible during a 5 minute test period.
Low-pressure test:
Reduce test pressure p = 5 bar (73 psi) and close
shut-off valve. No pressure drop is allowed during a 5
minute test period.
Test media:
8-37.PNG
Mount adjusting bolts and use 380002303 lifting Engine oils SAE 10-W corresponds to MIL-L 2104 C,
device to bring output into contact position with axle MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils type
housing. Secure output using hex bolts. Torque to A, Suffic A Dexron of II D.
NOTE: Attach lifting device with wheel stud.
STEP 38
8-40.PNG
Check operability of DHL. Build up maximum

pressure p = 20 bar (290 psi) and close connection to
pump via shut-off valve.
8-38.PNG Lock on:
Mount bleeder valve (arrow).
When rotating input flange, both outputs must have
same direction of rotation.
6004-51
Lock off:
When rota tin g inp ut flang e, on e side ha s no
movement or rotates in opposite direction.
NOTE: Before axle operation, fill with oil according to
lubrication and maintenance instructions.
6004-52
Section
6004
6004
MULTITRAC MT-L 3105 II AXLE
6004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6004-3
SPECIAL TOOLS
Planetary bearing puller collet set ............................................................................................................... CAS2881
Brake housing seal installer......................................................................................................................... CAS2880
Differential bearing cone puller collet set..................................................................................................... CAS2871
Differential bearing preload wrench ............................................................................................................. CAS2851
Brake housing outer bearing cup installer ................................................................................................... CAS2878
Wear ring installer adapter .......................................................................................................................... CAS2874
Wear ring installer adapter ......................................................................................................................... CAS2875
Pinion depth gauge set................................................................................................................................ CAS2872
Pinion depth gauge block ............................................................................................................................ CAS2873
Puller body and screw ................................................................................................................................. CAS2882
Support bracket ........................................................................................................................................... CAS2883
Slide hammer puller adapter ..................................................................................................................... CAS10846
Slide hammer ..............................................................................................................................................OEM4252
Replacer ...................................................................................................................................................... CAS2297
Magnetic base with indicator ................................................................................................................... CAS10066A
Heat gun .................................................................................................................................................... CAS10810
Lifting sling...................................................................................................................................................OEM4106
Engine stand................................................................................................................................................OEM4135
Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288
Step plate ............................................................................................................................................................8061
Step plate ............................................................................................................................................................8067
Step plate ............................................................................................................................................................8073
Hexagonal Wrench 105 mm ..............................................................................................................SPX 380003004
6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015
6004-6
LUBRICATION
921F Open Differential Front Axle
5 4
3
2 1
921F Locking Differential Front Axle
5 4
4
2
3
2 1
RH11C103.PNG RH11C104.PNGBS00M070
6004-7
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a
changed braking behavior.
A wear measurement has to be made on both wheel ends.
Remove plug, actuate brake and determine dimension “X” using a feeler gauge.
If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.
Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).
6004-8
OUTPUT AND BRAKE
Disassembly STEP 3
NOTE: Tools and axle shown in the following images
may appear slightly different than the tools and axle
you may have. The use of the tools and
disassembly/assembly of the axle is the same
regardless of appearance.
STEP 1
1-03.PNG
Remove plugs and drain oil from outputs.

STEP 4
1-01.PNG
Use a suitable lifting device and attach axle to

assembly stand.
STEP 2
1-04.PNG
Remove bleeder valves to avoid damage when

separating outputs.
1-02.PNG
Remove plug and drain oil from differential carrier.

6004-9
STEP 5 STEP 8
1-05.PNG 1-08.PNG
Attach lifting device 380002303 to output assembly. Use a lever to remove output shaft cover.
Loosen hex bolts and separate output assembly from
axle housing. STEP 9
WARNING: Attach load carrying device with wheel
nut.
STEP 6
1-09.PNG
Remove locking bolts and releasing cover.
STEP 10
1-06.PNG
Pull stub shaft and sun gear shaft from output.

NOTE: Look for loose shim(s).
STEP 7
1-10.PNG
Using a two-armed puller, press planetary carrier

from profile of output shaft.
1-07.PNG
Attach output to suitable work stand.

6004-10
STEP 11 STEP 14
1-11.PNG 1-14.PNG
Use a suitable lifting device. Lift planetary carrier out Pull off planetary gears.
of brake housing.
STEP 15
STEP 12
1-15.PNG
1-12.PNG Lift end plate out of brake housing.

Pull tapered roller bearing from planetary carrier.
STEP 16
STEP 13
1-16.PNG
1-13.PNG Lift disk package out of brake housing.
Remove retaining rings.
6004-11
STEP 17 STEP 20
1-17.PNG
Remove hex bolts, releasing cover and cup spring.
STEP 18
1-20.JPG
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
1-18.PNG
6. Back-up ring
Mount breather valve. Use compressed air to remove
piston from brake housing. 7. Metal Face Seal (Heavy Duty Option) Combi
Seal (Standard)
STEP 19 8. Output shaft
STEP 21
1-19.PNG
If needed, remove guide ring, back-up rings and

grooved rings from annular grooves of brake housing 1-21.PNG
(see arrows). Use a suitable lifting device. Lift brake housing from
NOTE: For position of single parts, see Step 20. output shaft.
6004-12
STEP 22
1-22.PNG
Use levers to remove slide ring seal from brake

housing. If needed, remove both bearing outer rings.
STEP 23
1-23.PNG
Use levers to remove slide ring seal from output

shaft.
STEP 24
1-24.PNG
Pull tapered roller bearing from output shaft.

6004-13
AXLE HOUSING
Disassembly STEP 3
STEP 1
2-03.PNG
Remove screw neck.

2-01.PNG
Secure axle housing to suitable lifting device. Loosen STEP 4

hex bolts. Separate axle housing from drive housing
NOTE: Be aware of possible release of differential.
STEP 2
2-04.PNG
Pull bearing outer ring and remove shim behind.

Then remove O-ring (arrow).
2-02.PNG
Loosen threaded connections and remove brake

release tube.
6004-14
INPUT
Disassembly STEP 3
STEP 1
3-03.PNG
Remove piston (arrow) from axle housing.

3-01.PNG NOTE: Step is only necessary for DHL version.
Use a suitable lifting device and pull differential from
axle drive housing. STEP 4
NOTE: Disassembly of differential is covered in
differential section.
STEP 2
3-04.PNG
Use compressed air to remove piston.
3-02.PNG
Pull bearing outer ring (arrow) from housing and

remove shim.
6004-15
STEP 5 STEP 7
3-05.PNG 3-07.PNG
Heat slotted nut. Pull input flange from pinion. Use a lever to remove
shaft seal.
NOTE: Slotted nut is secured with Loctite (Type no.
262).
STEP 8
parts.
STEP 6
3-08.PNG
Press input pinion from axle drive housing and

remove releasing tapered roller bearing.
STEP 9
3-06.PNG
Remove slotted nut and shim using special wrench

CAS2842 and clamping device 380001546.
3-09.PNG
Remove spacer ring and pull tapered roller bearing

from input pinion.
6004-16
STEP 10
3-10.PNG
If needed, remove both bearing outer rings from axle

drive housing.
6004-17
DIFFERENTIAL
Disassembly Multi-disk Differential STEP 4

Lock DHL-2400
STEP 1
4-04.PNG
Preload housing cover/compression spring with a

press and disengage retaining ring. Remove sliding
sleeve and compression spring from housing cover.
4-01.PNG
Remove axial roller cage (arrow).

STEP 5
STEP 2 2 3
1 4
4-05.PNG
Remove single parts.

4-02.PNG
Pull both tapered roller bearings from differential. 1. Pressure piece

2. Cage
STEP 3
3. Lever (12x)
4. Disk carrier
5. Disk package
4-03.PNG

6004-18
STEP 6 STEP 9
4-06.PNG 4-09.PNG
Preload differential using a press. Remove locking Remove both shor t differential axles. Remove
bolts and housing cover. releasing spider gears and thrust washers from
STEP 7
STEP 10
4-07.PNG
Remove axle bevel gear and thrust washers from 4-10.PNG
differential housing. Remove long differential axle, spider gears and thrust
washers from differential housing.
STEP 8
STEP 11
4-08.PNG
Remove both slotted pins. 4-11.PNG

6004-19
STEP 12 STEP 15
4-12.PNG 4-15.PNG
Press crown wheel from differential carrier. Preload differential using a press. Remove locking
bolts and housing cover.
Disassembly Differential D-2400
STEP 16
STEP 13
4-16.PNG
4-13JPG
Remove axle bevel gear with thrust washers from
Pull both tapered roller bearings from differential. differential housing.
STEP 14 STEP 17
4-17.PNG
4-14.PNG
Preload differential using a press. Remove hex bolts Force out both slotted pins.
6004-20
STEP 18 STEP 21
4-18.PNG 4-21.PNG
Force out both shor t differential axles. Remove Press crown wheel from differential carrier.
releasing spider gears with thrust washers from
STEP 19
4-19.PNG
Pull long differential axle. Remove releasing spider

gears with thrust washers from differential housing.
STEP 20
4-20.PNG

6004-21
DIFFERENTIAL
Reassembly Multi-disk Differential STEP 3

Lock DHL-2400
STEP 1
5
5-03.PNG
STEP 4
5-01.PNG
Mount two locating pins (S). Press heated crown

wheel onto differential housing until contact is made.
parts.
STEP 2
5-04.PNG
I ns e r t s p i d e r g e a r s w i t h t h r u s t wa s he r s i n t o
shaft.
5-02.PNG
Insert thrust washer into differential housing.

6004-22
STEP 5 STEP 7
1
2
5-05.PNG 5-07.PNG
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto Mount second axle bevel gear.

differential housing. Attach them with two shor t
spider shafts. STEP 8
attention to radial installation position of spider shaft
attaching holes (2).
STEP 6
5-08.PNG

grease.
STEP 9
5-06.PNG
Secure short spider shafts with slotted pins.

5-09.PNG
Mount two adjusting bolts (S) and insert housing

cover until contact with differential housing is made.
Preload differential using a press and secure with
new locking bolts. Torque to 400 Nm (295 pound
feet).
6004-23
STEP 10 STEP 12
Setting of disc package
5-10.PNG
Install compression spring onto sliding sleeve.

5-12.JPG
Premount single parts according to illustration.

STEP 11
1. Housing cover
2. Pressure piece
3. Cage
4. Lever (12x)
5. Disk carrier
6. Pressure ring
7. Inner discs
8. Outer discs (optional)
9. Snap ring.
NOTE: For number of discs and disc arrangement
5-11.PNG refer to related spare parts list.
Insert premounted sliding sleeve into housing cover.
Preload compression spring with a press and engage
retaining ring into annular groove of sliding sleeve.
6004-24
STEP 13 STEP 15
5-13.PNG 5-15.PNG
Preload disk package with an axial force of F = 50 Position housing cover onto dealer fabricated
+30 KN. Then check setting dimension “A” = 1.05 pressure piece (arrow). Insert two hex bolts into
+/-0.1 mm (0.04 +/- 0.003 in) from collar of differential housing cover to radially attach disc package.
cover to plane face of outer disc (also see illustration
in step 14). STEP 16
NOTE: Any deviation from specified setting
dimension must be corrected with a corresponding
outer disk.
NOTE: Special tooling to be determined. Contact
Special Tools for assistance.
STEP 14
5-16.PNG
Use a suitable lifting device. Position premounted

differential onto housing cover and temporarily attach
with hex bolts.
STEP 17
5-14.JPG
A = Setting dimension = 1.05 +/- 0.1 mm (0.04 +/-

0.003 in)
B = Contact face.
NOTE: To obtain correct measuring result, housing
cover may only be supported on contact face (B).
Ensure that assembly stand is only supported on
disk package and not on disk carrier.
5-17.PNG
Preload differential using a press and pressure piece.

Final tighten housing cover with hex bolts. Torque to
6004-25
STEP 18 Reassembly Differential D-2400
STEP 20
5-18.PNG
Heat both tapered roller bearings and insert until

contact is made. Adjust tapered roller bearing after 5-20.PNG
cooling down. Mount locating pins and press heated crown wheel
WARNING: Always wear protective gloves to onto differential housing until contact is made.
parts. prevent burning your hands when handling heated
parts.
STEP 19
STEP 21
5-19.PNG
Attach axial roller cage (arrow) to sliding sleeve with 5-21.PNG

grease. Insert thrust washer into differential housing.
STEP 22
5-22.PNG

6004-26
STEP 23 STEP 25
5-23.PNG 5-25.PNG
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto Secure short spider shafts with slotted pins.
shaft.
NOTE: Thrust washers must be positioned with tabs STEP 26
STEP 24
1 2
5-26.PNG
Mount second axle bevel gear.
5-24.PNG STEP 27
In s e r t spi der gear s wi t h th r us t wa s h e r s i nto
differential housing. Secure them with two short
spider shafts.
attention to radial installation position of spider shafts
securing holes (2).
5-27.PNG

grease.
6004-27
STEP 28 STEP 30
5-28.PNG 5-30.PNG
Mount two adjusting bolts and insert housing cover Heat both tapered roller bearings and insert until
until contact with differential housing is obtained. contact is made. Adjust tapered roller bearing after
Preload differential using a press. Secure with new cooling down.
locking bolts. Torque to 400 Nm (295 pound feet).
STEP 29 parts.
5-29.PNG
Attach housing cover and preload differential with a

suitable press. Secure housing cover with hex bolts
and torque to 185 Nm (136 pound feet).
6004-28
INPUT
Reassembly STEP 3
STEP 1
Determination of shim thickness to
obtain a correct contact pattern
6-03.PNG
Determine dimension III (bearing width). Dimension

III e.g. 42.60 mm (1.67 in).
Calculation Example “A”:
6-01.PNG Dimension I: 245.60 mm (9.67 in)
NOTE: If crown wheel or input pinion are damaged, Dimension II: -202.00 mm (7.95 in)
both parts must be replaced together. In case of an
installation of a complete new bevel gear set, pay Dimension III: -42.60 mm (1.68 in)
attention to an identical mating number on input Difference = shim s = 1.00 mm (0.04 in)
pinion and crown wheel.
NOTE: The following measuring procedures must be STEP 4
completed accurately. Inaccurate measurements Reassembly of input pinion
lead to incorrect contact pattern requiring additional
disassembly and reassembly of input pinion and
differential.
Read dimension I (arrow) from axle drive housing.
Dimension I e.g. 245.60 mm (9.67 in).
STEP 2
6-04.PNG
Cool external bearing. With a driver tool, insert it into

axle drive housing until contact is made.
cooled parts.
6-02.PNG
Read pinion dimension (arrow), Dimension II.

Dimension II e.g. 202.00 mm (7.95 in).
6004-29
STEP 5 STEP 7
6-05.PNG 6-07.PNG
Insert determined shim size e.g. s = 1.00 mm (0.04 Heat tapered roller bearing. Insert it onto input pinion
in) into housing hole. until contact is made.
STEP 6 prevent burning your hands when handling heated or
cooled parts.
STEP 8
Setting rolling torque of input pinion
bearing without shaft seal 1.5 to 3.0 Nm
(13.3 to 26.6 pound inches)
6-06.PNG
Cool internal bearing outer ring. Bring it into contact

position within housing hole using 380100001
assembly fixture.
cooled parts.
6-08.PNG
Insert spacer (e.g. s = 8.18 mm (0.32 in))

NOTE: Based on experience, necessary rolling
torque is obtained when reusing the spacer removed
during disassembly e.g. s = 8.18 mm (0.32 in).
NOTE: A later check of tolling torque is needed.
6004-30
STEP 9 STEP 11
6-09.PNG 6-11.PNG
Insert preassembled input pinion into axle drive Insert input flange and secure it with disk and slotted
housing. Insert heated tapered roller bearing until nut. Torque to 1200 Nm (885 pound feet). Uses
contact is made. slotted nut wrench CAS2842 and clamping device
380001564.
prevent burning your hands when handling heated or NOTE: Temporarily mount slotted nut without
cooled parts. Loctite. While tightening, rotate input pinion several
times in both directions.
STEP 10
STEP 12
6-10.PNG
Press protection plate onto input flange (arrow) until 6-12.PNG
contact is made. Check rolling torque. It should be 1.5 to 3.0 Nm (13.3

to 26.6 pound inches) without shaft seal.
NOTE: Do not fit shaft seal until contact pattern has
been checked as shown in shown in step 24. NOTE: When installing new bearings try to achieve
upper value of rolling torque.
NOTE: In case of deviations from needed rolling
torque, correct with a corresponding spacer as
specified in Step 8. For insufficient rolling torque -
install thinner spacer ring. Excessive rolling torque -
install a thicker spacer ring.
6004-31
STEP 13 STEP 15
Determination of shims for setting
bearing rolling torque (differential
housing) and backlash (bevel gear set)
6-13.PNG
Grease O-rings (arrows) and insert them into annular

grooves of piston.
NOTE: Steps 13 and 14 are only necessary for DHL
6-15.PNG
versions.
Determine required shims on the basis of the read
value (deviation /te st dimension) and the
STEP 14 corresponding specifications of the following table:
(KRS - SET - RIGHT) (KRS = bevel gear set):
For deviation, see rear side of crown wheel.
The test dimension “106” is stamped into the crown
wheel rear side. If no + or - deviation is indicated, this
value corresponds to actual value “0” in the table
below. According to this value, the required shims are
allocated in the table below.
Any + or - deviation of the test dimension caused by
production is also marked on the crown wheel rear
side (e.g. - 20 or - 10 or 10 or 20). In accordance with
this deviation, the required shims are allocated in the
6-14.PNG following table.
Inser t piston (arrow) into bearing housing until
contact is made. STEP 16
6-16.JPG
1 = Axle housing
2 = Shim (crown wheel side)
3 = Shim (differential carrier side)
4 = Axle housing
6004-32
Shims for differential D/DL and DHL-2400 in ZF axles MT-L 3105 II
Crown wheel -20 -10 - 10

marking
Deviation -0.2 -0.1 0 0.1
Shim 0.8 0.9 1.0 1.1

Diff. cage side
Shim thickness
Shim 84354725 84354726 84354727 84354728

Order no.
Shim 1.2 1.1 1.0 0.9

Crown wheel side
Shim thickness
Shim 84354730 84354728 84354727 84354726

Order no.
6004-33
STEP 17 STEP 20
6-17.PNG 6-20.PNG
Insert selected shim e.g. s = 1.0 mm (0.04 in) into Mount two locating pins and bring axle housing into
hole of axle housing and adjust bearing outer ring contact position with axle drive housing using a
(arrow) until contact is obtained. suitable lifting device. Temporarily attach axle
housing with hex bolts. Torque to 560 Nm (413 pound
STEP 18 feet).
NOTE: Test mount axle housing without O-ring.
STEP 21
6-18.PNG
Cover some drive and coast flanks of crown wheel

with marking ink. Insert premounted differential into
axle drive housing.
6-21.PNG
Leakage test of lock

STEP 19
Pressurize lock p = 1 bar (14.5 psi), close shut-off
valve and remove air line. No noticeable pressure
loss is allowed to occur within 10 seconds.
NOTE: This operation is only necessary for version
with DHL.
6-19.PNG
Insert selected shim e.g. s = 1.0 mm (0.04 in) into

hole of axle housing and adjust bearing outer ring
(arrow) until contact is made.
6004-34
STEP 22 STEP 24
Reassembly of shaft seal (Steps 24 to 26)
6-22.PNG
In both directions several times, rotate input flange to

6-24.PNG
roll crown wheel over input pinion. Remove axle
Loosen slotted nut using CAS2842 slotted nut
housing and lift differential out of axle drive housing.
wrench with 380001564 clamping device and pull
Compare obtained contact pattern with contact patter
input flange from input pinion.
examples at the beginning of this section.
NOTE: If a contact pattern deviation exists, a STEP 25
measuring error was made during shim size
determination (Step 5). This must be corrected.
STEP 23
6-25.PNG
Use driver tool CAS2841 to mount shaft seal with

seal lip facing oil chamber.
NOTE: Exact installation position of seal is obtained
6-23.PNG
when using specified driver tool.
After contact pattern check, insert differential into
axle drive housing again. NOTE: Wet outer diameter of shaft seal with mineral
spirits just before installation. Fill space between seal
and dust lip with grease.
6004-35
STEP 26
6-26.PNG
Insert input flange and secure with disc and slotted

nut using slotted nut wrench CAS2842 and clamping
device 380001564. Torque to 1200 Nm (885 pound
feet).
NOTE: Cover threads of slotted nut with Loctite
(Type no. 262).
6004-36
AXLE HOUSING
Reassembly STEP 3
STEP 1
7-03.PNG
Mount fitting. Torque to 36 Nm (27 pound feet).

7-01.PNG
Grease O-ring (arrow) insert it into axle housing. STEP 4
STEP 2
7-04.PNG
Grease O-ring. Insert it into annular groove of brake

7-02.PNG
tube (arrow).
Mount M20 locating pins. Use a suitable lifting device
and bring axle housing into contact position with axle STEP 5
drive housing. Secure axle housing with hex bolts.
WARNING: After assembling axle housing secure
axle with clamping brackets.
7-05.PNG
Mount brake tube with threaded connection and hex

nut (arrow). Torque to 100 Nm (74 pound feet).
6004-37
STEP 6
7-06.PNG
Install plug and new O-ring. Torque to 50 Nm (37

pound feet).
6004-38
OUTPUT AND BRAKE
Reassembly STEP 3
STEP 1
8-03.PNG
Wet O-ring of slide ring seal and locating hole with

mineral spirits. Snap new slide ring seal (part 1) into
8-01.PNG
output shaft.
Pull wheel stud into output shaft until contact is
made.
STEP 4
NOTE: A special tool should be used for repairs
when exchanging individual wheel studs with a
mounted output shaft. On a new output shaft, mount
wheel studs with a press.
STEP 2
8-04.PNG
Mount new slide ring seal (part 2) into brake housing.

NOTE: For installation position of seal, go to Step 9.
NOTE: Surface of slide ring seal may not have any
grooves, scratches or other damage. Make sure that
8-02.PNG sealing surface is parallel to housing face. O-rings
Heat tapered roller bearing and insert it into output must be mounted evenly into locating hole and must
shaft until contact is made. not bulge out.
WARNING: Always wear protective gloves to WARNING: Risk of injury - metal rings have
prevent burning your hands when handling heated or extremely sharp edges. Wear protective gloves.
cooled parts.
6004-39
STEP 5 STEP 7
8-05.PNG 8-07.PNG
Insert both bearing outer rings (arrows) into brake Insert back-up rings and grooved rings into annular
housing until contact is made. grooves of brake housing (arrows).
NOTE: For installation position, go to Step 9.
STEP 6
STEP 8
8-06.PNG
Use a suitable lifting device and insert premounted

8-08.PNG
brake housing over output shaft until contact is made.
Clean annular groove of brake housing with mineral
NOTE: Before clamping seal rings (slide ring seal) to spirits. Insert guide ring into annular grove (go to
installation dimension, clean sliding surfaces and Step 9). Secure it with Loctite (type no. 415) at its
apply an oil film. A leather cloth soaked in oil is ends (arrows).
recommended for this step.
NOTE: Full circumference of guide ring must be in
an exact contact position.
WARNING: Upon installation, orifice of guide ring
must show upwards - 12 o’clock position.
6004-40
STEP 9 STEP 11
8-11.PNG
Insert piston into brake housing and install with

dealer fabricated fixing device until contact is made.
NOTE: Sufficiently oil seal surface of piston/back-up
rings, grooved rings and guide ring with W-10 oils.
STEP 12
8-09.JPG
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal Face Seal (Heavy Duty Option) Combi
Seal (Standard)
8-12.PNG
8. Output shaft Insert disk and cup spring with convex side showing
upwards into piston.
STEP 10
STEP 13
8-10.PNG
Flush-mount slotted pins into holes of piston. 8-13.PNG
Insert cover and secure it with hex bolts. Torque to 34

Nm (25 pound feet).
6004-41
STEP 14 STEP 17
1 3
4
8-14.PNG 8-17.PNG
Insert outer and inner disks. Insert cylindrical roller bearing into planetary gear. To
do this, press cylindrical roller bearing (1) through
NOTE: For number of disks and disk arrangement,
packaging sleeve (2) until snap ring (3) engages into
refer to related spare parts list.
annular groove of planetary gear (4).
STEP 15 NOTE: Use packaging sleeve to facilitate assembly.
STEP 18
8-15.PNG
Insert end plate.

8-18.PNG
STEP 16 Heat bear ing inner r ings. Inser t premounted

planetary gears with large radius facing planetary
carrier (downwards) until contact is made. Secure
planetary gears with retaining rings.
2 NOTE: Adjust bearing inner rings after cooling.
1 WARNING: Always wear protective gloves to
cooled parts.
8-16.JPG
Press stop bolt (1) into planetary carrier (2) until

contact is obtained.
6004-42
STEP 19 STEP 21
8-19.PNG 8-21.PNG
Heat tapered roller bearing. Install it on planetary Align disk package centrally and radially. Heat output
carrier until contact is made. shaft. Use a suitable lifting device to insert planetary
carrier into teeth of output shaft.
parts. prevent burning your hands when handling heated or
cooled parts.
STEP 20
STEP 22
2
1
8-20.PNG
Wet contact face of bearing inner ring (1) and profile 8-22.PNG
teeth (2) in output shaft with anti-corrosive agent. Bring planetary carrier into contact position with
c ove r a n d o l d l o ck i n g b o l t s r e m ove d d u r i n g
disassembly. Remove old locking bolts.
6004-43
STEP 23 STEP 25
8-23.PNG 8-25.PNG
Pivot output 90 degrees. Insert disk and secure Insert cover into output shaft until contact is made.
planetary carrier with new locking bolts.
NOTE: Tighten locking bolts successively with a STEP 26
tightening torque of 200 Nm (148 pound feet). Then,
retighten locking bolts successively with a torque of
STEP 24
8-26.PNG
Set axial play of sun gear shaft 0.5 to 2.0 mm (0.02 to

0.08 in). Use a straight edge to determine dimension
I, from mounting face of brake housing to front face of
1 stop bolt.
8-24.PNG Dimension I e.g. 40.80 mm (1.61 in)
Install new O-ring (1) and cover. Wet contact face (2)
with Terostat - MS 9360.
NOTE: Curing period for Terostat is greater than
24-hours.
6004-44
STEP 27 STEP 29
8-27.PNG 8-29.PNG
Insert stub shaft into teeth of axle bevel gear until Using a straight edge measure dimension II, from
contact is made. front face of sun gear shaft to mounting surface of
axle housing.
NOTE: Be aware of installation position. Mount stub
shaft with long teeth towards differential. Dimension II e.g. 38.20 mm (1.50 in)
CALCULATION EXAMPLE:
STEP 28
Dimension I: 40.80 mm (1.61 in)
Dimension II: 38.20 mm (1.50 in)
Difference: 2.60 mm (0.10 in)
Required axial play e.g.: 1.00 mm (0.04 in)
Difference = shim e.g.: s = 1.60 mm (0.06 in)
STEP 30
8-28.PNG
Insert sun gear shaft until contact is made.
8-30.PNG
Insert sun gear shaft into planetary carrier.

6004-45
STEP 31 STEP 34
8-314.PNG 8-34.PNG
Insert shim(s) e.g. s = 1.60 mm (0.06 in) with grease M o u n t a d j u s t i n g b o l ts a n d u s e l i f t i n g d ev i c e

into sun gear shaft. 380002303 to bring output into contact position with
axle housing. Secure output using hex bolts. Torque
STEP 32 to 560 Nm (413 pound feet).
NOTE: Attach load carrying device with wheel stud.
STEP 35
8-32.PNG
Attach O-ring (arrow) with grease into countersink of

brake housing.
8-35.PNG
STEP 33 Mount bleeder valve (arrow).
8-33.PNG
Grease O-ring (arrow) and install it in axle housing.

6004-46
STEP 36 Differential Lock off:
When ro tatin g inp ut flan ge, on e side ha s no
movement or rotates in opposite direction.
NOTE: Before axle operation, fill with oil according to
lubrication and maintenance instructions.
8-36.PNG
Check brake hydraulics for leakage. Before starting

test bleed hydraulic system. Pressurize brake
temporarily (5x) with a max pressure of p = 100 bar
(1450 psi).
High-pressure test:
Build up test pressure p = 100 -10 bar maximum and
close connection to HP pump via shut-off valve. A
maximum pressure drop of 2% or 2 bar (29 psi) is
permissible during a 5 minute test period.
Low-pressure test:
Reduce test pressure p = 5 bar (73 psi) and close
shut-off valve. No pressure drop is allowed during a
5-minute test period.
Test media:
Engine oils SAE 10-W corresponds to MIL-L 2104 C,
MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils type
A, Suffic A Dexron of II D.
8-37.PNG
Check operability of DHL. Build up maximum

pressure p = 20 bar (290 psi) and close connection to
pump via shut-off valve.
Differential Lock on:
When rotating input flange, both outputs must have
same direction of rotation.
Section
6005
DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL

JOINTS
6005
6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6005-3
SPECIAL TORQUES
Coupler to Flywheel Bolts...................................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler Bolts ...................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler Bolts (821F/921F 5-Speed Transmission)........... 86 to 126 Nm (63 to 93 pound feet)
Engine Drive Shaft to Transmission Bolts.............................................................. 75 to 81 Nm (55 to 60 pound feet)
Center, Rear and Front Drive Shaft Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet)
Carrier Bearing Bolts ........................................................................................... 99 to 128 Nm (73 to 94 pound feet)
Lock Nut for Yoke on Front Drive Shaft.......................................................... 339 to 375 Nm (250 to 275 pound feet)
6005-4
FRONT DRIVE SHAFT
Removal STEP 5
Loosen the set screws that secure the center bearing
NOTE: The 921F Series machines use mechanical
to the front drive shaft.
style yokes (no bearing straps) and may appear
different from the machine pictured.
STEP 6
STEP 1 Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD03A166
Loosen and remove the bolts and straps that fasten
the center drive shaft to the yoke of the front drive
shaft.
STEP 2 BD03A167

the front drive shaft to the front axle.
STEP 8
Use a prybar to disengage the front drive shaft from
the front axle and remove the front drive shaft from
the machine.
NOTE: If necessary, use a brass hammer to drive
the front drive shaft out of the center bearing.
BD03A183
Remove the lock nut that fastens the yoke to the front
drive shaft.
STEP 3
Make an alignment mark on the yoke and the end of
the front drive shaft to make sure that the yoke is
installed correctly.
STEP 4
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
6005-5
FRONT DRIVE SHAFT
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
BD03A183
STEP 11
Install the lock nut and washer which fastens the
yoke to the front drive shaft. Tighten the lock nut to a
torque of 339 to 375 Nm (250 to 275 pound feet).
STEP 15
Tighten the set screws that secure the center bearing
to the front drive shaft alternately until they stop
turning and the hex head socket wrench starts to
spring.
STEP 16
BD03A167
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure BD03A166
the alignment marks made during removal are Install the bolts and straps that fasten the front drive
aligned. shaft to the center drive shaft. Tighten the bolts to a
NOTE: If a new front drive shaft has been installed, torque of 75 to 81 Nm (55 to 60 pound feet).
make sure the yoke being installed is 90° to the yoke
on the other end of the front drive shaft.
6005-6
CENTER BEARING
Removal STEP 19
STEP 17
BD03A183
Loosen and remove the lock nut that fastens the yoke
STEP 20
Make an alignment mark on the yoke and the front
BD03A166
drive shaft to be sure that the yoke is installed
correctly.
the center drive shaft to the front drive shaft.
STEP 21
STEP 18
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 23
Loosen the set screws that secure the center bearing
BD03A183
Loosen and remove the lubrication hose from the
center bearing.
6005-7
STEP 24
BD03A183
Loosen and remove the bolts, washers and nuts that

fasten the bearing housing to the front frame.
STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
6005-8
CENTER BEARING
NOTE: The center bearing and the bearing housing
are not serviced separately. If the center bearing is
worn or damaged or if the bearing housing is
cracked, a new center bearing and bearing housing
must be used.
STEP 26
Apply antiseize compound to the bearing area of the
BC05M214
front drive shaft.
Turn the set screw down to the shaft and then back it
off 1/4th turn and lock it with the jam nut. Repeat the
STEP 27 procedure with the other set screw.
Install the bearing housing so that the lubrication
fitting is at the top.
STEP 30
Apply antiseize compound to the splines on the front
STEP 28 drive shaft. Install the yoke to the front drive shaft,
making sure the alignment marks made during
removal are aligned.
STEP 31
BD03A183
Apply Loctite 242 to bolt threads. Install the bolts,
washers and nuts that fasten the bearing housing to
the front frame. Tighten the bolts to a torque of 99 to
128 Nm (73 to 94 pound feet).
BD03A183
Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
of 339 to 375 Nm (250 to 275 pound feet).
6005-9
STEP 32
BD03A166
Install the straps and bolts that fasten the center
drive shaft to the yoke on the front drive shaft.
Tighten the bolts to a torque of 75 to 81 Nm (55 to 60
pound feet).
STEP 33
Install the lubrication hose into the fitting on the
bearing housing.
STEP 34
Lubr icate the center bear ing with the grease
specified in Section 1002.
6005-10
CENTER DRIVE SHAFT
NOTE: The 921F Series machines use mechanical NOTE: The 921F Series machines use mechanical
style yokes (no bearing straps) and may appear style yokes (no bearing straps) and may appear
different from the machine pictured. different from the machine pictured.
STEP 35 STEP 39
BD03A166 BD03A165
Loosen and remove the bolts and straps that fasten Hold the center drive shaft in position and install the
the center drive shaft to the yoke of the front drive bolts and straps that fasten the center drive shaft to
shaft. the transmission. Tighten the bolts to a torque of 75
to 81 Nm (55 to 60 pound feet).
STEP 36
Use a prybar to disengage the center drive shaft from STEP 40
the yoke of the front drive shaft.
STEP 37
BD03A166
Install the bolts and straps that fasten the center

drive shaft to the yoke of the front drive shaft. Tighten
BD03A165
the bolts to a torque of 75 to 81 Nm (55 to 60 pound
Loosen and remove the bolts and straps that fasten feet).
the center drive shaft to the transmission.
STEP 38
Hold the center drive shaft and remove from the
machine.
6005-11
REAR DRIVE SHAFT
STEP 41 STEP 45
BD01D323 BD01F304
Loosen and remove the bolts and straps that fasten Hold the rear drive shaft into position and install the
the rear drive shaft to the transmission. bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 75 to 81 Nm
STEP 42 (55 to 60 pound feet).
Use a prybar to disengage the rear drive shaft from
the transmission. STEP 46
STEP 43
BD01D323
Install the bolts and straps that fasten the rear drive
BD01F304
shaft to the transmission. Tighten the bolts to a
Loosen and remove the bolts and straps that fasten torque of 75 to 81 Nm (55 to 60 pound feet).
the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the
machine.
6005-12
ENGINE DRIVE SHAFT
STEP 47 STEP 50
BD01D342 BD01D342
Remove and discard the bolts and straps that fasten Place the engine drive shaft into position on the
the engine drive shaft to the transmission. transmission and install new straps and bolts.
Tighten the bolts to a torque of 61 to 81 Nm
IMPORTANT: The bolts and straps that fasten the
(45 to 60 pound feet).
engine drive shaft to the transmission must be
replaced when removed.
STEP 51
STEP 48
BD03A172
Install new bolts that fasten the engine drive shaft to

BD03A172
the engine. Tighten bolts to a torque of 53 to 62 Nm
Loosen, remove and discard the bolts that fasten the
(39 to 46 pound feet). For 821F/921F machines
engine drive shaft to the engine.
equipped with 5-Speed transmissions, tighten bolts
to a torque of 86 to 126 Nm (63 to 93 lb ft.).
STEP 49
Remove the engine drive shaft from the machine. NOTE: The bolts that fasten the engine drive shaft to
the engine must be replaced when removed.
6005-13
UNIVERSAL JOINTS
NOTE: The bearing race and journal that make up
STEP 52 the universal joint are not serviced separately. If the
Remove the drive shaft from the machine. bearing race or journal is worn or damaged, a new
universal joint must be used.
STEP 53
STEP 55
Clean the slots in the yoke of the drive shaft.
2
1
STEP 56
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 53.
STEP 57
Install the drive shaft.
BD01F304
1. RING 2. BEARING
Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on
the machine and is for reference of the ring and
bearing only.
STEP 54
Remove the universal joint from the drive shaft.
6005-14
Section
6006
WHEELS AND TIRES
6006
6006-2
TABLE OF CONTENTS
WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6006-3
WHEELS AND BOLTS
General Information Torque Specification

The wheel bolts must be tightened after every 20 Tighten the wheel bolts to 278 Nm (205 lb ft.) in the
hours of operation until the wheel bolts stay tight: sequence shown in Figure 1 or Figure 2. Then use a
final torque of 640 - 720 Nm (475 - 530 lb ft.) in the
A. If the machine is new.
same sequence.
B. If a wheel has been removed and installed.
FRONT TIRE PRESSURES

23.5 x 25 12 ply L2 .............................................................................................................................345 kPa(50 psi)
23.5 x 25 12 ply L3 ............................................................................................................................345 kPa (50 psi)
23.5R25 L2 ....................................................................................................................... 276 - 448 kPa (40 - 65 psi)
23.5R25 Radial L3............................................................................................................ 276 - 448 kPa (40 - 65 psi)
REAR TIRE PRESSURES

23.5 x 25 12 ply L2 .............................................................................................................................276 kPa(40 psi)
23.5 x 25 12 ply L3 ............................................................................................................................276 kPa (40 psi)
23.5R25 L2 ......................................................................................................................... 207 - 276kPa (30 - 40psi)
23.5R25 Radial L3................................................................................................................207 - 276kPa (30 - 40psi
CHANGING TIRES
1. Have a qualified tire mechanic service the split
The split rim wheels used on this machine rim wheels used on this machine.
can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and 2. The correct tire equipment, especially a tire
stand at the front or rear of the tire. inflation cage, is required. Using the wrong
procedure for a split rim wheel can result in
When inflating a tire off the machine, put death.
the wheel in a tire inflation cage. The IMPORTANT: When installing a Michelin tire,
retaining ring and rim can come off with lubricate the tire with a tire mounting lubricant and
enough force to result in death to a person inflate the tire to 551 kPa, 5.5 bar (80 psi) to make
in front of the rim. sure that the tire is seated on the rim. Then decrease
48-44 the pressure to the specified pressure.
6006-4
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and
axle flange are clean and free of dirt and grease.
2. Install the wheel, hardened washers and wheel
bolts or nuts depending on axle configuration.
THe 721F/821F Heavy Duty Axles and all 921F
axles have wheel studs on the axles and use
wheel nuts.
3. Use a hand wrench (not an impact) to tighten the
wheel b olts to pu ll the wheel against the
planetar y housing. DO NOT use an impact
wrench to tighten the wheel bolts.
4. Tighten the wheel bolts to 278 Nm (205 lb ft.) in
the sequence shown in Figure 1, Figure 2 or
Figure 3. Then tighten to final torque of 640 - 720
Nm (475 - 530 lb ft.).
1 84324413_205.TIF
10 8 FIGURE 2. 821F SERIES WHEEL NUT/BOLT TORQUE
SEQUENCE
6 12
3
4
11 5
7 9
2
B0987A88.TIF
FIGURE 1. 721F SERIES WHEEL NUT/BOLT TORQUE
SEQUENCE
OROR201007RCIL10WHL288BAL1.TIF
FIGURE 3. 921F SERIES WHEEL NUT/BOLT TORQUE
SEQUENCE
Stud Mounted Wheels (If equipped)

Machines equipped with optional heavy duty axles
have a stud mounted wheel. The heavy duty axle
incorporates a stud and nut assembly.
Torque Rates
First tighten nuts/bolts using correct sequence.
Initially tighten to 278 Nm (205 lb ft.) Then tighten to
final torque of 640 - 720 Nm (475 - 530 lb ft.).
7001
Section
7001
REMOVAL AND INSTALLATION OF BRAKE

COMPONENTS
7001-2
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7001-3
9
5
1 6
10
8
2
BC05M136
1. FRONT AXLE 6. REAR ACCUMULATOR

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

2. REAR ACCUMULATOR LINE 7. REAR BRAKE LINE
3. PARKING BRAKE LINE 8. FRONT ACCUMULATOR
4. BRAKE PUMP INPUT 9. RETURN TO TANK
5. BRAKE VALVE DISCHARGE 10. PARKING BRAKE ACCUMULATOR
BRAKE VALVE ILLUSTRATION
7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS
Removal 18. Disconnect the hose from brake damping

accumulators (9) and (10). See illustration on
NOTE: 821F and 921F machines are now equipped page 3.
with brake Damping Accumulators located on the
front axle (9) and frame (10). See illustration on page 19. Remove brake damping accumulators from
3. machine.
1. Park the machine on a level surface and lower 20. Install plugs in hoses.
the loader bucket to the floor. Stop the engine.
Installation
2. Put blocks on both sides of each tire to prevent
machine movement. NOTE: 821F and 921F machines are now equipped
with brake Damping Accumulators located on the
3. Make sure the service brake accumulators (1),
front axle (9) and frame (10). See illustration on page
the parking brake accumulator (2), and brake
3.
damping accumulators (9) and (10) are
completely discharged. Push down and release 1. Mount the accumulators (1) in the accumulators
the brake pedal at least 30. clamps (7), do not tighten clamps at this time.
Refer to illustration on page 7.
4. Turn the master disconnect switch to the OFF
position. 2. Connect the tubes to both brake accumulators
(1) and tighten.
5. Remove the left cab skirt located under the cab
or canopy to gain access to accumulators. 3. Tighten accumulator clamp studs (7) to 17Nm
(13 pound feet).
6. To release the pressure on the parking brake
accumulator, the line at the accumulator must be 4. Install the parking brake accumulator (2) into the
SLOWLY cracked open. A pan will be needed to bracket.
catch the hydraulic oil.
5. Install the nut (3) and tighten.
7. Connect a drain hose to the quick disconnect
6. Connect the line to the parking brake
couplings in each brake circuit to release any
accumulator (2).
pressure in the brake circuit.
7. Install the brake damping accumulators (9) and
8. Clean the brake accumulators (1), parking brake
(10).
accumulator (2), brake damping accumulators
(9) and (10) and lines. Refer to illustrations on 8. Connect the lines to the brake damping
pages 3 and 7. accumulators (9) and (10).
9. Put identification tags on the line that is 9. Stop the vacuum pump and remove.
connected to the parking brake accumulator (2).
10. Install the left cab skirt.
11. Turn the master disconnect switch to the ON
reservoir. Start the vacuum pump.
position.
11. Disconnect the tubes from both brake
12. Bleed the brake system. See Section 7002.
accumulators (1).
13. Refer to Section 7008 and perform the Parking
12. Loosen the clamp stud (8) on the accumulator
Brake Test Procedure.
clamp (7).
14. Check the hydraulic reservoir oil level and add oil
13. Remove the accumulators (1) from the
as required. See Section 1002 for the correct oil.
accumulator clamps (7).
14. Install plugs in the tubes.
15. Disconnect the hose from parking brake
accumulator (2).
16. Remove the nut (3), remove the parking brake
accumulator (2).
17. Install a plug in the hose.
7001-7
2 3
6
4
7
8
7
1
1
BC05M138
1. BRAKE ACCUMULATORS 5. TUBE FRONT BRAKE ACCUMULATOR

2. PARKING BRAKE ACCUMULATOR 6. TUBE REAR BRAKE ACCUMULATOR
3. MOUNTING NUT 7. CLAMP ACCUMULATOR
4. HOSE PARKING BRAKE ACCUMULATOR 8. CLAMP STUD
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION
7001-8
BRAKE PUMP
1. Park the machine on a level surface and lower 1. Install gear (6) onto the pump shaft, install
the loader bucket to the floor. Stop the engine. washer (7) and slotted nut (8), torque nut to 70 to
79 Nm (52 to 58 pound feet). Refer to the
2. Put blocks on both sides of each tire to prevent
machine movement.
2. Install the cotter pin (9).
3. Turn the master disconnect switch to the OFF
position. 3. Install the brake pump (1), mounting bolts (2) and
washers (3).
4. Clean the brake pump (1) and lines, refer to the
illustration on page 9. 4. Torque mounting bolts (2) to 57 to 65 Nm (42 to
48 pound feet).
5. Put identification tags the lines that are
connected to the brake pump (1). 5. Remove the plugs or caps and connect the lines
to the brake pump (1).
reservoir. Start the vacuum pump. 6. Stop the vacuum pump and remove.
7. Disconnect the lines from the brake pump (1) 7. Turn the master disconnect switch to the ON
and put plugs in each line. position.
8. Remove the mounting bolts (2) and washers (3) 8. Bleed the brake system. See Section 7002.
from the brake pump (1) and remove the brake
9. Check the hydraulic reservoir oil level and add oil
pump (1).
as required. See Section 1002 for the correct oil.
7001-9
9 8
7
6
3
2
BC05M139
1. BRAKE PUMP 4. SUCTION HOSE 7. WASHER

2. MOUNTING BOLT (2) 5. PRESSURE HOSE 8. SLOTTED NUT
3. WASHER (2) 6. DRIVE GEAR 9. COTTER PIN
BRAKE PUMP ILLUSTRATION
7001-10
NOTES
7002
Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING

7002-2
ABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7002-3
SPECIFICATIONS
Brake pump output ..............................................................................................................42 to 45 L/min at 172 bar
(11 to 12 gpm at 2500 psi at 2000 rpm)
Accumulator nitrogen charge pressure...........................................................................48 to 59 bar (700 to 850 psi)

Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2280 to 2420 psi)
Accumulator valve cut out pressure....................................................................... 190 to 196 bar (2755 to 2845 psi)
Brake warning pressure switch (normally closed) opening set point ......................106 to 115 bar (1530 to 1670 psi)
Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi)
Brake light pressure switch (normally open) closing set point .............................. 5 to 6 bar increasing (75 to 85 psi)
Modulation pressure front brake cylinders..................................................................80 to 87 bar (1160 to 1260 psi)
Modulation pressure rear brake cylinders...................................................................78 to 85 bar (1130 to 1230 psi)
SPECIAL TOOLS
G
94L95
CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND
CHARGE THE ACCUMULATOR WITH NITROGEN.
BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER
7002-4
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM

NOTE: The hydraulic brake schematic is included in 8. Stop the engine. Turn the ignition switch to the
the hydraulic schematic. Refer to the rear pocket of ON position. Push and release the brake several
this manual. times while reading the pressure on the gauges.
Each push and release of the pedal will result in
1. Check the oil level in the hydraulic reservoir; add
a slight drop in pressure, but not necessarily
oil as necessary.
equal on the two gauges. As the lowest pressure
2. Push and release the brake pedal many times reaches 106 to 115 bar (1530 to 1670 psi) the
with the engine stopped to remove all hydraulic brake warning lamp and alarm buzzer must
pressure from the brake system until there is no actuate. If the warning lamp and alarm buzzer fail
pressure on the pedal. to work, test the low brake pressure warning
switches and electrical circuit. If the warning
3. Install two 207 bar (3000 psi) pressure gauges to
lamp and alarm buzzer actuate at a higher or
front and rear hydraulic brake accumulator test
lower pressure than specified, test the low brake
ports, refer to page 7 for the locations of the test
pressure war ning switches and replace as
ports.
needed.
4. Make sure that the pressure gauge hoses are
9. As the lowest pressure reaches 106 to 115 bar
long enough so the gauges can be read while
(1530 to 1670 psi) the brake warning lamp and
sitting in the operators seat.
alarm buzzer must actuate. If the warning lamp
NOTE: The gauges can not be connected to the test and alarm buzzer fail to work, test the low brake
ports if hydraulic pressure remains in the system. pressure warning switches and electrical circuit.
If the warning lamp and alarm buzzer actuate at
5. Start the engine. Run the engine at low idle while
a higher or lower pressure than specified, test
reading the pressure gauges. The alar ms
the low brake pressure warning switches and
(buzzer, master warning light and brake pressure
replace as needed.
war ning light) should shut off when the
accumulator with the lowest pressure reaches 10. After the low brake pressure light activates, press
106 to 115 bar (1530 to 1670 psi), approximately the brake pedal eight more times.
40 seconds at any engine speed. 11. Record the readings on the pressure gauges.
6. After the alarms stop, run the machine at high The pressure gauges should read at or above
idle to finish charging the accumulators. The 48 to 59 bar (700 to 850 psi).
pressure must increase on both gauges until 190 12. If the pressures are at or above 48 to 59 bar (700
to 196 bar (2757 to 2843 psi) is reached. This is to 850 psi), the test is complete.
the accumulator valve cut-out pressure. It is 13. If the pressures are not within the required
normal for the pressure to drop slightly once the specifications, then the brake system must be
cut-out pressure is reached. bled.
7. With the engine running at high idle, push and 14. After bleeding the brake system, perform the
release the brake pedal rapidly while reading the brake system check again.
drop in pressure on the gauges. The pressure
drops may not be equal, but as the lowest 15. Continue to slowly push and release the brake
pressure reaches 157 to 167 bar (2280 to 2420 pedal several times until the gauge pressure
psi), the system pressure must start to increase. suddenly drops to zero. The last pressure
This is the valve cut in pressure. reading before the drop to zero is the nitrogen
charge pressure in the accumulator. Test the
NOTE: The brake cut-in and cut-out pressures of the pressure in both accumulators. If the pressure is
brake system charge valve are factory preset and are below 48 to 59 bar (700 to 850 psi), charge or
not adjustable. replace the accumulator(s) (see page 5).
NOTE: If the pressure on one of the pressure NOTE: Nominal temperature of 20° C (68° F), colder
gauges is lower than specified, the problem can be a temperature will reduce pressure, hotter temperature
bad accumulator valve. will increase pressure.
7002-5
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is
completely discharged by doing the following: E
C
A. Stop the engine.
B. Push down and release the brake pedal many
times to release the pressure.
F
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.
D B A
4. Turn the stem out of valve F until the stem stops.
94L95
5. Remove the cap screws and guard from the NITROGEN CHARGING KIT
accumulator.
8. Make sure that valve D is open.
6. Remove the cap from the accumulator valve
9. Turn the stem into valve F and read the pressure
stem.
gauge E.
7. Connect valve F to the accumulator valve stem.
10. The pressure must be 48 to 59 bar (700 to 850
psi). If the pressure is too low, charge the
accumulator with dry nitrogen.
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator 5. If the pressure increases above 59 bar
according to the instructions in Checking the (850 psi), quickly open and close valve D and
Nitrogen Charge in the Accumulator. Keep the read gauge E. If the pressure is still too high,
nitrogen charging kit connected to the accumulator. close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
1. Close (turn counterclockwise) valve A and open
pressure shown on gauge E is the charge
valve B. Close valves C and D.
pressure.
2. Turn the stem out of valve F until the stem stops
6. Connect valve F to the accumulator valve stem.
moving. Disconnect valve F from the
Turn the stem into valve F until the stem stops
accumulator valve stem.
m o v i n g a n d o p e n va l ve D t o c h a r g e t h e
3. Connect the nitrogen charging kit to a dry accumulator.
nitrogen tank.
7. After the accumulator stops charging, turn the
4. Slowly turn valve A clockwise and read gauge E stem out of valve F until the stem stops moving.
until the pressure is 48 to 59 bar (700 to 850 psi).
8. Close valve B and disconnect the nitrogen
Stop turning valve A.
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
I n s t a l l t h e g u a r d a n d c a p s c r ew s o n t h e
accumulator.
7002-6
BLEEDING THE BRAKE SYSTEM

1. Check the level of hydraulic fluid in the reservoir. 8. Start the engine and run at low idle.
Add fluid to the reservoir if necessary.
9. Push the brake pedal all the way down and
IMPORTANT: If machine is equipped with slowly release for one cycle.
10. Close all four wheel end bleed screws.
11. Fully depress the brake pedal three times in 5
second cycles.
12. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
bubbles). Close the bleed screw.
13. Open the bleed screw on the right front axle.
Repeat step 12.
1 14. Open the bleed screw on the left rear axle.
Repeat step 12.
15. Open the bleed screw on the right rear axle.
BD03A092
Repeat step 12.
1. SAFETY LINK 16. Replace all bleed screws, caps and plugs.
17. Check the hydraulic fluid and add as necessary.
2. Raise loader arms and install the safety link (1)
for safe access to the front axle bleed screws.
4. Keep the engine speed at high idle until both
brake accumulators are fully charged.
NOTE: This will be approximately 30 seconds after
the low brake pressure light goes out.
5. Stop the engine.
6. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).
7. Remove the plastic and rubber caps from each
wheel end and slowly open all four bleed screws.
NOTE: Attach a hose to the bleed screws to prevent
spilling any fluids.
7002-7
BRAKE MODULATION PRESSURE CHECK
2 3
BD06F145
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
Testing the Brake Modulation 6. Start the engine.

Pressure 7. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
1. Make sure the hydraulic accumulator cut-in and the gauges rise above 170 bar (2645 psi).
cut-out pressures are correct. Refer to page 4 of
this section. 8. Apply and hold the brakes for 10 to 15 seconds.
2. Stop the engine. Pump the brake pedal until 9. Make a note of the pressure on the gauges for
there is no pressure in the brake system. the front and rear brakes.
3. Remove the cab skirts to gain access to the 10. The front brake pressure should read 80 to 87
brake test ports. bar (1160 to 1260 psi). This is the modulation
pressure for the front axle.
4. Connect two 207 bar (3000 psi) pressure gauges
to the front brake test port (1) and the rear brake 11. The rear brake pressure should read 78 to 85 bar
test port (2). (1130 to 1230 psi). This is the modulation
pressure for the rear axle
to the front brake accumulator test port (4) and 12. If the pressures are not within the specified
the rear brake accumulator test port (3). ra n g e, i t w i l l b e n e c e s s a r y t o a d j u s t t h e
modulation pressures.
7002-8
Adjusting the Brake Modulation 1. Remove the tamper evident cover (1).
Pressure NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
NOTE: The adjusting bolt to adjust the modulation pressure is adjusted.
pressure is located under the cab, under the brake
pedal. 2. Turn the adjusting bolt to adjust the modulation
pressure.
NOTE: The rear brake modulation pressure cannot
be adjusted separately from the front brake
modulation pressure.
3. Repeat steps 5 through 11 in the Testing the
Brake Modulation Pressure procedure.
4. Repeat these steps until the brake modulation
pressure is within the specified range.
BD00N121
7002-9
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)
2 3
4
BD06F145
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
NOTE: Prior to doing this procedure make sure that 6. Start the engine and let idle until both the front
the accumulator pressures are correct. and rear accumulators 3 and 4 are fully charged.
1. Check the level of the hydraulic fluid in the The accumulators are fully charged at 190 to 196
reservoir, add as needed. bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal down slowly, allowing for
full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal down. The
low brake pressure light should activate when the
pressure reaches 106 to 115 bar (1530 to 1670
psi). After the low brake pressure light activates,
press the brake pedal eight more times.
1 10. Record the readings on the pressure gauges.
The pressure gauges should read at or above
BD00M030 48 to 59 bar (700 to 850 psi).
11. If the pressures are at or above 48 to 59 bar (700
2. Install the articulation lock (1) before doing this to 850 psi), the test is complete.
test. 12. If the pressures are not within the required
3. Remove the left side cab skirt to gain access to specifications, then the brake system must be
the brake accumulator test ports. bled.
4. Pump the brake pedal until there is no hydraulic 13. After bleeding the brake system, perform the
pressure in the brake system (approximately 20 brake system check again.
pumps).
to the test ports 3 and 4.
7002-10
BRAKE PUMP OUTPUT TEST

1. Connect the flowmeter to the brake pump as 3. Measure the flow at 0 bar (0 psi). Record the flow
shown, refer to the illustration below. reading. Slowly close the load valve on the
flowmeter and read the flow at 170 bar (2500
2. Make sure the load control of the flowmeter is
psi). Record the flow reading.
open. Start the engine. Run the engine at full
throttle. Make sure the oil is at operating 4. Divide the flow reading at 170 bar (2500 psi) by
temperature. the reading at 0 bar (0 psi). Multiply the result by
100. This is the percent efficiency of the pump. If
the efficiency of the pump is less than 85%,
repair or replace the pump.
NOTE
4
3
BS03B021
1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD

2. PUMP OUTPUT ELBOW 4. FLOWMETER OUTLET HOSE 6. FILTERS
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
7002-11
NOTES
7002-12
Section
7003
7003
BRAKE PUMP
7003-2
TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7003-3
14
17 15
16
10
18
10
19 13
7
8
9
11
12
11
9 10
8
7
5
4 6
3
2
1
BC06F594
1. RETAINING RING 8. BACKUP SEAL 14. WASHER

2. SEAL RETAINER 9. CHANNEL SEAL 15. BOLT
3. 0-RING 10. DOWEL PIN 16. DRIVEN GEAR
4. OUTER LIP SEAL 11. THRUST PLATE 17. DRIVE GEAR
5. INNER LIP SEAL 12. GEAR HOUSING 18. DRIVE SCREW
6. SHAFT END COVER HOUSING 13. PORT END COVER HOUSING 19. NAME PLATE
7. QUAD RING
PUMP ILLUSTRATION
7003-4
BRAKE PUMP
1. Secure the pump by the port end cover (13) in a 1. Install a new lip seal (3) into the seal retainer (2)
soft jawed vise. so the lip of the seal will be facing away from the
2. Draw a line the length of the pump to assist gears when the seal retainer (2) is installed into
during assemble. the shaft end cover housing (6).
3. Loosen and remove bolts (15). 2. Install a new lip seal (4) into the shaft end cover
housing (6) with the lip of the seal facing towards
4. Tap the shaft end cover housing (6) with soft the gears.
hammer to loosen it, remove the shaft end cover
housing (6). 3. Install a new O-ring (3) onto the seal retainer (2),
lubricate the O-ring with hydraulic oil.
5. Remove the backup seal (8), channel seal (9),
and thrust plate (11). 4. Press the seal retainer (2) into the shaft end
cover housing (6) and install the retaining ring
6. Remove the drive gear (17) from the gear (1).
housing (12).
5. Place the shaft end housing (6), facing down,
7. Remove the driven gear (16) from the gear into a soft jawed vise.
housing (12).
6. Install new backup seals (8) and channel seals
8. Tap the gear housing (12) with a soft hammer to (9) into the thrust plates (11).
loosen it, remove the gear housing (12).
7. Place a thrust plate (11) onto the shaft end cover
9. Remove the backup seal (8), channel seal (9), housing (6).
and thrust plate (11).
IMPORTANT: Be sure to place the thrust plate (11)
10. Remove the retaining ring (1) form the shaft end
onto the shaft end cover housing (6) in the position
cover housing (6).
shown in the illustration on page 3.
11. Remove the seal retainer (2), O-ring (3), and
8. Lubricate the driven gear (16) with hydraulic oil,
outer lip seal (4) from the shaft end cover
slide the driven gear (16) through the thrust plate
housing (6).
(11) into the shaft end cover housing (6).
12. Remove the inner lip seal (5) from the shaft end
9. Lubricate the drive gear (17) with hydraulic oil,
cover housing (6).
slide the drive gear (17) through the thrust plate
(11) into the shaft end cover housing (6).
Inspection
10. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
1. Discard all seals and quad rings. Clean all parts either in the gear housing (12) or the shaft end
in cleaning solvent. Check all machined surfaces cover housing (6).
for damage or wear.
11. Align the marks made during disassembly,
2. Hold a straightedge across each gear housing carefully place the gear housing (12) onto the
and use a feeler gauge to measure the amount gears.
of wear caused by the gear teeth in the gear
12. Slide the thrust plate (11) onto the shafts of the
pocket. If the wear in any gear pocket is more
gears.
than 0.18 MM. (0.007 inch), use a new gear
housing. IMPORTANT: Be sure to place the thrust plate (11)
3. Inspect the thrust plates for scoring, pitting, or onto the gears in the position shown in the illustration
other damage. on page 3.
4. Inspect the gears for wear and damage. There 13. Install a new quad ring (7) into the gear housing
must be no scoring on the gear hubs or on the (12). Check that dowel pins (10) are in place
outside edges of the gear teeth. There must be either in the gear housing (12) or the port end
no more than 0.05 MM. (0.002 inch) wear in the cover housing (13).
seal area of the drive shaft. If any gear must be 14. Align the marks made during disassembly, place
discarded, you must use a new hydraulic pump. the port housing (12) onto the gear housing (12).
15. Install bolts (15) with clean and dry threads,
washers (14). Torque bolts to 192 ± 5.5 Nm
(141.5 ± 4 pound feet).
Section
7004
7004
BRAKE ACCUMULATORS
7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7004-3
SPECIAL TOOL
C E
G
D B A
94L95 BC04A001
CAS10899 NITROGEN CHARGING KIT 380001168 ACCUMULATOR CHARGING ADAPTER
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Remove cover from accumulator charge port. 6. Connect valve F to the valve stem on the
Loosen the Allen screw in the charge port. adapter.
NOTE: Do not turn the Allen screw more than 1/8 of 7. Turn the T-handle inward on valve F to engage
a turn or gas will escape uncontrolled. the pin in the valve stem, open valve G.
2. Install adapter on accumulator, use the 8. Open valve D and check the charge pressure on
CAS10899 nitrogen charging kit to discharge the gauge E.
accumulator, refer to illustrations above. The tool
9. To discharge the accumulator, partially open
must be disconnected from the nitrogen tank.
valve B. The accumulator charge will bleed down
3. Close valves B, C and D. through the regulator.
4. Adjust the regulator A to the minimum pressure 10. Once the accumulator is fully discharged,
setting by turning the knob counterclockwise. disconnect valve F from the valve stem and
remove adapter.
5. Turn the T-handle on valve F fully out.
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

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

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

ACCUMULATOR
Section
7008
PARKING BRAKE
7008
7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7008-3
PARKING BRAKE
Disassembly STEP 7
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wheel chocks on each wheel to prevent
machine movement.
STEP 3
BD03A185
Loosen the jam nut, tur n adjusting bolt

counterclockwise until the brake pads are loose.
STEP 8
BD01F143
Install the articulation lock.
STEP 4
position.
STEP 5 BD03A186
Remove the retainer pin and brake pin.
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP 9
STEP 6
BD03A187
Remove the two brake pads from the parking brake
BD03A184 assembly.
Loosen and remove the cover from the parking
brake.
7008-4
Inspection STEP 14
Disengage the parking brake.
STEP 10 NOTE: Hydraulic pressure will not be applied to the
Clean and inspect all parts for wear and damage. parking brake until the parking brake rocker switch is
Inspect the brake disc for wear and damage. turned off, the service brakes applied and the
transmission is put into gear.
Replace all parts that are worn or damaged.
A. Place the parking brake rocker switch in the
OFF position.
Assembly
B. Apply the service brake and put the machine
STEP 11 into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.
STEP 15
BD03A187
Install the two brake pads in the parking brake

assembly.
STEP 12
BD0CA185
Turn the adjusting bolt clockwise until both brake

pads contact the brake disc, then turn the adjusting
bolt counterclockwise one turn. Tighten the jam nut
to secure the adjusting bolt.
STEP 16
Install the cover on the parking brake.
STEP 17
Perfor m the Parking Brake Test Procedure as
BD03A186
described in this section.
Install the brake pins and retainer pins.
STEP 18
STEP 13
Return the articulation lock to the operating position.
Place the master disconnect switch to the on
position. Start the machine and run the engine at low
idle with the bucket resting on the ground.
IMPORTANT: It will be necessary to have an
assistant help for this procedure. An operator must
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.
7008-5
PARKING BRAKE TEST PROCEDURE

STEP 19 STEP 24
While testing, the machine must be on a clear level
surface with the bucket in the travel position.
WARNING: Always know the location of all

workers in your area. Warn them before you
start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015
STEP 20
Start the machine and run the engine at low idle in
third gear neutral.
RCPH10WH381BAH
Use up or down arrow and highlight test park brake

STEP 21 and press the confirm key to enter selection.
Place the Transmission-Auto switch to the manual
position.
STEP 22
Place the Parking Brake switch to the ON position.
STEP 23
BD06F143
Monitor will display Test Park Brake if all conditions

are met to test the brake, press the enter key.
NOTE: If all conditions are not met to test the brake
BD06F141 the monitor will display the condition that needs
Press and hold the enter key for 2 to 3 seconds until corrected prior to proceeding.
the instrument cluster monitor display changes to the
select screen. STEP 25
Monitor will display Test Park Brake Ready.
STEP 26
Shift the gear selector into third gear forward and
slowly increase the engine speed to wide open
throttle.
STEP 27
Verify that the machine does not move.
STEP 28
Reduce the engine speed to low idle and return the
transmission neutral.
7008-6
STEP 29
Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
throttle.
STEP 30
Verify that the machine does not move.
STEP 31
Reduce the engine speed to low idle and return the
transmission to neutral.
STEP 32
BD06F141
Press the escape switch on the key pad to exit the

test mode.
STEP 33
If any machine movement was detected, the parking
brake must be adjusted, see procedures this section.
8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC

COMPONENTS
8001-2
TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8001-3
LOADER CONTROL VALVE
Removal STEP 5
STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with
STEP 2
BD06H198
Relieve the pressure in the ride control accumulator

with the manual bleeder valve located on the top of
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.
STEP 6
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
BD03A092
STEP 7
Raise the lift arms and install the safety link on the lift
arm cylinder. Drain the hydraulic reservoir.
STEP 3 STEP 8
Stop the engine and apply the parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
STEP 4
position.
BD03A093
Loosen and remove the bolts and washers that

fasten the access cover plate for the loader control
valve. Remove the cover plate.
8001-4
REAR OF MACHINE
6
7
5
3
1
2 4
BC05M094
1. GREEN WHITE GREEN 4. ORANGE BLACK GREEN 7. GREEN BLACK GREEN

2. RED WHITE GREEN 5. GREEN WHITE GREEN 8. RED BLACK GREEN
3. YELLOW BLACK GREEN 6. RED WHITE GREEN 9.
HYDRAULIC VALVE PILOT LINE CONNECTIONS
8001-5
1 2
3
4
6 7
BC05M093
1. DUMP LINE 4. RAISE LINE RIGHT 6. LOWER LINE RIGHT

2. ROLLBACK LINE 5. LOADER VALVE 7. RAISE LINE LEFT
3. LOWER LINE LEFT
LOADER CONTROL VALVE LINE CONNECTIONS
8001-6
STEP 9 Installation
Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5,
IMPORTANT: Before installing the fittings or
and 6) from the remote control valve(s) at the loader
connecting the tubes to the fittings, install new
control valve. Refer to the illustration on page 4 for
O-rings on the fittings.
color coding. Install a plug in each hose and a cap on
each fitting.
STEP 16
NOTE: Line 1, 2, 5, and 6 will need to be tagged as
right or left of valve.
STEP 10
Loosen and remove tilt cylinder lines (1 and 2). Install
a plug in each line and a cap on each fitting.
STEP 11
Loosen and remove lines (3 and 4). Install a plug in
each line and a cap on each fitting.
STEP 12 BC05M096
Loosen and remove lines (6 and 7). Install a plug in Install and align the loader control valve with the
each line and a cap on each fitting. valve mounting plate.
STEP 13 STEP 17
Loosen and remove supply and return lines. Install a Install the bolts and washers that fasten the loader
plug in each line and a cap on each fitting. control valve to the valve mounting plate. Tighten the
bolts.
STEP 14
Attach proper lifting equipment to lift loader control STEP 18
valve. Tighten the left lift cylinder lines (6 and 7).
STEP 15 STEP 19
Install and tighten the supply and return lines.
STEP 20
Install and tighten right lift cylinder lines (3 and 4).
STEP 21
Install and tighten tilt cylinder lines (1 and 2).
STEP 22
Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and
6) to the remote control valve(s) at the loader control
BC05M096
valve. Refer to the illustration on page 4 for color
Loosen and remove the three bolts and washers that
coding.
hold the loader control valve to the valve mounting
plate. Remove the loader control valve.
8001-7
STEP 23 STEP 27
Fill the hydraulic reservoir with oil. Refer to Section Run engine at half throttle.
1002 for the correct oil.
STEP 28
STEP 24 Slowly and completely extend and retract all
Tighten the accumulator manual bleeder valve cylinders at least 10 times to remove any air from the
located on the top of the ride control valve to a torque circuits.
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in). STEP 29
Stop the engine and check for leaks.
STEP 25
Place the master disconnect switch in the ON STEP 30
position. Install the access cover on the front of the machine.
STEP 26 STEP 31
Check the level of the hydraulic oil and add hydraulic
oil as required.
BD03A092
Raise the loader arms and remove the safety link.

8001-8
REMOTE CONTROL VALVE
Removal STEP 37
STEP 32
bucket to the floor. Stop the engine and apply the
parking brake.
circuit, turn ignition switch OFF. BD06F208
Open and remove the access panel.

STEP 33
Place the master disconnect switch in the OFF STEP 38
position.
STEP 34
Unlatch and open the right hand side access door.
STEP 35
Lift the access door up and remove the access door
from the pins.
STEP 36
BD06F209
Remove the front access panel.
STEP 39
BD06F207
Unlatch and open the window on the right hand side.
BD06F210
Disconnect the electrical connectors for the remote

control valve.
STEP 40
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.
8001-9
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install STEP 45
plugs in the hoses and caps on the fittings. Install new O-rings on the adapters for the remote
control valve.
STEP 42
Loosen and remove the screws and washers holding STEP 46
the hydraulic control tower cover. Remove the cover. Install the remote control valve and screws in the
hydraulic control tower and tighten the screws.
STEP 43
Loosen and remove the screws that fasten the STEP 47
remote control valve to the hydraulic control tower. Install the cover over the remote control valve and
install the screws and washers.
STEP 44
Remove the remote control valve from the hydraulic STEP 48
control tower. Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 11, 12, and 13 as necessary.
STEP 49
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 50
BD06F210
Connect the electrical connectors for the remote

control valve.
STEP 51
position.
STEP 52
Start the engine and run the engine at low idle.
STEP 53
Check to see that the remote control valve works
correctly.
8001-10
STEP 54 STEP 57
Check for hydraulic oil leakage at the remote control
valve.
STEP 55
Check the level of hydraulic oil in the reservoir and
add as required.
STEP 56
BD06F208
Install and close the access panel.
STEP 58
BD06F209
Position the access panel on the ROPS cab or the

ROPS canopy and install and tighten the screw.
BD06F207
Close the right hand window.

8001-11
3
8
6
7
1
5
7 8
7 5
1 2
8 3
6 4
BC05M092
1. PILOT TANK HOSE 4. ORANGE BLACK GREEN 7. GREEN WHITE GREEN

2. PILOT PRESSURE HOSE 5. GREEN BLACK GREEN 8. RED WHITE GREEN
3. YELLOW BLACK GREEN 6. RED BLACK GREEN
JOYSTICK AND 2 LEVER HOSE COLOR CODING
8001-12
5 5
7 1 4 7
3
4
6 3
2 1
6
2
7 7
7 7
1 1
2 2
6 6
3 3
4 5 4 5
BC05M091
1. PILOT TANK HOSE 1. PILOT TANK HOSE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK GREEN 3. RED BLACK GREEN
4. ORANGE BLACK GREEN 4. ORANGE BLACK GREEN
5. YELLOW BLACK GREEN 5. YELLOW BLACK GREEN
6. GREEN BLACK GREEN 6. GREEN BLACK GREEN
7. RED WHITE GREEN 7. RED WHITE GREEN
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING
8001-13
1
5
4 5 4 6
6 3 2
3 1
2
2 1 2 1
6 6
3 3
4 5 4 5
BC05M090

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING
8001-14
HYDRAULIC PUMP
10
7 15
4
6
4
16
5
8 15
6
2 13
3
14
11
9
12
BC05M095
1. PUMP MAIN HYDRAULIC 5. SPLIT FLANGE 9. STEERING HIGH PRESSURE 13. LOADER HIGH PRESSURE
2. MOUNT BOLTS 6. TUBE 10. CLAMPS 14. STEERING PRIORITY MANIFOLD
3. DRAIN HOSE 7. HOSE SUCTION 11. STEERING LOAD SENSE HOSE 15. CLAMPS
4. BOLT 8. HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE 16. FITTINGS
8001-15
Removal STEP 69
Connect lifting equipment to hydraulic pump (1). Take
NOTE: When disconnecting hydraulic fittings, plug
up all slack in lifting equipment. Remove four
hoses and cap fittings to prevent entry of foreign
mounting bolts (2) and washers securing pump to
matter into hydraulic system.
transmission. Pull hydraulic pump from transmission
and remove from loader. Remove and discard O-ring
STEP 59 from pump.
bucket to the floor. Stop the engine and apply the Installation
parking brake.
NOTE: Install new O-rings where required.
STEP 60
Place the master disconnect switch in the OFF STEP 70
position. Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
STEP 61 four washers and bolts (2) to secure pump (1) to
Loosen the filler cap on the reservoir to release any transmission, tighten the bolts. Disconnect lifting
air in the reservoir. Connect a vacuum pump to the equipment from pump.
STEP 71
STEP 62 Connect pump pressure hoses (9 and 13) to steering
Refer to Section 9007 and remove the ROPS cab or priority manifold (14).
ROPS canopy.
STEP 72
STEP 63 Connect drain hose (3).
Remove eight bolts (4) and washers. Remove four
split flanges (5). Disconnect tubes (6) with suction STEP 73
hoses (7) from hydraulic pump. Remove and discard Connect load sense hoses (11 and 12).
O-ring face seals from flange heads of tubes.
STEP 74
STEP 64 Install and connect case drain hoses (8).
Loosen clamps (10). Tag and disconnect suction
hoses (7) from hydraulic reservoir and remove from STEP 75
machine. Install suction hoses (7), tighten clamps (10) to 10 to
11 Nm (90 to 100 pound inches).
STEP 65
Tag and disconnect case drain hoses (8) from fittings STEP 76
(16); remove hoses (8). Remove and discard O-ring Install four split flanges (5). Install eight bolts (4) and
face seals from fittings. washers, tighten bolts (4) to 73 to 90 Nm (53.8 to
66.3 pound feet).
STEP 66
Tag and disconnect load sense hoses (11 and 12). STEP 77
Remove and discard O-ring face seals from fittings. Refer to Section 9007 and install the ROPS cab or
ROPS canopy.
STEP 67
Tag and disconnect drain hose (3). Remove and STEP 78
discard O-ring face seals from fittings. Turn off the vacuum pump and disconnect from the
STEP 68
Tag and disconnect pump pressure hoses (9 and 13) STEP 79
from steering priority manifold (14). Remove and Place the master disconnect switch in the ON
discard O-ring face seals from flange heads of position.
hoses.
8001-16
STEP 80 STEP 81
Start the engine and run the engine at low idle for two Stop the engine and check for hydraulic oil leakage at
minutes. the hydraulic pump.
NOTE: If any unusual vibration is heard coming from
the pump, stop the machine immediately and check STEP 82
for obstructions in the pump suction line. Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
8001-17
LIFT CYLINDERS
Removal STEP 87
STEP 83
parking brake.
BD01D709
STEP 84 Loosen and remove the bolt, washer and spacer that
Relieve the pressure in the ride control accumulator hold the pivot pin for the yoke.
with the manual bleeder valve located at the rear of
the front chassis. STEP 88
STEP 85
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 86
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 89
BD01D708
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.
8001-18
STEP 93
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 94
BD01D710
Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.
STEP 91
BD01D714
Use a proper lifting device and position the lift

cylinder on the machine.
STEP 95
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 92
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.
8001-19
STEP 96 STEP 99
BD01D710 BD01D712
Align the pivot pin with the front frame and install the Install the pivot pin for the yoke. Stop the engine.
spacer, washer and bolt. Tighten the bolt.
STEP 100
STEP 97
BD01D709
BD01D708 Align the pivot pin with the yoke and install the
Remove the caps and plugs and connect the hoses spacer, washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 101
STEP 98 SLOWLY extend and retract the piston rod three
If the yoke of the lift cylinder is not aligned with the times to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 102
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 103
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the
8001-20
BUCKET CYLINDER - Z-BAR LOADER
Removal STEP 108
STEP 104
parking brake.
STEP 105
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 106
BD01D695
Loosen and remove the two bolts that fasten the

mounting bracket to the machine. Remove the
mounting bracket.
STEP 109
BD01D694
Disconnect the proximity switch connector from the

wiring harness connector.
STEP 107
BD01D697

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.
BD01D696

target bar to the mounting bracket. Remove the
target bar.
8001-21
STEP 110 STEP 113
BD01D699 BD01D701
Disconnect the hoses from each side of the bucket Remove the pivot pin from the rod end of the bucket
cylinder. Install plugs in the hoses and caps on the cylinder.
fittings.
STEP 114
STEP 111
BD01D704
BD01D700 Remove the pivot pin from the head end of the bucket
Use acceptable equipment to hold the bucket cylinder.
cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
STEP 112 replaced.
STEP 115
BD01D698
Loosen and remove the bolt, washer and spacer that

fasten the pivot pin from both ends of the bucket
BD01D706
cylinder.
Raise the bucket cylinder and remove the cylinder
from the machine.
8001-22
STEP 116
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 117
BD01D699
Connect the hoses to each side of the bucket

cylinder.
STEP 121
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD01D706
engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 118 STEP 122

Install the pivot pin and stop the engine.
STEP 123
BD01D704
Install the pivot pin to the head end of the bucket

cylinder.
BD01D698
STEP 119 Install the spacer, washer and bolt that fasten the
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
pivot pin to the front frame. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect
the grease line to the pivot pin.
8001-23
STEP 124 STEP 127
BD01D697 BD01D694
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 125 STEP 128

See Section 9006 for the adjustment procedure for
adjusting the proximity switch.
STEP 129
Start and run the engine at low idle.
STEP 130
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 131
Lubricate the pivot pins with molydisulfide grease.
BD01D695
Install the two bolts for the mounting bracket for the STEP 132
target bar.
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
STEP 126 hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.
8001-24
OIL COOLER
Removal STEP 138
STEP 133
parking brake.
STEP 134
position.
STEP 135
Raise the engine hood and remove the shield on the
right side of the machine between the tire and the oil BD03A154
cooler. Disconnect the top hose and install a plug in the hose
and a cap on the fitting.
STEP 136
STEP 139
BD03A120
Have assistant hold side panel in raised position,

BD03A179
remove two mounting screws, remove side panel.
Loosen and remove the bolt and washer that fasten
the oil cooler to the cooling frame.
STEP 137
STEP 140
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
BD06H195
Disconnect the hose from the bottom of the oil cooler.
Install a plug in the hose and a cap on the fitting.
Remove the two mounting nuts, remove the oil cooler
from the machine.
8001-25
STEP 141
BD03A120
Have assistant hold side panel in raised position,

install and tighten two mounting screws.
BD06H195
Place the oil cooler in position in the cooling frame.

Connect the lower hose to the oil cooler, install and STEP 145
tighten the two mounting nuts. Turn off the vacuum pump and disconnect from the
STEP 142
STEP 146
position.
STEP 147
Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 148
Install the shield between the right rear tire and the
oil cooler and tighten the two bolts holding the shield.
BD03A179
Install the bolt and washer that fasten the oil cooler to STEP 149
the cooling frame Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
STEP 143
BD03A154
Connect the hose to the top of the oil cooler.

8001-26
RIDE CONTROL ACCUMULATOR
Removal STEP 153
STEP 150
parking brake.
circuit, turn ignition switch OFF. BD06H196
Disconnect the hose from the elbow at the bottom of
STEP 151 the ride control accumulator. Install a plug in the hose
and a cap on the fitting.
STEP 154
BD06H198

the ride control valve. Remove the plug and turn the BD06H197
valve two turns counter-clockwise. Loosen and remove the nuts and washers from the
U-bolt. Remove the U-bolt.
STEP 152
STEP 155
accumulator bracket to the front frame. Remove the
ride control accumulator from the machine.
pump.
8001-27
STEP 156
Place the ride control accumulator in position on the
front frame.
STEP 157
Install the two bolts that fasten the accumulator
bracket to the front frame. Tighten the bolts.
STEP 158
BD06H196
Remove the caps and plugs and install the hose on

the elbow at the bottom of the r ide control
accumulator.
STEP 160
Turn off and disconnect the vacuum pump from the
STEP 161
BD06H197
Tighten the accumulator manual bleeder valve
Install the U-bolt, washers and nuts. Tighten the nuts. located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).
STEP 162
Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.
STEP 163
8001-28
RIDE CONTROL VALVE
Removal STEP 166

STEP 164 release the air pressure in the reservoir. Connect a
Park the machine on a level surface and lower the vacuum pump to the hydraulic reservoir, turn on the
bucket to the floor. Stop the engine and apply the pump.
parking brake.
STEP 167
position.
loader control valve back and forth several times to STEP 168
release any hydraulic pressure in the pilot control Disconnect the electrical connector on top of the ride
circuit, turn ignition switch OFF. control valve.
STEP 165 STEP 169

Tag and disconnect the hoses from the ride control
valve. Install a plug in the hoses and caps on fittings.
STEP 170
Loosen and remove the two bolts and washers that
fasten the ride control valve to the frame.
STEP 171
Remove the ride control valve from the machine.
STEP 172
BD06H198 Remove and discard all O-rings.
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.
8001-29

Connect the electrical connector to the ride control
STEP 173 valve.
Install the ride control valve in position on the front
frame. STEP 179
STEP 174 hydraulic reservoir.
Install the washers and bolts through the frame and
into the ride control valve. Tighten the bolts. STEP 180
STEP 175 position.
STEP 181
Start and run the engine at low idle for two minutes.
STEP 182
Stop the engine and check for hydraulic oil leakage at
the ride control valve.
STEP 183
BD06H198 hydraulic reservoir.
Tighten the accumulator manual bleeder valve
located on the top of the ride control valve to a torque STEP 184
of 3.5 Nm (31 lb-in). Install the plug and torque to Refer to Section 8002 and perform the Ride Control
7 Nm (62 lb-in). Test Procedure.
STEP 176
Lubricate and install new O-rings.
STEP 177
Connect the hoses to the ride control valve.
8001-30
FAN REVERSING VALVE
Removal STEP 188
STEP 185
parking brake.
the brake repeatedly to be sure the brake 2
1
BD03A174
STEP 186 Tag and disconnect the fan forward hose (1) from the
Loosen the filler cap on the hydraulic reservoir to fan reversing valve. Install a plug in the hose and a
release the air pressure in the reservoir. Connect a cap on the fitting. Tag and disconnect the fan reverse
vacuum pump to the hydraulic reservoir, turn on the hose (2) from the fan reversing valve. Install a plug in
pump. the hose and a cap on the fitting.
STEP 187 STEP 189
3
4
BD03A173
BD03A174
Tag and disconnect the fan valve return hose (3) from
Disconnect the electrical connector for the fan the fan reversing valve. Install a plug in the hose and
reversing valve. a cap on the fitting. Tag and disconnect the fan valve
supply hose (4) from the fan reversing valve. Install a
plug in the hose and a cap on the fitting.
STEP 190
Loosen and remove the nuts, washers and bolts.
STEP 191
Remove the fan reversing valve from the machine.
STEP 192
Remove and discard all O-rings from the fittings.
8001-31
STEP 193
Place the fan reversing valve into position on the
machine.
STEP 194
Lubricate and install new O-rings in the fittings.
STEP 195
Install the bolts, washers and nuts. Tighten the nuts.
STEP 196
BD03A174
Connect the electrical connector for the fan reversing

valve.
STEP 199
STEP 200
3 Check the level of the hydraulic oil in the reservoir.
4
STEP 201
BD03A173
Connect the fan valve supply hose (4) to the fitting on Start the engine and run the engine at low idle for two
the fan reversing valve. Connect the fan valve return minutes.
hose (3) to the elbow on the fan reversing valve.
STEP 202
STEP 197 Stop the engine and check for hydraulic oil leakage at
the fan reversing valve.
STEP 203
reservoir.
BD03A174
Connect the fan reverse hose (2) to the fitting on the

fan reversing valve. Connect the fan forward hose (1)
to the fitting on the fan reversing valve.
8001-32
THERMAL VALVE
STEP 204 STEP 208
Park the machine on a level surface and lower the Place the thermal valve into position on the machine.
parking brake. STEP 209
IMPORTANT: With the engine NOT running, pump Lubricate and install new O-rings in the fittings.
accumulators have no hydraulic pressure, put the STEP 210
ignition switch in the ON position then move the Install the bolts, washers and nuts. Tighten the nuts.
release any hydraulic pressure in the pilot control STEP 211
Connect the hoses to the thermal valve, remove and
discard tags.
STEP 205
Loosen the filler cap on the hydraulic reservoir to STEP 212
pump.
STEP 213
STEP 206
Check the level of the hydraulic oil in the reservoir.
STEP 214
Start the engine and run the engine at low idle for two
minutes.
STEP 215
Stop the engine and check for hydraulic oil leakage at
the thermal valve.
STEP 216
BD06F211
Tag and disconnect the hoses from the thermal valve. and add as required. Tighten the filler cap on the
Install a plug in the hose and a cap on the fitting. reservoir.
STEP 207
Remove the mounting bolts from the thermal valve,
remove the valve from the machine.
8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS
8002-2
TABLE OF CONTENTS
821F - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TESTING AND ADJUSTING THE HIGH PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TESTING AND ADJUSTING THE LOW PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8002-3
821F - SPECIFICATIONS
Manufacturer........................................................................................................................................ Bosch-Rexroth
High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 3600 psi at 2000rpm)
Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2000 psi at 2000rpm)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Circuit relief valve pressure setting
Auxiliary A and B port.................................................................................................................290 bar (4200 psi)
Bucket A port..............................................................................................................................290 bar (4200 psi)
Bucket B port..............................................................................................................................290 bar (4200 psi)
Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Brake accumulator pressure .......................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.
8002-4
921F - SPECIFICATIONS
Manufacturer ....................................................................................................................................... Bosch-Rexroth
High pressure pump (closest to transmission) ............................................... 170 L/min at 24822 kPa, at 2000 r/min
(44.9 gpm at 3600 psi at 2000rpm)
Low pressure pump (furthest from transmission) ........................................... 120 L/min at 24822 kPa, at 2000 r/min
(31.6 gpm at 2000 psi at 2000rpm)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Auxiliary A and B port ................................................................................................................290 bar (4200 psi)
Bucket A port..............................................................................................................................290 bar (4200 psi)
Bucket B port..............................................................................................................................290 bar (4200 psi)
Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi)
Steering relief valve pressure setting ............................................................................................ See Section 5002
Brake accumulator pressure .......................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.
8002-5
SPECIAL TOOLS
633L95 B877168V
CAS-1904 PRESSURE FITTING KIT CAS-1808 FLOWMETER FITTING KIT
632L95 B877895M
CAS-1906 PRESSURE FITTING KIT CAS-10090 HAND PUMP
B785789M B877558M
CAS-10280 FLOWMETER CAS-1804 PRESSURE FITTING KIT
8002-6
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and

damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is Fill the hydraulic reservoir with the hydraulic oil
No specified in Section 1002.
the oil level correct?.
Yes
Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.
Problems in All Circuits

Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for contaminated See Page 19. Do the flow meter test of the
No hydraulic pump.
oil. Is the oil contaminated?
Yes
See Section 8003 and clean or replace the

oil.
Problem in All Loader Circuits

See Page 12 and check the pressure setting
Adjust the limit pressure. See page 12 in this
of the limit pressure in the loader control valve. No section.
Is the pressure setting correct?
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.
8002-7
Problem in a Single Loader Circuit

Star t and run the engine at full throttle. The loader control valve is damaged. See
Operate the control for the bad circuit. Does No Section 8005 and repair the loader control
the cylinder move in both directions? valve
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 21. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of c o n t r o l va l ve a n d c h e ck fo r wo r n o r
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes
See Page 14. Do the Steering Pump Limit

Pressure Test and Adjustment
Problem in the Ride Control

Lift ar ms rapidly and continuously sink See the Ride Control Test Procedure page
towards the ground. No 22 in this section.
Yes
Check the manual bleed valve for the ride

control accumulator to be sure that it is
closed.
8002-8
TESTING AND ADJUSTING THE HIGH PRESSURE

PUMP DIFFERENTIAL PRESSURE
Pressure Check STEP 3
STEP 1
BD06G180
BD00M041
1. ARTICULATION LOCK 2
Install articulation lock (1).
STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54°C to 57°C (129°F to 135°F). The following
is the procedure for heating the hydraulic oil.
BD06F148
● To measure the oil temperature with the instrument 1. TEST PORT (LOAD SENSE)
cluster: 2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to
B. Stop at the info screen with the temperatures the test port (2) located on the priority valve, and one
that need to be monitored are on. on the pump load-sense pressure tap (1 closest to
● To heat the hydraulic oil do the following: transmission).
A. Start the engine and run at full throttle. IMPORTANT: Do not steer or operate loader controls
while the gauges are connected, gauges could be
B. Hold the bucket control lever in the damaged.
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full STEP 4
height.
Start the engine and run at low idle.
C. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to STEP 5
135°F).
Make sure all of the controls are in the neutral
After heating oil to operating temperature, lower position and record the readings on the test gauges
bucket to the ground, turn off the engine, and relieve (1) and (2).
all pressure in the hydraulic system.
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).
8002-9
STEP 7 Adjusting the High Pressure Pump
The difference between the two readings should be Differential Pressure
24 to 27 bar (350 to 390 psi).
STEP 9
STEP 8
The load-sense adjusting screw is directly below the
If this reading is more or less than specified, it will be load-sense pressure tap. Turn the screw clockwise to
necessary to adjust the pump load-sense pressure. increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense
pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).
8002-10
TESTING AND ADJUSTING THE LOW PRESSURE

PUMP DIFFERENTIAL PRESSURE
STEP 1
BD06G180
1
2
BD00M041
STEP 2
BD06F148
● To measure the oil temperature with the instrument 1. TEST PORT (LOAD SENSE)
cluster: 2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to
B. Stop at the info screen with the temperatures the test port (2) located on the priority valve, and one
that need to be monitored are on. on the pump load-sense pressure tap (1 furthest
● To heat the hydraulic oil do the following: from the transmission).
A. Start the engine and run at full throttle. IMPORTANT: Do not steer of operate loader controls
while the gauges are connected, gauges could be
B. Hold the bucket control lever in the damaged.
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d
lowering the lift arms from ground level to full STEP 4
height.
Start the engine and run at low idle.
of the hydraulic oil is 54° to 57°C (129° to STEP 5
135°F).
Make sure all of the controls are in the neutral
After heating oil to operating temperature, lower position and record the readings on the test gauges
bucket to the ground, turn off the engine, and relieve (1) and (2).
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).
8002-11
STEP 7 Adjusting the Low Pressure Pump
The difference between the two readings should be Differential Pressure
25 to 28 bar (360 to 400 psi).
STEP 9
STEP 8
The differential adjusting screw is directly below the
If this reading is more or less than specified, it will be load-sense pressure tap. Turn the screw clockwise to
necessary to adjust the pump differential pressure. increase the load-sense pressure. Turning the screw
counterclockwise will decrease the differential
pressure.
8002-12
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE

STEP 1 at least 54°C to 57°C (129°F to 135°F). The following
● To measure the oil temperature with the instrument
cluster:
that need to be monitored are on.
● To heat the hydraulic oil do the following:
A. Start the engine and run at full throttle.
1 B. Hold the bucket control lever in the
RO L L B AC K p o s i t i o n w h i l e r a i s i n g a n d
lowering the lift arms from ground level to full
BD00M041
height.
of the hydraulic oil is 54° to 57°C (129° to
135°F).
STEP 2 After heating oil to operating temperature, lower
bucket to the ground, turn off the engine, and relieve
STEP 4
1 Run the engine at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
Record the reading on the test gauge.
BD06F148
1. TEST PORT (LOAD LIMIT) STEP 7

Reading should be 248 to 255 bar (3600 to 3700 psi).
Connect a 345 bar (5000 psi) test gauge to the test
port (1), located on the priority valve. STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump limit pressure.
8002-13
Adjusting the Loader Limit STEP 9

Pressure The limit adjusting screw is located on the left side of
the loader valve. Tur n the screw clockwise to
increase the limit pressure. Turning the screw
counterclockwise will decrease the limit pressure.
BD06H193
8002-14
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE

cluster:
BD00M041
height.
135°F).
STEP 4
1 Start the engine and run at full throttle.
STEP 5
Steer hard in either direction over relief pressure.
STEP 6
BD06F148
1. TEST PORT (LOAD LIMIT) STEP 7

Connect a 345 bar (5000 psi) test gauge to the test
port (1), located on the priority valve. STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the steering limit pressure.
8002-15
Adjusting the Steering Limit STEP 9

Pressure The steering priority valve is located on the hydraulic
p u m p, t h e a d j u s t i n g va l ve i s l o c a t e d o n t h e
transmission side of the priority valve. Turning the
screw clockwise to increase the limit pressure.
Turning the screw counterclockwise will decrease the
limit pressure.
BD06F147
1. STEERING LIMIT VALVE

8002-16
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE

cluster:
BD00M041
height.
135°F).
1 all pressure in the hydraulic system.
STEP 4
Start the engine and run at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
BD06F148
1. TEST PORT (PUMP PRESSURE) STEP 7

Connect two 345 bar (5000 psi) test gauge to the test
port (1) located on the large hydraulic tube on the STEP 8
bottom of the pump. If this reading is more or less than specified, it will be
necessary to adjust the pump cutoff pressure.
8002-17
Adjusting the Loader Pump Cutoff

Pressure
STEP 9
BD06G179
The unloading adjuster is the longer of the two

adjusters on the loader pump. Tur n the screw
clockwise to increase the cutoff pressure. Turning the
screw counterclockwise will decrease the cutoff
pressure.
NOTE: The adjusting screw is located just above the
steering priority valve on the pump furthest from the
transmission.
8002-18
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE

NOTE: This pressure is factory preset and is not STEP 6
adjustable. Open the right side compartment to gain access to
the loader control handle.
Pressure Check
STEP 7
STEP 1 Attach a gauge capable of reading 70 bar (1000 psi)
Make sure that the temperature of the hydraulic oil is to the test port under loader control handle.
is the procedure for heating the hydraulic oil. STEP 8
● To measure the oil temperature with the instrument Start and run the machine at low idle, hold the bucket
cluster: control lever in the ROLLBACK position to increase
the system pressure.
B. Stop at the info screen with the temperatures STEP 9
that need to be monitored are on. A pressure reading of 29.5 to 39.5 bar (425 to 575
● To heat the hydraulic oil do the following: psi) should be obtained, if pressure is not as
specified do the following steps.
B. Hold the bucket control lever in the STEP 10
RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d Lower the bucket to the ground and turn off the
lowering the lift arms from ground level to full engine. Turn the ignition switch to the “RUN” position.
height.
C. Continue this procedure until the temperature STEP 11
of the hydraulic oil is 54° to 57°C (129° to Operate the pilot controls several times until the
135°F). gauge pressure suddenly drops to zero. The last
pressure reading before the drop to zero is the
STEP 2 nitrogen charge pressure in the accumulator. If the
pressure is below 13 to 15 bar (188 to 218 psi),
Raise lift arms to the top and turn off the engine. Turn
replace the accumulator. If accumulator test is good,
the ignition switch to the “RUN” position.
go to next step.
STEP 3 STEP 12
Repeatedly put the loader control lever into “FLOAT”
Replace the pilot controls, see section 8001, retest
position and back to neutral.
the system, if test fails go to next step.
STEP 4 STEP 13
The system should allow a minimum of 10 actuations
Replace the loader control valve, see section 8001,
into float and still cause the lift arms to come down.
retest the system.
NOTE: If 10 full actuations cannot be made, an
internal hydraulic leak exists, proceed to next step.
STEP 5
Start machine and lower the bucket to the ground
and turn off the engine. Turn the ignition switch to the
“RUN” position, operate the pilots controls a
minimum of 30 strokes to relieve any pressure in the
system.
8002-19
HIGH PRESSURE PUMP FLOW TEST

NOTE: The pump differential pressure must be set STEP 6
before attempting any other tests. Refer to page 8 of Using the temperature gauge on the flow meter,
this section. continue to run the engine at high idle until the
temperature of the hydraulic oil is at least 52°C to
STEP 1 60°C (125°F to 140°F).
Connect the flow meter (3) by disconnecting the inlet
hose (6) to the valve supply tube (13), installing a cap STEP 7
(12) on the fitting at the valve supply tube (13). Refer Run the engine at low idle, fully open the flow meter
to illustration on page 20. valve.
STEP 2 STEP 8
Disconnect the load sense hose (7) and install a cap Open the needle valve (8) and operate the engine at
(12) the fitting at the loader valve (15). 2000 rpm. At 0 bar (0 psi) the flow should be 250 to
NOTE: This is the line that returns to the pump 255 L/min (66 to 67.4 gpm).
compensator valve.
STEP 9
STEP 3 Close the flow meter valve slowly and read the flow
Connect a “T” fitting (10) into the loader control valve at 34.5 bar (500 psi) the flow should be 249 to 255
inlet hose (6) and to the flow meter inlet hose (11). L/min (65.8 to 66.8 gpm).
STEP 4 STEP 10
Use a union (9) and connect an in line needle valve Close the flow meter valve slowly and read the flow
(8) to the open port in the “T” fitting (10), connect the at 2000 psi @ 2000 rpm. The flow should read 244.5
load sense hose (7) to the needle valve (8). to 247.5 L/min (64.6 to 65.4 gpm).
STEP 5 STEP 11
Make sure that the flow meter valve and the installed Continue to close the flow meter valve slowly, at
needle valve are in the open position. Start and run approximately 2900 psi the flow should drop
the engine at high idle, slowly close the flow meter significantly, this will be the low pressure pump
valve until a pressure reading of 103 bar (1500 psi) is destroking.
obtained.
STEP 12
Continue slowly closing the flow meter valve until
3500 psi is reached. The flow should read between
120 to 122 L/min (31.6 and 32.1 gpm).
STEP 13
If any of the pump flow readings are not within
specifications, the pump may be out of calibration
and Technical Support Services should be contacted.
8002-20
2 4
3
5
6
11
12
13
7
10
9
12
8
14
15
BS06G117
1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB 11. FLOW METER INLET HOSE
2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP
3. FLOW METER 8. NEEDLE VALVE 13. VALVE TUBE SUPPLY
4. PUMPS 9. UNION 14. ELBOW M14 ORB
5. PRIORITY VALVE 10. T FITTING 15. LOADER VALVE
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
8002-21
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Remove the safety strut and lower the bucket to the
STEP 1 floor. Shut off the engine. Find an easy place to
Circuit relief valves are located as shown below. disconnect the line for the circuit to be tested.
4 STEP 5
3 5
1 Connect the hand pump to the disconnected line that
1 goes to the loader control valve.
2
STEP 6
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21°C (70°F).
STEP 7
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
6 be sure of the reading.
STEP 8
Compare the reading to the specifications on Page 3.
STEP 9
1 If the pressure is not correct, adjust the circuit relief
1
valve.
3 5
4 Adjustment
BS03B022
1. CIRCUIT RELIEF VALVES STEP 1

2. PUMP LIMIT PRESSURE ADJUSTMENT Loosen the lock nut. Turn the adjustment screw
3. BUCKET SPOOL
clockwise to increase the pressure or
4. LIFT SPOOL
counterclockwise to decrease the pressure.
5. AUXILIARY SPOOL
6. LOADER CONTROL VALVE NOTE: One turn of the adjusting screw will change
STEP 2
Raise the lift arms and install the safety link on the lift STEP 2
arm cylinder. Check the pressure again. Repeat the adjustment as
necessary.
STEP 3
Loosen and remove the bolts and washers that
fasten the access cover plate for the loader control
valve. Remove the cover plate.
8002-22
TESTING THE RIDE CONTROL

STEP 1 STEP 6
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP 2
Install the ar ticulation lock, star t the machine, STEP 7
activate the parking brake.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
STEP 3 their stops, place the pilot control lever in the neutral
With the pilot controller in neutral, set the ride control position.
rocker switch on the right side console to the “Always
On” position and observe the switch lamp, the lamp STEP 8
should illuminate.
Set the ride control rocker switch to the “Always On”
position. The lift arms should rise 15 to 30 cm (6 to
STEP 4 12 inches) with an empty bucket.
Set the ride control rocker switch to the “Off” position
and observe the switch lamp, the lamp should go out. NOTE: Test results will be for a machine with a
empty factory bucket and no attachments.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not STEP 9
illuminate see section 4002 and troubleshoot the
If there is little or no lift arm raise, the test may have
electrical system for the ride control.
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
STEP 5
Raise the lift arms to the top of their travel and dump NOTE: If test was done to slowly repeat in the
the bucket. allotted time.
STEP 10
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator, see section 8013.
8002-23
HYDRAULIC COMPONENT LOCATIONS
5
6 8
7
9
4 10
2 8
3
11
15 12
14 13
16
19
18
17
1
BC00N140
1. REAR BRAKE CYLINDERS 11. FRONT BRAKE CYLINDERS
2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC 12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND
COUPLER RIDE CONTROL VALVE (OPTIONAL)
3. BRAKE ACCUMULATORS 13. PARKING BRAKE CYLINDER
4. FRONT AND REAR AXLE BRAKE PRESSURE 14. STEERING PRESSURE DIAGNOSTIC COUPLER
DIAGNOSTIC COUPLERS 15. STEERING PRIORITY VALVE
5. BRAKE LIGHT PRESSURE SWITCH 16. STEERING CYLINDERS
6. BRAKE WARNING PRESSURE SWITCH 17. AUXILIARY STEERING PUMP AND MOTOR
7. BRAKE AND ACCUMULATOR CHARGING VALVE
18. AUXILIARY STEERING PRIORITY VALVE
8. LIFT CYLINDERS
19. AUXILIARY STEERING PRESSURE SWITCH
9. BUCKET CYLINDER (TILT CYLINDER)
10. RIDE CONTROL ACCUMULATOR
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
8002-24
23
24
21 25
26
22
20
30
29 27
28
31
32
33
34
BC00N140
20. FAN DRIVE MOTOR 28. PUMP PRESSURE DIAGNOSTIC COUPLER

21. HYDRAULIC RESERVOIR BREATHER 29. LOAD SENSING DIAGNOSTIC COUPLER
22. HYDRAULIC RESERVOIR 30. IMPLEMENT HYDRAULIC PUMP
23. PILOT PRESSURE DIAGNOSTIC COUPLER 31. HYDRAULIC FILTER
24. PILOT CONTROL VALVE 32. HYDRAULIC COOLER
25. PILOT PRESSURE ACCUMULATOR 33. BRAKE HYDRAULIC PUMP
26. LOADER CONTROL VALVE 34. FAN VALVE
27. PARKING BRAKE ACCUMULATOR
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
8002-25
NOTES
8002-26
Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM
8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8003-3
SPECIAL TOOLS
806128
CAS10508, fitting kit.
806127
CAS101162A, filter unit, portable.
TR98H032
CAS10192, vacuum pump.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check the
hydraulic system permits efficient operation with a hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.
8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.
8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.
8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39-4
NOTE: Any attachment or part of an attachment that 18. Slowly and completely extend all cylinders. As
is raised must be supported with acceptable the piston rod comes in/out of the cylinder, oil will
equipment to prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that
release pressure in the hydraulic circuits. is raised must be supported with acceptable
4. Loosen and remove the filler cap from the equipment to prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.
8003-8
NOTES
Section
8004
8004
HYDRAULIC PUMP
8004-2
TABLE OF CONTENTS
821F - PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
921F - PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8004-3
821F - PUMP SPECIFICATIONS

High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 3600 psi at 2000rpm)
Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2000 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts...................................................................................................165 Nm (121.5 pound-feet)
Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet)
Control piston plug ..............................................................................................................90 Nm (66 pound-feet)
921F - PUMP SPECIFICATIONS

)
High pressure pump (closest to transmission) ............................................... 170 L/min at 24822 kPa, at 2000 r/min
(44.9 gpm at 3600 psi at 2000rpm)
Low pressure pump (furthest from transmission) ........................................... 120 L/min at 24822 kPa, at 2000 r/min
(31.6 gpm at 2000 psi at 2000rpm)Rotation .......................................... Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts...................................................................................................165 Nm (121.5 pound-feet)
Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet)
Control piston plug...................................................................................................................90 Nm (66 pound-feet)
PREPARING THE EQUIPMENT PUMP FOR USE

Do the following procedure any time you install a new 4. Repeat Step 3 for three minutes.
or overhauled equipment pump:
5. Increase the engine speed to full throttle and
1. Start and run the engine at half throttle for three repeat Steps 3 and 4.
minutes.
6. Stop the engine and check for leaks.
2. With the engine running at half throttle, move the
7. Replace the hydraulic filter.
bucket control lever into roll back position. Hold
the bucket control lever in this position until the
bucket stops moving.
3. Hold the bucket control lever in the roll back
position for five seconds. Then put the bucket
control lever in the NEUTRAL position for five
seconds.
8004-4
EQUIPMENT PUMP
7 8 9
6 5
5 4
4
3
10
2 11
1
12 24
13 23
22
21
20
19
18
17
15
14 16
30
29
15 28
27
26
25
BC06F550
1. SNAP RING 11. TAPERED BEARING 21. PRESSURE PINS

2. SEAL 12. BEARING RACE 22. BACKUP PLATE
3. MAIN BODY 13. SHIM 23. SPRING
4. O-RING 14. SPRING 24. SNAP RING
5. PLUG 15. HALF BEARING 25. PORT PLATE
6. CONTROL VALVE 16. SWASH PLATE 26. SHIM
7. CAP SCREW 17. PISTONS 27. TAPERED BEARING
8. PISTON ROD 18. RETAINING PLATE 28. BEARING RACE
9. CONTROL PISTON 19. BALL 29. DOWEL PIN
10. SHAFT 20. CYLINDER 30. END COVER
8004-5
Disassembly STEP 3
STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.
STEP 2
BC06F552
Remove the control valve.
STEP 4
BC06F551
Put alignment marks on the end cover and housing.
BC06F553
Remove the four bolts.

8004-6
STEP 5 STEP 6
BC06F555
BC06F554
Remove the end cover. Use a suitable bearing race puller and pull the
bearing race from the end cover.
NOTE: Watch for the flow plate, it can be stuck to
either the end cover or pump body. NOTE: Do not damage the sealing surfaces.
8004-7
STEP 7 STEP 9
BC06F558
Remove plug, pull control piston using a suitable tool

as shown.
NOTE: Do not use a magnet to pull the piston.
STEP 10
BC06F556
Remove the bearing and shim.
STEP 8
BC06F559
Remove the piston rod and swash plate. Turn the

swash plate slightly to break it free from the bearings.
BC06F557
Remove the rotary group from the housing in a

horizontal position.
8004-8
STEP 11 STEP 14
BC06F560
Remove the bearing and spring.
STEP 12
BC06F563
Use a suitable bearing race puller and pull the

bearing race from the housing.
STEP 15
BC06F561
Remove the shaft and bearing.
STEP 13
BC06F564
Remove the shim and plug.
BC06F562
Remove the retaining ring an seal.

8004-9
Inspection STEP 19
STEP 16
Clean all parts in cleaning solvent. Be careful not to
remove the alignment mar ks made dur ing
disassembly.
STEP 17
BC06F567
Check the bearing surface.
STEP 20
BC06F565
Check for wear on the splines, seal areas for

grooves, bearing areas for scaring, and key set.
STEP 18
BC06F568
Check that the retaining plate is free of grooves and

that there is no sign of wear.
STEP 21
BC06F566
Check the surface that the pistons contact for

grooves and scaring.
BC06F569
Check the sliding surface for scratches or metal

deposits, check the tightness of the cup on the
piston.
NOTE: If a piston needs to be replaced, all of the
pistons must be replaced.
8004-10
STEP 22 STEP 24
BC06F572
BC06F570
Check the cylinder bores and splines for damage. Check cylinder surface for grooves, wear, embedded
particles. Check flow plate for scratches or wear.
STEP 23
STEP 25
BC06F571
BC06F573
Check ball for grooves and wear.
Check mounting surface for the flow plate for
damage.
8004-11
Assembly STEP 27
STEP 26
BC06F574 BC06F575
Install the plug in the housing and tighten to 127 Nm Put the shaft and bearing in the housing.
(93.5 pound-feet). Install shim and press in the
bearing race. STEP 28
BC06F576
Press in a new race into the end cover.

8004-12
STEP 29 STEP 31
BC06F579
Install the seal and retaining ring.
STEP 32
BC06F577
Install the end cover, 4 bolts and hand tighten.
STEP 30
BC06F578
A bearing pre load of 0.05 mm (0.002 inch) must be

obtained, add remove shims from bear ing as
required.
BC06F580
Put new bearings in the housing. Install the reaction

spring.
8004-13
STEP 33 STEP 34
BC06F582
Install the piston into the housing with flat surface

out. Lubricate the O-ring and install the plug, tighten
the plug to 90 Nm (66 pound-feet).
STEP 35
BC06F581
Install the swash plate into the housing, work the

swash plate from side to side to seat it in the
bearings and spring. Install the piston rod.
BC06F583
Use grease to hold the pressure pins into position,

install the spacer, spring and snap ring.
8004-14
STEP 36 STEP 39
BC06F584
Use a suitable compressor, compress the spring and

install the snap ring.
STEP 37
BC06F585 BC06F587
Place the ball onto the pressure pins, install the Hold the pistons in the rotating housing using an
pistons into the retaining plate. O-ring, install the rotating group into the housing,
remove the O-ring.
STEP 38
BC06F586
Lubricate the piston and retaining plate with clean oil,

install the piston into the rotating housing.
8004-15
STEP 40 STEP 41
BC06F588
Use the shim that was required for the bearing pre
load in step 30. Install the shim and bearing onto the
shaft.
BC06F589
Install a new O-ring on the end cover, place the flow

plate onto the rotating group with aligning notch up.
Place the end cover onto the housing, make sure that
the aligning pin in the end cover aligns with the slot in
the flow plate.
8004-16
STEP 42 STEP 43
BC06F591
Use new O-rings, install and tighten the control valve.
BC06F590
Instal and tighten the four bolts to 165 Nm

(121.5 pound-feet).
Section
8005
LOADER CONTROL VALVE
8005
8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8005-3
SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
Special Torques
End plate mounting bolts.................................................................................................. 70 Nm (51.5 pound feet)
Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound inches)
Allen head plugs.............................................................................................................. 240 Nm (177 pound feet)
Allen head locking screw................................................................................................ 100 Nm (73.7 pound feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches)
Anticavitation valves ....................................................................................................... 100 Nm (73.7 pound feet)
Combination anticavitation and circuit relief ................................................................. 200 Nm (147.5 pound feet)
Main relief valve pressure settings (XT and Z-Bar) ............................................... 248 to 252 bar (3596 to 3654 psi)
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A port (XT and Z-Bar) ....................................................................................................152 bar (2205 psi)
Bucket B port (XT and Z-Bar) ....................................................................................................290 bar (4206 psi)
8005-4
4
3
5
22
6
6 7
21
6
20
19 8
18
17
6 9
16
10
11
15 14
8
12 12
13
BS03C033
1. BOLT 7. LOAD SENSE SHUTTLE CHECK 13. FLOAT SOLENOID 18. LOAD CHECK
8. ANTICAVITATION AND CIRCUIT
2. WASHER 14. PLUG 19. FLOW LIMIT VALVE
RELIEF
15. REGENERATION CHECK
3. LOCKING SCREWS 9. LOAD SENSE BLEED DOWN ORIFICE 20. PRESSURE RELIEF VALVE
VALVE
4. PLATE 10. FLOW COMPENSATOR SPOOL 16. LOCKING SCREW 21. CONE
5. REGENERATION
11. HOUSING 17. SPRING 22. LOCKING SCREW
RELIEF VALVE
6. O-RINGS 12. PLUG
2 SPOOL VALVE HOUSING CONFIGURATION
8005-5
27
26
25
24
23
6 28
31 29
30
6
6
33 33 32
34
31
6
23 24
24 23
34 6
35
32
30
29
BC06F593
6. O-RINGS 27. BOLT 32. BOLT

23. SPRING RETAINER 28. PISTON 33. COVER
24. SPRING 29. CAP NUT 34. ADJUSTING ROD
25. SPRING 30. JAM NUT 35. SPOOL
26. COVER 31. PISTON
2 SPOOL VALVE SPOOL CONFIGURATION
8005-6
37
36
37
BS03C036
36. HOUSING 37. ANTICAVITATION AND CIRCUIT RELIEF

3 SPOOL MOUNTING CONFIGURATION
8005-7
38
39
BS03C035
38. NUT 39. STUD

4 SPOOL MOUNTING CONFIGURATION
8005-8
31 29
30
33
34
6 6
23
24
23 32
35
33 23
31 24
6
6
34
29
30 32
BS03C037
3 AND 4 SPOOL VALVE SPOOL CONFIGURATION
6. O-RINGS 31. PISTON

23. SPRING RETAINER 32. BOLT
24. SPRING 33. COVER
29. CAP NUT 34. ADJUSTING ROD
30. JAM NUT 35. SPOOL
8005-9
DISSASEMBLY
STEP 1 STEP 7
Remove valve from machine, see section 8001. Remove pressure relief valve (20).
STEP 2 STEP 8
Remove bolts (27), cover (26), springs (24 and 25), Remove flow limit valve (19).
and spring retainer (23).
STEP 9
STEP 3 Remove locking screw (16), spring (17), and cone
Remove bolts (32), covers (33), spring (24), and (18).
spring retainer (23).
STEP 10
STEP 4 Remove regeneration check valve (15).
Use wooden dowel or brass drift and push spools
(35) from housing (11). STEP 11
IMPORTANT: Do not force spools from housing, if Remove locking screw (14).
spool binds work back and forth until spool comes
out freely. STEP 12
NOTE: Repeat steps 3 and 4 for a 3 and 4 spool Remove load sense shuttle check valve (7).
valve configuration.
STEP 13
STEP 5 Remove locking screws (12).
Remove anticavitation valves (5, 8, 10, and 13).
STEP 14
NOTE: Repeat step for a 3 and 4 spool anticavitation
Remove pilot pressure reducing valve (9).
valves (37).
STEP 15
STEP 6
Remove bolts (1) and washers (2), remove plate (4)
Remove locking screw (22) and cone (21).
from housing (11).
NOTE: For 4 spool configuration remove nut (38)
from stud (39), remove housings (36) from housing
(11).
8005-10
STEP 16 STEP 18
2
1
2
1
1
1
BS03C025 BS03C027
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING

Remove and discard O-rings and thrust rings from Remove and discard O-rings and thrust ring from
pilot pressure reducing valve (9). locking screw (14).
STEP 17
2 STEP 19
1
2
1
1
3
1 1
BS03C026 2
1. O-RINGS 2. THRUST RINGS BS03C028
Remove and discard O-rings and thrust rings from 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL
flow limit valve (19).
Remove and discard O-rings, thrust ring, and spool
seal from anticavitation valve (5).
8005-11
STEP 20
1
1
2
BS03C029
1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (20).
STEP 21
1
2
1
2
BS03C030

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).
8005-12
STEP 22
BS03C031
1. O-RINGS 2. COIL
Remove and discard O-rings and thrust rings from anticavitation valve (13).
8005-13
STEP 23
3
4
2 1
1
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 37).
8005-14
INSPECTION
1. Discard all O-rings, thrust rings, and spool seals. 4. Check the parts of the pressure relief valve,
anticavitation valves, and the anticavitation and
2. Clean all parts in cleaning solvent.
circuit relief valves. Use new parts as necessary.
3. Check the spools and the spool bores for
Inspect the other parts of the control valve. If any of
damage and wear.
the parts are damaged, install new parts.
ASSEMBLY
STEP 1
3
4
A
2 1
1 See Note
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (8 and 37). Torque relief valve (A) into
anticavitation valve to 200 Nm (147.5 pound feet).
NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in
direction of arrow.
8005-15
STEP 2
A
1
BS03C031
1. O-RINGS 2. COIL
Install new O-rings and thrust rings on anticavitation valve (13). Hand tighten coil nut (A).
STEP 3
1
2
1
2
1 A
BS03C030

Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm
(73.7 pound feet).
8005-16
STEP 4
1
1
2
BS03C029

Install new O-rings and thrust rings on pressure relief valve (20).
8005-17
STEP 5 STEP 8
2 1
1
1
3
1 1
2
BS03C025 BS03C028
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL

Install new O-rings and thrust rings on pilot pressure Install new O-rings, thrust ring, and spool seal on
reducing valve (9). anticavitation valve (5).
STEP 6 STEP 9
Install and torque regeneration check valve (15) to
2
100 Nm (73.7 pound feet).
STEP 10
Install and torque locking screw (14) to 100 Nm
2 (73.7 pound feet).
1
1 STEP 11
Install and tighten load sense shuttle check valve (7).
STEP 12
BS03C026 Install and torque locking screws (12) to 240 Nm
1. O-RINGS 2. THRUST RINGS (177 pound feet).
Install new O-rings and thrust rings on flow limit valve
(19). STEP 13
Install and torque pilot pressure reducing valve (9) to
STEP 7 60 Nm (44 pound feet).
STEP 14
1 Install new O-rings on housing (11). Install plate (4),
bolts (1) and washers (2), onto housing (11). Torque
2 bolts to 70 Nm (51.5 pound feet).
1 NOTE: For 4 spool configuration install new O-rings

between housings (36) and housing (11), install nuts
(38) on studs (39). Torque nuts to 70 Nm (51.5 pound
feet).
STEP 15
BS03C027 Install anticavitation valves (5, 10, and 13) and torque
1. O-RINGS 2. THRUST RING to 100 Nm (73.7 pound feet).
Install new O-rings and thrust ring on locking screw NOTE: Repeat step for a 3 and 4 spool anticavitation
(14). valves (37).
8005-18
STEP 16 Circuit Relief Pressure Test
Install anticavitation valves (8) and torque to 200 Nm
(147.5 pound feet). STEP 1
Connect the hand pump to the port for anticavitation
STEP 17 and circuit relief valves (21).
Install and torque flow limit valve (19) to 20 to 25 Nm
NOTE: Repeat steps for machines that are
(177 to 221 pound inches).
configured with a 3 or 4 spool valve.
STEP 18 STEP 2
Install cone (18), spring (17), locking screw (16).
Make sure that the hand pump is full of hydraulic oil
Torque locking screw to 100 Nm (73.7 pound feet).
and that the temperature of the oil is approximately
21°C (70°F).
STEP 19
Install cone (21) and locking screw (22). Torque STEP 3
locking screw to 40 Nm (30 pound feet).
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
STEP 20 be sure of the reading.
Lubricate spools with hydraulic oil and push spools
(35) into housing (11). STEP 4
IMPORTANT: Do not force spools into housing. Compare the reading to the specifications on Page 3.
STEP 21 STEP 5
Install spring retainers (23), springs (24), covers (33), If the pressure is not correct, adjust the circuit relief
and bolts (32). Torque bolts to 10.4 Nm (92 pound valve.
inches).
NOTE: Repeat steps 18 and 19 for a 3 and 4 spool Circuit Relief Adjustment
valve configuration.
STEP 1
STEP 22 Loosen the lock nut. Turn the adjustment screw
Install spring retainers (23), spring (24 and 25), cover clockwise to increase the pressure or
(26), and bolts (27). Torque bolts to 6 Nm (53 pound counterclockwise to decrease the pressure.
inches). NOTE: One turn of the adjusting screw will change
NOTE: Prior to installation in the machine, circuit the pressure approximately 138 bar (2000 psi).
reliefs can be tested.
STEP 2
STEP 23 Check the pressure again. Repeat the adjustment as
Install valve in machine, see section 8001. necessary.
STEP 24
Check loader limit pressure, see section 8002.
Section
8006
CYLINDERS
8006
8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8006-3
SPECIFICATIONS
Approximate weight
Lift Cylinder...........................................................................................................................142.2 kg (313.5 pounds)
Bucket Cylinder........................................................................................................................199.2 kg (439 pounds)
SPECIAL TORQUES
Gland Bolts Bucket Cylinder .......................................................................420 to 500 Nm (310 to 368.8 pound-feet)
Screw in Gland for Lift Cylinders ...................................................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders................................................................2830 to 3220 Nm (2087 to 2374.9 pound-feet)
Lock Screw for Lift Cylinders ............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier ......................................................................................................................................... CAS-1039
8006-4
LIFT CYLINDER
1. Clean exterior of cylinder. If hoses were removed 1. Clean all parts in cleaning solvent. Use only lint
with cylinder, remove hoses from cylinder. free cloths for cleaning and drying.
2. Fasten tube (1) in an acceptable repair stand or 2. Check to be sure that piston rod (13) is straight. If
other holding equipment. Do not damage tube piston rod is not straight, replace it with a new
(1). piston rod.
3. Loosen and remove self-tapping screw (12). 3. Shine a light inside tube (1) and check for deep
grooves and other damage. If there is any
4. Use a spanner wrench to loosen and remove
damage to tube, replace with a new tube.
gland (4) from tube (1).
4. Remove any small scratches on piston rod (13)
5. Pull piston rod (13) straight out of tube (1) to
or inside tube (1) with emery cloth of medium
prevent damage to tube.
grit. Use emery cloth with a rotary motion.
6. Fasten piston rod eye or yoke in a vise and put a
5. Inspect bushings (2) in tube eye. Replace as
support under piston rod (13) near piston (15).
required.
Put a shop cloth between support and piston rod
to prevent damage to piston rod. 6. Inspect gland (4) for rust. Clean and remove rust
as necessary.
7. Use a torque multiplier, CAS-1039, to loosen and
remove bolt (14) that fastens piston (15) to piston 7. Inspect gland end of tube (1) for sharp edges
rod (13). that may cut gland O-ring (11) and remove as
necessary.
8. Remove piston (15) from piston rod (13).
8. Inspect piston (15) for damage and wear. If
9. Remove gland (4) from piston rod (13).
piston is damaged or worn, replace with a new
10. Remove and discard seal (16), ring (17), and piston.
wear ring (18) from piston (15).
11. Remove and discard O-ring (10), backup ring (9),
O-ring (11), wiper (5), rod seal (6), buffer seal (7),
and bushing (8) from gland (4).
8006-5
13
5
6
7
4
8
11
9
10
15
12
17
16
18
14
1
3
2
2
3
BC05J002
1. TUBE 6. ROD SEAL 11. O-RING 16. SEAL

2. BUSHING 7. BUFFER SEAL 12. SCREW 17. RING
3. WIPER 8. BUSHING 13. ROD 18. WEAR RING
4. GLAND 9. BACKUP RING 14. BOLT
5. WIPER 10. O-RING 15. PISTON
LIFT CYLINDER
8006-6
Assembly 17. Install a new ring (17) in the other groove on the
outside of the piston (15).
NOTE: If a new gland is being used, put part number
of cylinder on new gland. 18. Install a new seal (16) on top of ring (17).
1. Install bushing (8) in gland (4). 19. Fasten tube (1) in an acceptable repair stand or
other holding equipment. Be careful to prevent
2. Install rod seal (6) in gland (4). Rod seal is to be damage to tube.
installed so that lips of seal are toward bushing
(8). Rod seal (6) can be difficult to install. 20. Lubricate inside of the tube (1) and piston (15)
with clean oil.
3. Install buffer seal (7) in gland (4). The side of
buffer seal with groove must be toward bushing 21. Push piston (15) straight into tube (1).
(8). 22. When the piston (15) is in smooth part of tube
4. Install a new wiper (5) in gland (4). Lips of wiper (1), start gland (4) into tube.
must be toward outside end of gland (4). 23. Lubricate O-rings (10 and 11) on gland (4) with
5. Install a new O-ring (11) in groove on OD of clean oil.
gland (4). 24. Turn gland (4) into tube (1). Tighten gland to a
6. Install a new backup ring (9) in groove on OD of torque of 135 to 542 Nm (100 to 400 pound-feet).
gland (4). If both sides of backup ring are not flat, 25. If the original parts are being assembled:
side that is not flat must be toward small end of
gland (4). A. Tighten gland to a torque of 135 to 542 Nm
7. Install a new O-ring (10) next to backup ring (9)
in groove on outside of gland (4). O-ring must be B. Install and tighten self-tapping screw (12) to a
toward small end of gland. torque of 2.3 Nm (20 inch-pounds).
8. Fasten piston rod (13) eye or yoke in vise. C. If, after tightening gland, the self-tapping
screw (12) holes are not aligned, a new hole
9. Remove any marks and sharp edges on chamfer for self-tapping screw must be drilled. See
at end of piston rod (13). Make sure that piston Step 26.
rod is clean.
26. If a new gland (4) or a new tube (1) are being
10. Lubricate bore of gland (4) and piston rod (13) assembled:
with clean oil.
A. Tighten gland (4) to 135 to 542 Nm (100 to
11. Push gland (4) onto piston rod (13). If necessary, 400 pound-feet).
use a soft hammer to drive gland onto piston rod.
B. Use a No. 27 drill bit and drill a hole half in
12. Put a support below and near end of piston rod gland (4) and half in tube (1). Drill to a depth of
(13). Use a shop cloth between support and the 11 mm (7/16 inch). Do not drill within 13 mm
piston rod to prevent damage to piston rod. (1/2 inch) of a hole for gland wrench.
13. Start piston (15) onto piston rod (13). C. Install and tighten self-tapping screw (12) to a
14. Clean the threads on the end of the piston rod torque of 2.3 Nm (20 inch-pounds).
(13) and the threads of the bolt (14) using Loctite 27. If hoses were removed with cylinder, install new
cleaning solvent. Allow to dry. Apply Loctite 242 O-rings, if equipped, on hose fittings. Lubricate
to piston rod threads 6.3 mm (1/4 inch) from O-rings with clean oil. Install hoses.
open end of piston rod so that there is 13 mm
(1/2 inch) of Loctite 242 on piston rod threads.
DO NOT apply Loctite to first 6.3 mm (1/4 inch)
of piston rod threads.
15. Install bolt (14) into piston rod (13). Tighten bolt
to a torque of 2830 to 3220 Nm (2087 to 2374.9
pound-feet). A torque multiplier can be used to
help torque the bolt.
16. Install a new wear ring (18) in wide groove on
outside of piston (15).
8006-7
BUCKET CYLINDERS
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder. 2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment. Do not damage the 3. Check to be sure that the piston rod is straight. If
tube (1). the piston rod is not straight, replace it with a new
3. Loosen and remove the cap screws (2) and piston rod.
hardened washers (18) from the gland (3) and 4. Illuminate the inside of the tube for deep grooves
the tube (1). and other damage. If there is any damage to the
4. Pull the piston rod (4) straight out of the tube (1) tube, replace it with a new tube.
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod or
5. Fasten the piston rod eye or yoke in a vise and inside the tube with emery cloth of medium grit.
put a support under the piston rod (4) near the Use the emery cloth with a rotary motion.
piston (7). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (4) to prevent damage to the yoke and the tube. Replace as required.
piston rod (4).
7. Inspect the gland for rust and clean and remove
6. Remove the retaining ring (10) that fastens the rust as necessary.
pin (11) in the piston (7) and piston rod (4).
8. Inspect the gland end of the tube for sharp edges
7. Remove the pin (11) from the piston (7) and the that will cut the gland O-ring and remove as
piston rod (4). necessary.
8. Turn the piston (7) off the piston rod (4) and 9. Inspect the piston for damage and wear. If the
remove the piston (7). piston is damaged or worn, replace it with a new
9. Remove the gland (3) from the piston rod (4). piston.
10. Remove the seal (6) from the OD of the piston
(7).
11. Remove the wear ring (5) from the OD of the
piston (7).
12. Remove the backup rings (8) and the O-ring (9)
from the ID of the piston (7).
13. Remove the O-ring (16), backup ring (15), wiper
(12), wide seal (13), narrow seal (14), and
bushing (17) from the gland (3).
8006-8
19
20
19
4
2
18
3
17
15
12
16 13
11 8 14
8 9
7
6
5 1
10
19
20
19
BC05M026
1. TUBE 7. PISTON 12. WIPER 17. BUSHING

2. CAP SCREW 8. BACKUP RING 13. WIDE SEAL 18. HARDENED WASHER
3. GLAND 9. O-RING 14. NARROW SEAL 19. SEAL
4. PISTON ROD 10. RETAINING RING 15. BACKUP RING 20. BUSHING
5. WEAR RING 11. PIN 16. O-RING
6. SEAL
BUCKET CYLINDER
8006-9
Assembly 11. Install a new backup ring (8) in the groove in the
ID of the piston (7). If both sides of the backup
NOTE: If a new gland is being used, put the part ring (8) are not flat, the side that is not flat must
number of the cylinder on the new gland. be toward the O-ring (9).
1. Install the bushing (17) in the gland (3), refer to 12. Install a new O-ring (9) in the groove in the ID of
illustration on page 8. the piston (7) next to the backup ring (8).
2. Install the wide seal (13) in the gland (3). The 13. Install the other new backup ring (8) in the
wide seal (13) is to be installed so that the lips of groove in the ID of the piston (7) next to the
the wide seal (13) are toward the bushing (17). O-ring (9). If both sides of the backup ring (8) are
The wide seal (13) can be difficult to install. not flat, the side that is not flat must be toward
3. Install a new wiper (12) in the gland (3). The lips the O-ring (9).
of the wiper (12) must be toward the outside end 14. Lubricate the ID of the piston (7) with clean oil.
of the gland (3).
15. Start the piston (7) onto the piston rod (4). Turn
4. Install the narrow seal (14) in the gland (3). The the piston (7) onto the piston rod (4) until the
side of the narrow seal (14) with the groove must piston (7) is seated against the shoulder of the
be toward the bushing (17). piston rod (4).
5. Install a new backup ring (15) in the groove on 16. If none of the holes in the piston (7) align with the
the outside of the gland (3). If both sides of the holes in the piston rod (4), turn the piston (7)
backup ring (15) are not flat, the side that is not counterclockwise until one of the holes in the
flat must be toward the small end of the gland piston (7) aligns with one of holes in the piston
(3). rod (4). Do not turn the piston (7) more than 90
6. Install the O-ring (16) next to the backup ring (15) degrees.
in the groove on the outside of the gland (3). The
O-ring (16) must be toward the small end of the 7
gland (3).
11
7. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (4). Make 10
sure that the piston rod (4) is clean.
8. Lubricate the bore of the gland (3) and the piston
rod (4) with clean oil.
9. Push the gland (3) onto the piston rod (4). If
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (4). 4
10. Put a support below and near the end of the
GS98J804
piston rod (4). Use a shop cloth between the
support and the piston rod (4) to prevent damage PISTON AND PISTON ROD HOLE ALIGNMENT
to the piston rod (4). 17. Install the pin (11) in the piston (7) and the piston
rod (4).
18. Install the retaining ring (10) in the pin (11).
8006-10
19. Install a new wear ring (5) in the wide groove on 27. Tighten the cap screws (2) in the sequence
the OD of the piston (7). shown. Torque to 420 to 500 Nm (310 to 368.8
20. Install a new seal (6) in the groove on the OD of pound-feet).
the piston (7).
21. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
damage to the tube (1).
22. Lubricate the inside of the tube (1) and the
outside of the piston (7) with clean oil.
23. Push the piston (7) straight into the tube (1).
24. Lubricate the O-ring (16) on the gland (3) with
clean oil.
25. Push the gland into the tube (1) and align the
holes in the tube (1).
26. Install the cap screws (2) and hardened washers
(18).
BC05M027
TUBE AND GLAND HOLE ALIGNMENT
8006-11
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Removal
1. Put piston tube (4) in a press.
2. Use an acceptable driver to press wipers (1) and
bushings (2) out of piston tube (4) eye.
3
3. Clean bore for bushings (2) in tube (4) eye.
1
Installation
4
1. Use an acceptable driver to press new bushings
(2) into tube (4) eye. Bushings shall be recessed
8 mm (0.315 inch) in tube eye.
2
2. Use an acceptable driver to install wipers (1) until
flush with tube (4) eye. The lips of wipers must be 1
toward outside of bore. 2
BS01C003
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
LIFT CYLINDERS
8006-12
REPLACING BUSHINGS FOR THE BUCKET CYLINDER
Removal
3
1. Put piston rod eye (3) in a press.
2. Use an acceptable driver to press wipers (1) and
bushing (2) out of piston rod eye (3). 2
3. Put tube (4) in a press. 1 1
4. Use an acceptable driver to press bushings (2) 2
out of tube (4) eye.
5. Clean bore for bushings (2) in piston rod eye (3)
and tube (4) eye.
4
1
Installation 2
(2) into piston rod eye (3) until recessed 8 mm
(0.315 inch).
2. Use an acceptable driver to install wipers (1) until
flush with piston rod eye (3). The lips of the 2
wipers (1) must be towards outside of bore.
(2) into tube (4) eye until recessed 8 mm (0.315
inch).
1
4. Use an acceptable driver to install wipers (1) until BS03B201
flush with tube (4) eye. The lips of wipers (1)
1. WIPER 3. PISTON ROD EYE
must be towards outside of bore. 2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
BUCKET CYLINDERS
Section
8007
COUPLER SOLENOID LOCKING VALVE
8007
8007-2
TABLE OF CONTENTS
coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8007-3
COUPLER SOLENOID LOCKING VALVE
Disassembly STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve. STEP 12
Install nut (1) to secure solenoid (2).
STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3). 1
STEP 3
Remove valve cartridge (3) from valve housing (7).
2
STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).
Cleaning and Inspection

STEP 5
Immerse valve cartridge (3) and valve housing (7) in
3
cleaning solvent and agitate cleaning solvent. WEAR
EYE PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign matter
from interior of valve cartridge and housing and to 4
ensure that all passage ways and bores are clear.
6
STEP 6 5
Check valve cartridge for (3) for cracks, breaks, 6
chipping, or other damage. Replace if any of these 6
conditions are seen.
5
6
STEP 7
6
Check bores in valve housing (7) for deep scratches, 5
gouges, and other damage. Replace valve if any of
these conditions are seen.
7 6
STEP 8
Connect an ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve
cartridge (3) if ohmmeter indicates short or open
circuit.
Assembly GS98J818
1. NUT 5. O-RING
STEP 9
2. SOLENOID 6. BACKUP RING
Install new O-rings (4 and 5) and back-up rings (6) as 3. VALVE CARTRIDGE 7. VALVE HOUSING
shown. 4. O-RING
STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
8007-4
NOTES
Section
8013
8013
RIDE CONTROL ACCUMULATOR
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8
Ride Control Accumulator Fluid Capacity ............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure ...........................................................248.4 bar (3600 psi)
ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap .................................................................................13.6 Nm (10 pound-feet)
Gas Charging Valve.............................................................................................88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)
SPECIAL TOOLS
94L95 B786441M
CAS10899 NITROGEN ACCUMULATOR CHARGING KIT CAS1456 GLAND WRENCH
8013-4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
C E
D B A
94L95
CAS10899 NITROGEN CHARGING KIT
1. Use the CAS-10899 Nitrogen Charging Kit to 7. Turn the T-handle inward on valve F to engage
d i s c h a r g e t h e a c c u m u l a t o r, r e fe r t o t h e the pin in the valve stem.
illustration above. The tool must be disconnected
8. Open valve D and check the charge pressure on
from the nitrogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open
3. Adjust the regulator A to the minimum pressure valve B. The accumulator charge will bleed down
setting by turning the knob counterclockwise. through the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
5. Remove the guard and valve assembly cap from
the accumulator. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the
accumulator.
8013-5
ACCUMULATOR
NOTE: Refer to Section 8001 for the proper 1. Fasten the body (1) in a vise. Be careful not to
procedure for the removal of the ride control damage the body (1). Refer to the illustration on
accumulator. page 6.
WA R N I N G : D O N O T a t t e m p t t o 2. Install a new wear ring (5), O-ring (7) and backup

disassemble any accumulator until the ring (6) on the piston (4).
nitrogen charge is properly discharged. 3. Lubricate the bore of the body (1) and the piston
SM386 (4) with clean oil.
1. Fasten the body (1) in a vise. Be careful not to 4. Start the piston (4) into the body (1), round
damage the body (1), refer to the illustration on surface first. Then push the piston (4) farther into
page 6. the body (1).
2. Remove the screws (9) and guard (11) from the
NOTE: The piston (4) must be installed squarely and
body (1).
slowly into the body (1). Once the piston (4) is started
3. Remove the pressure valve (12) from the straight into the bore of the body (1), use a hammer
body (1). and wood block to gently tap the piston into the
4. Remove and discard the O-ring (10) from the polished area of the bore. Keep force on the piston
pressure valve (12). (4) while tapping into the bore or damage may occur
to the O-ring.
5. Loosen and remove the cap (8) from the body
(1). 5. Install and tighten the cap (8) into the body (1).
6. Loosen and remove the gland (3) from the body 6. Install new seals (2) on the gland (3).
(1).
7. Lubricate the seals (2) with clean oil and start the
7. Remove the piston (4) from the body (1). gland (3) into the body (1).
8. Remove and discard the wear ring (5), O-ring (7)
8. Tighten the gland (3).
and the backup ring (6) from the piston (4).
9. Remove the seals (2) from the gland (3). 9. Install a new O-ring (10) on the pressure valve
(12).
Inspection 10. Install the pressure valve (12) in the body (1).
1. Clean body (1), gland (3), cap (8) and piston (4) 11. Install the guard (11), screws (9) in the body (1).
in cleaning solvent, refer to the illustration on 12. Charge the accumulator with dry nitrogen
page 6. according to instructions on page 7.
2. Inspect the piston (4) for cracks, burrs or other
damage. WA R N I N G : U s e o n l y n i t r o g e n w h e n
charging the accumulator. DO NOT use air
3. Inspect the bore of the body (1) for scratches or or oxygen that will cause an explosion.
scoring using a light. SM115A
NOTE: Minor scratches or scoring in the bore of the

body (1) can be removed using crocus cloth.
4. Inspect the pressure valve (12) and replace as
needed.
8013-6
1 2 5 6 7 9
8
3 4
10 11
12
9
BS01B224
1. BODY 5. WEAR RING 9. SCREW

2. SEALS (2) 6. BACKUP RING 10. O-RING
3. GLAND 7. O-RING 11. GUARD
4. PISTON 8. CAP 12. PRESSURE VALVE
RIDE CONTROL ACCUMULATOR ILLUSTRATION
8013-7
CHARGING THE ACCUMULATOR WITH NITROGEN
6 5
4 3
GS98N801
1. VALVE C 4. VALVE B
2. TO NITROGEN TANK 5. VALVE D
3. VALVE A 6. TO ACCUMULATOR
NITROGEN CHARGING KIT CAS10899
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.
8013-8
1. Close the shutoff valve A by turning it all the way 12. Open the shutoff valve A on the nitrogen supply
to the left (counterclockwise), refer to the tank. While observing the pressure on the gauge,
illustration on page 7. slightly open the needle valve on the
accumulator charge hose. By regulating the
2. Open valve B by turning it out all the way to the
needle valve, fill the accumulator to pressure
left (counterclockwise).
according to temperature chart below. Close the
3. Close valve C by turning it all the way to the right needle valve. Close the shutoff valve A on the
(clockwise). nitrogen supply tank.
4. Close the gauge valve D by turning it all the way TEMPERATURE CHARGE PRESSURE
to the right (clockwise). 10° C 50° F 1606 KPA 233 PSI
13° C 55° F 1634 KPA 237 PSI
5. Connect the charging hose to the nitrogen supply
16° C 60° F 1669 KPA 242 PSI
tank.
18° C 65° F 1696 KPA 246 PSI
6. SLOWLY turn valve A clockwise while watching 21° C 70° F 1724 KPA 250 PSI
the high pressure gauge. Stop turning valve A 24° C 75° F 1751 KPA 254 PSI
when the needle on the gauge reaches 31 bar 27° C 80° F 1779 KPA 258 PSI
(450 psi). 29° C 85° F 1813 KPA 263 PSI
32° C 90° F 1841 KPA 267 PSI
NOTE: If the needle goes over the needed pressure,
35° C 95° F 1868 KPA 271 PSI
quickly open and close valve D and check the
38° C 100° F 1896 KPA 275 PSI
pressure setting again.
The charging kit is now ready to be installed on the TEMPERATURE/CHARGE PRESSURE RIDE CONTROL
accumulator. ACCUMULATOR
13. Close valve B by turning to the right (clockwise).
7. Remove the two cap screws (9) and the
After a few minutes, check the accumulator for
protection bracket (11) from the body (1) on the
leakage.
accumulator, refer to the illustration on pages 6.
14. Back off the needle valve on the accumulator end
8. Remove the valve cap from the pressure valve
of the charging hose by tur ning it
(12) on the accumulator.
counterclockwise the maximum amount. This will
9. Back off the needle valve on the accumulator end p r eve n t n it r o g e n f r o m e s c a p i n g f r o m t h e
of the charging hose by tur ning it accumulator as the hose is removed. Remove
counterclockwise to the maximum amount. This the charging hose from the accumulator pressure
prevents nitrogen from escaping from the valve (12).
accumulator when the charging hose is attached
15. Install the valve cap onto the pressure valve (12)
to the accumulator gas charging valve.
on the accumulator.
10. Install the charging hose fitting onto the
16. Install the protection bracket (11) over the
accumulator pressure valve (12).
pressure valve (12) and secure it with cap screws
11. Tighten the needle valve by turning it clockwise. (9).
Slowly open the gauge valve D and observe the
17. Remove the charging hose from the nitrogen
reading on the gauge. This reading is the
supply tank.
nitrogen pressure level inside the accumulator.
Section
8014
8014
RIDE CONTROL VALVE
8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8014-3
RIDE CONTROL VALVE
9 11
10
8
7 13 12
14
15
6
5
4
3 16
2
1 17
BC05B015.
1. PLUG 6. SPRING 10. ACCUMULATOR DRAIN SCREW 14. POPPET

2. CAP SCREW 7. SPOOL 11. PLUG 15. ORFICE
3. BUSHING 8. PLUG 12. SOLENOID 16. VALVE BLOCK
4. SPRING CARRIER 9. PLUG 13. ORFICE 17. RELIEF VALVE
5. SPRING
Dissasembly STEP 8
Remove the pressure relief valve (17).
STEP 1
Remove ride control valve, refer to section 8001. Inspection
1. Discard all O-rings.
STEP 2
Remove plugs (1), (8), (9), and (11). 2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for
STEP 3 damage and wear.
Remove the solenoid (12). 4. Check the parts of the pressure relief valve.
STEP 4 If any of the parts are damaged, install new parts.

Remove the spool (7) from the valve block (16).
STEP 5
Remove cap screw (2), bushing (3), spring carrier
(4), springs (5 & 6) from spool (7).
STEP 6
Remove orifice (13), poppet (14), and orifice (15).
STEP 7
Remove accumulator drain screw (10).
8014-4
Assembly STEP 6
Install springs (5 &6), spring carrier (4), bushing (3),
STEP 1 cap screw (2) onto spool (7) and torque cap screw
Install new O-rings. (2) to 5.5 Nm (48.5 lb-in).
STEP 2 STEP 7
Install and torque pressure relief valve (17) to 50 Nm Install spool (7) into valve block (16).
(37 lb-ft).
STEP 8
STEP 3 Install and torque plug (1) to 270 Nm (199 lb-ft).
Install and torque accumulator drain screw (10) to
3.5 Nm (31 lb-in). Install the plug for accumulator STEP 9
drain screw and torque to 7 Nm (62 lb-in). Install plug (8) and torque to 140 Nm (103 lb-ft), plug
(9) and torque to 30 Nm (22 lb-ft), and plug (11) and
STEP 4 torque to 90 Nm (66 lb-ft).
Install and torque orifice (15) to 15 Nm (11 lb-ft),
install poppet (14), install and torque orifice (13) to STEP 10
15 Nm (11 lb-ft). Install the ride control valve in the machine, see
section 8001.
STEP 5
Install and torque solenoid valve to 12 Nm (106 lb-in). STEP 11
Test the ride control system, see section 8002.
9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM

CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if you
when removed from a system during servicing.
are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioner systems. Refrigerant HFC-134a does not
the air conditioner system before reclaiming
contain any chlorofluorocarbons (CFC’s) which are
refrigerant and when you test the system.
harmful to the earth’s ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with Refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixtures of HFC-134a and air can for m a
Liquid refrigerant getting into the eyes can cause
combustible gas.
ser ious injur y. Do the following if you get
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.
9002-4
299L7C A22094
BELT TENSION TOOL CAS-10808 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, OEM-1415
A22090
109L7
ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES CAS-10073-3
9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
contains five major components: compressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. evap orator mete rs refr ig erant flow based on
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and flowing
pressure gas. The compressor then compresses the through the evaporator fins. The combination of
refrigerant and sends it in the form of a high pressure increased heat and decreased pressure causes the
gas to the condenser. The air flow through the air flow through the evaporator fins to become very
c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A.C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER
9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
Check Page 8
Compressor Runs No
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem

See Pressure Testing, Page 13
9002-7
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
See Mechanical Compressor Check Page 8.

HEATER
Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.
Problem:
System Makes Noise
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.

ELECTRICAL
See Compressor Clutch Check Page 9.
INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13. INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13.

9002-8
SYSTEM CHECKS
Mechanical Compressor Check

1. Too much belt wear - replace a worn belt,
Compressor and Fan Belts because a worn belt will cause too much
slippage.
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
Compressor Mounting Brackets 2. Bracket has cracks or breaks - replace the
bracket.
1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Remove the compressor for
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
Compressor Clutch b e t w e e n t h e f r o n t p l a t e a n d p u l l ey
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor
rotation should be smooth and not require
much effort.
1. The compressor pulley and the

compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Pulley and Belt Alignment Use a straight edge to check pulley
alignment. Adjust the compressor
mounting bracket if needed.
9002-9
Blower and Compressor Clutch Check

NOTE: Check supply voltage with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch
1. If there is electrical system voltage to the
clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.
1. See Section 4002 and check the high and

Low and High Pressure Switches low pressure switches.
Blower Fuse (10 amp) 1. Check for damaged blower fuse.
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor 2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.
1. With key in ON position, turn switch to

maximum cold. Compressor clutch must
engage.
NOTE: Blower must be operating, since
electrical power to temperature control switch
is received from blower switch.
Temperature Control Switch 2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
switch ter minals. If continuity is not
present when switch is on maximum cold,
replace switch.
9002-10
Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers louvers must be closed.
2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning 1. Feel the air conditioning hoses. The high pressure hoses
(small line) must be warmer than the low pressure hose
(large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and

r u n t h e c o m p r e s s o r fo r f i v e m i n u t e s t o m a k e
temperature stable. Refer to page 12.
2. Duct temperature must be below 25° C (72° F) if the
system is operating at maximum efficiency.
Duct Temperature NOTE: Ambient temperature must be 27 to 43° C (80 to
110° F).
3. If temperature is above 25° C (72° F), system is low on
refr igerant, there is a restr iction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
Temperature Sensing Probe Check 4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control switch
should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.
9002-11
Visual and Leak Check

1. Make sure that all hose connections are
tight.
Compressor Hoses 2. Check hoses for bends or cracks. Replace
all hoses that have damage.
1. Shut off the engine.

WARNING: When refrigerant comes in
contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. Use
instructions from manufacturer of leak
Leak Finding Check finding tool.
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion valve
for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.
1. Make sure the condenser is clean and the

seals are in place. Make sure condenser
Condenser fans run when temperature control switch
is ON.
9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fins that have bends or
damage must be made straight.
3. Inspect the evaporator/heater core for
r e s t r i c t i o n s. I f t h e c o r e i s d r y, u s e
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
water drains freely from the
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
1. See Section 9004 for access to the

2. Make sure seals are in place so blower
Evaporator/Heater Core Sealing will pull air only through the
evaporator/heater core and not around the
Filters 1. Make sure the filters are clean.

9002-13
PRESSURE TESTING
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 10 to 35 psi (0.7 to 2.4
NOTE: The gauge set is not accurate enough to bar) after the system has run 10 to 15 minutes.
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether HIGH PRESSURE GAUGE - The high pressure
undercharge or overcharge exists, and then gauge is used to indicate pressures in the high side
evacuate, reclaim and recharge system with the of the system. The gauge must indicate from 0 to 400
recommended quantity (charge) of HFC-134a. psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool During normal operation, the high pressure gauge
used to service the air conditioning system. The will normally indicate from 120 to 310 psi (8.3 to 21.4
manifold gauge set is used to measure the high and bar). See pressure-temperature chart on page 14.
low pressures of the system, as a tool to troubleshoot
for correct refrigerant charge quantity, system Pressure Test Connection
diagnosis, and operating efficiency. The manifold
C o n n e c t t h e m a n ifo l d g a u g e s e t i n t o t h e a i r
gauge set can read both the high (discharge) and low
conditioning system as shown. Make sure that both
(suction) sides at the same time, since pressure must
valves in the manifold gauge set are closed.
be compared in order to make a diagnosis of system
operation.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. It is best used to judge
eva cuat io n effe ctiven ess. A vac uum rea ding
indicates a system malfunction. For this reason, it is
necessar y to use a compound gauge that will
indicate both pressure and vacuum.
9002-14
PRESSURE-TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH

AIR LOUVER (BEHIND
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)

(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction
pressure. The table shown represents readings taken 5. Measurements taken 15 minutes after startup.
in low relative humidity. Adjust the chart according to
local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART
PROBLEM LOW PRESSURE HIGH PRESSURE SEE

GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 16
NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25
9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1 STEP 4
Clean the external surfaces of the compressor and Connect the hose from the high pressure gauge to
hoses. Remove the caps from the service ports on the port on the discharge hose.
the suction and pressure hoses.
WARNING: Always wear safety goggles
WARNING: Do not steam clean any air when working with liquid refrigerant. Liquid
conditioning system parts while the system is r e f ri g er a n t i n y o u r ey e s c o u l d c a u s e
charged. The heat will cause the refrigerant blindness. SM105A
to rise to a pressure that could cause the
system to explode. SM104A
STEP 5
Make sure the charging station manifold gauge
STEP 2 valves are in the closed position.
Connect the hoses from the test gauges to the
service ports by turning the knurled knobs on the STEP 6
depressors. Start the engine and run at 1500 RPM maximum
speed. Operate the air conditioner system at
STEP 3 maximum cooling setting and blower speed for 15
Connect the hose from the low pressure gauge to the minutes with the cab door open. Observe the test
port on the suction hose. gauges and check the chart on page 13 against the
gauge readings.
9002-16
PROBLEM: NO COOLING
VERY LOW VERY LOW
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate and reclaim remaining

refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow

the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off 4. Check level of oil in compressor - possible
Yes
rapidly after start-up. (A/C warning light for compressor to have an oil loss.
in cab should illuminate).
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See

Section 9003.
7. Continue performance test for other

possible problems.
9002-17
HIGH HIGH
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm Yes 3. Remove air and moisture from the
Section 9003.
Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
reclaim and recharge refrigerant until gauge
pressure is normal. See Section 9003.
4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
caused by oil or reduced heat transfer.
condenser) is very hot.
A. Remove refrigerant from the system. See
B. Discharge air from evaporator warm.
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible

problems.
9002-18
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at See Section 9004 and replace the expansion
compressor. valve.
C. Much condensation on evaporator
outlet.
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
Refrigerant Contamination
table represent the boiling point for HFC-134a.
C. Pressure readings below range given in chart indicate
contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart
Temperature ° F (° C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)
9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO
SLIGHTLY HIGH NORMAL
476L7
Air in the System - Indications:

1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand. 3. Repair system leak as necessary.
B. Discharge air from heater/evaporator 4. Replace receiver-drier.
only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.
9002-20
LOW LO W
476L7
Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator 3. Repair system leaks as needed.

cool or warm - not cold.
4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace

Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section

9003.
High Side Restriction - Indications:

A. Discharge air from heater/evaporator
1. Discharge refrigerant from system-restriction in
only a little cool.
receiver-drier or liquid line must be removed.
B. Condensation or frost on
2. Remove and replace part with restriction.
receiver-drier.
3. Remove air and moisture from the system. See
C. Liquid line to receiver-drier cool, with
Section 9003.
frost or condensation.
4. Charge system with new refrigerant. See Section
NOTE: The frost will form downstream from
9003.
or at the point of the restriction
9002-21
Expansion Valve Not Operating - Indications:

1. Expansion valve outlet with condensation or frost is
A. Discharge air from evaporator warm an indication of a restriction in the expansion valve.
or cool - not cold. Replace expansion valve. See Section 9004.
B. Condensation or frost on expansion 2. Inlet end of expansion valve is warm (not hot),
valve outlet. indicating expansion valve is not completely open.
C. Inlet end of expansion valve is If the valve is stuck closed, there will be little or no
warm. flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.
9002-22
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
Compressor Turning But Not Pumping Properly - Indications:

1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged. 4. Replace compressor.
B. Cool discharge air from evaporator. 5. Replace receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.
Expansion Valve Stuck Open

Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.
9002-23
HIGH HIGH
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
B. Add refrigerant until gauge pressures are
A. Liquid line very hot.
normal. See Section 9003.
B. Discharge air from evaporator warm.
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System - Indications:

1. Discharge refrigerant from system. See
Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the
Section 9003.
9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL NORMAL
476L7
Moisture in the System - Indications:

1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the freezing of this
moisture can stop refrigerant flow. See
Section 9003.
2. Replace receiver-drier. The moisture

removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day. 3. Remove air and moisture from the
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

Section 9003.
9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
HIGH
TO HIGH
476L7
Too Much Refrigerant in System - Indications:

1. Remove refrigerant from system until gauge
readings are below normal. See Section
A. Cool discharge air from heater/evaporator.
9003.
B. Compressor makes noise.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.
9002-26
TUBE CONNECTIONS TORQUE CHART
TUBING SIZE 3/8 inch 1/2 inch 5/8 inch

THREAD SIZE M10 -1.25 5/8-18 3/4-18 7/8-18 1-14
OR OR
3/4-16 7/8-14
STEEL TO STEEL 31-36 Nm 31-36 Nm 40-46 Nm 45-52 Nm 45-52 Nm
ALUMINUM TO BRASS 10-14 Nm 10-14 Nm 24-30 Nm 30-37 Nm 45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.
Section
9003
9003
AIR CONDITIONER SYSTEM SERVICE
9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415
9003-4
SAFETY PROCEDURES

4. Always reclaim refrigerant from the system, if you
Refrigerant HFC-134a is the most stable and easiest conditioner system.
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFC’s) which are
harmful to the Earth’s ozone layer.
with refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.
9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refr igerant passes through an oil STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD03A213
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
BD03B001
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the por t on the discharge hose. Tur n in valve
depressor.
9003-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.
BD03A213
Remove the hoses from the service ports and install

the caps.
9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or Air and moisture are removed from the system by a
more of the following conditions occurs before you va c u u m p u m p. A v a c u u m p u m p i s t h e o n l y
remove the air and moisture from the system. equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
A. The system has been opened for service
from the system.
before.
NOTE: Refer to the vacuum pump manufacturer’s
B. Receiver-drier has operated two or more
user manual for additional information.
years.
C. Disassembly of compressor shows small STEP 11
particles of moisture removing material (gold
or brown particles).
D. Large system leak (broken hose, break in
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
A22113
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum of
45 minutes and press the Enter key. The display will
flash once indicating the programmed data has been
accepted.
STEP 12
BD03B001
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
A22115
Removal of air and moisture from the system is
necessary after the refrigerant has been removed Press the Charge key. “Program” and “Charge” will
after the system has been opened for maintenance. appear on the display.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.
NOTE: The pump on the reclamation unit will not pull
a sufficient vacuum to remove air and moisture.
9003-8
STEP 13 STEP 16
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. “Automatic” will appear on the
will flash once indicating the programmed data has display. Vacuum will appear on the display and after
been accepted. a slight delay, the vacuum pump will star t. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
l e a k - f r e e s y s t e m w i l l l e a c h r e f r i g e ra n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
Fully open the low and high pressure valves.

STEP 17
STEP 15
A22113
Press the charge key to begin refrigerant charging.

A22107
“Automatic” and “Charge” will appear on the display.
Open the red (vapor) and blue (liquid) valves on the The display shows the programmed amount and
tank. counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.
9003-9
STEP 18 STEP 21
A22114 BD03B001
Completely close the high and low pressure manifold Stop the engine, close any open valves and carefully
valves. remove the manifold gauge hoses.
ATTENTION: Check the OEM equipment manual
before performing Step 19 to avoid damaging the STEP 22
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure BD03B213
indicator lamp will illuminate when the relay is Install the caps on the service ports on the suction
actuated by a low or high pressure and the and discharge hoses.
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.
STEP 20
A22117
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
and pressure variations.
9003-10
PRESSURE - TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.5)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.1 to 14.5)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.5 to 15.8)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.6)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.9 to 19.3)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position and all
9. Measurements taken 15 minutes after start-up.
louvers open.
4. Cab temperature control set to maximum
cooling.
Section
9004
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING
AND HEATER COMPONENTS
9004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXPANSION VALVE, EVAPORATOR/HEATER CORE,
HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9004-3
SAFETY PROCEDURES

4. Always reclaim refrigerant from the system if you
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFC’s) which are
harmful to the earth’s ozone layer.
with Refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.
9004-4
SPECIAL TOOLS
A22094 BS03H012
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415
9004-5
COMPRESSOR
Removal STEP 4
STEP 1
position.
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD06F116
Remove the fan belt.
STEP 5
BD06F113
BD06F117
Disconnect the low pressure line from the suction

port and the high pressure line from the discharge
p o r t o n t h e c o m p r e s s o r. I m m e d i a t e l y i n s t a l l
protective caps on the open ports and lines.
BD06F114
Loosen and remove the four bolts holding the

protective shield. Remove the shield.
9004-6
STEP 6 Installation
STEP 9
Place the compressor into position on the machine.
STEP 10
BD06F117
Disconnect the compressor clutch wire from the

engine harness assembly.
STEP 7
BD06F117
Install the three bolts to mount the compressor.
STEP 11
BD06F117
Loosen and remove the three compressor mounting

bolts.
STEP 8 BD06F117
Remove the compressor from the machine. Connect the compressor clutch wire to the engine
harness assembly.
9004-7
STEP 12 STEP 13
Carefully remove the protective cap, install a new
O-ring, and connect the low pressure line to the
suction port on the compressor.
STEP 14
Install the belt.
STEP 15
Install the protective shield.
STEP 16
Charge the air conditioning system according to the
BD06F117 instructions in Section 9003.
Slowly remove the protective cap, install a new
O-ring, and connect the high pressure line to the
discharge port on the compressor.
IMPORTANT: Use caution when removing cap as
new compressors have internal pressure when
shipped.
9004-8
EXPANSION VALVE, EVAPORATOR/HEATER CORE,

HEATER VALVE, BLOWERS
3 6
5
7
8
9
18 10
17
12 11
14
13
16
15
BS06G118
1. EVAPORATOR 7. WASHER 13. LOWER BOX PPE

2. UPPER BOX PPE 8. GROMMET 14. EXPANSION VALVE
3. COVER PPE 9. HEATER CORE 15. BLOWER
4. SOLENOID DRIVER 10. HEATER VALVE 24V 16. RECIRCULATING VAIN
5. UPPER BOX 11. THERMOSTAT 17. RECIRCULATING MOTOR
6. BOLT 12. LOWER BOX 18. RESISTOR BLOWER MOTOR
9004-9
Removal STEP 23
STEP 17
bucket to the floor.
STEP 18
If changing any air conditioning components,
discharge the air conditioning system according to
STEP 19
BD06G212
Open the cover on the cooler.
STEP 24
BD02N160
If changing the heater core, put a 37 liter (10 gallon)

container below radiator drain. Remove radiator cap.
Remove cap and drain coolant into container. Install
cap after coolant has drained. Install radiator cap. BD06G213
Remove the four screws securing the air vent,

STEP 20 remove the vent cover.
Place the master disconnect in the OFF position.
STEP 25
STEP 21
Disconnect the wiring harness from the operator’s
seat (if equipped with air seat option).
STEP 22
BD06G214
Remove the three screws securing the cooler to the

cab, remove the cooler.
STEP 26
Fold the rubber mat over to gain access to the upper
BD06G202
box mounting bolts.
Remove the four bolts that fasten the operator’s seat
to the upper box, remove the seat from the machine.
9004-10
STEP 27 STEP 30
BD06G215 BD06G217
Remove the six bolts securing the upper box. G o i n g t h r o u g h th e i n s i d e f i l t e r a r e a fe e l th e

recirculating vain to make sure is is in the outside air,
STEP 28 “closed”, position.
STEP 31
BD06G216
Remove two screws, one on each side of the upper

box, securing the upper box to the lower box. BD06G218
The above photo shows that the recirculating vain is

STEP 29 not in the outside air “closed” position.
Place the air selector on the control panel to outside
air. STEP 32
NOTE: In step 30 and 33 the upper box is shown
removed for clarity only, these steps must be done
prior to removing the upper box.
BD06G240
Use a screw driver and disconnect the linkage.

9004-11
STEP 33 STEP 36
BD06G219
Close the vain so the upper cover can be removed. BD06G203
Disconnect the solenoid driver.

STEP 34
Remove the upper box up and rest it against the STEP 37
console.
NOTE: The wiring harness for the HVAC system
goes through the upper cover, by resting the cover
against the console the wiring harness will not need
to be removed.
STEP 35
BD06G236
Remove the upper PPE from the heater and air

conditioning cores.
NOTE: If testing on the electrical components are
required the solenoid driver can be reconnected
once the upper PPE is removed.
BD06G220
Pull the wiring harness loose from the upper PPE.

9004-12
NOTE: If replacing the heater control valve, heater STEP 40
core, air conditioning expansion valve, air
conditioning evaporator core do steps 38 through 47,
if replacing electrical components go to step 48.
STEP 38
BD06G206
Remove the thermostat probe and clamp from the

evaporator core.
STEP 41
BD06G204
Remove the right side cab skirt.
STEP 39
2 3
1 BD06G237
Disconnect the electrical connectors from the

thermostat control.
STEP 42
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
Fasten identification tags on the hoses. Disconnect

the hoses for the heater core and evaporator core,
install plugs in the hoses and caps on the fittings.
BD06G236
Disconnect the electrical connectors from the heater

control valve.
9004-13
STEP 43 STEP 49
Pull the heater core and evaporator core from the
lower box PPE.
STEP 44
Remove the expansion valve from the evaporator
core.
STEP 45
Remove and discard the O-rings from the openings
in the expansion valve.
STEP 46
Remove the screws from the heater core and remove BD06G208
the control valve. D i s c o n n e c t t h e e l e c t r i c a l c o n n e c t o r fo r t h e

recirculating vain motor, disconnect the linkage from
STEP 47 the vain. Remove the mounting screws and remove
the motor.
Remove and discard the O-rings from the heater
control valve.
STEP 50
STEP 48
1 2
3
BD06G209
1. FAN SPEED AND A/C SWITCH
BD06G207 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
1. RESISTORS
3. THERMOSTAT
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR R e m ove t h e sw i t c h p a n e l f r o m t h e c o n s o l e.
Disconnect the electrical connectors and remove
Remove the fans from the lower PPE, disconnect the
switches as required.
electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.
9004-14
STEP 51
1
1 2
3
BD06G207
1. RESISTORS
2. RESISTOR CONNECTOR
BD06G209 3. BLOWER MOTOR CONNECTOR
1. FAN SPEED SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH Install the resistor, install the two mounting screws
3. THERMOSTAT and tighten. Install the fans in the lower PPE, connect
Re place switches and connect the electr ical the electrical connectors.
connectors as required. Install the switch panel in the
console. STEP 54
Install new O-rings on the heater control valve.
STEP 52
STEP 55
Install the control valve, install and tighten the screws
to the heater core.
STEP 56
Install new O-rings on the openings of the expansion
valve.
STEP 57
Install the heater core and evaporator core into the
lower box PPE.
BD06G208 STEP 58
Install the motor and install the mounting screws and
tighten. Connect the electrical connector for the
recirculating vain motor, connect the linkage to the
vain.
BD06G236
Connect the electrical connectors to the heater

control valve.
9004-15
STEP 59 STEP 61
2 3
BD06G237
Connect the electrical connectors to the thermostat BD06G205

control.
3. HEATER HOSES
STEP 60
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings in the evaporator
fittings, connect the heater and evaporator hoses.
Remove and discard identification tags that were
used during disassemble.
STEP 62
BD06G206
Install the thermostat probe coil and clamp to the

evaporator core “cold” tube.
BD06G204
Install the right side cab skirt.
STEP 63
BD06G238
Install the upper PPE on the heater and air

conditioning cores.
9004-16
STEP 64 STEP 67
BD06G210.
BD06G203 Make sure that the recirculating vain is in the closed

Connect the solenoid driver. position.
IMPORTANT: This photo shows it in the open
STEP 65 position and the upper box will not go back into
position without damaging the recirculating vain.
STEP 68
BD06G239
Push the wiring harness into the preformed notches

in the upper PPE.
BD06G241
Set the upper box into position on the heater and

STEP 66 evaporator cores.
Place the air selector on the control panel to outside
air. STEP 69
BD06G216
Install two screws, one on each side of the upper box

securing the upper box to the lower box.
9004-17
STEP 70 STEP 74
BD06G242 BD06G214
Install the insolation panel in the center of the upper Install and tighten the three screws securing the
box. cooler to the cab.
STEP 71 STEP 75
BD06G215 BD06G213
Install and tighten the six bolts securing the upper Install the vent cover, install and tighten the four
box. screws securing the air vent.
STEP 72 STEP 76
BD06G243
Install the right rear floor mat into the cab, if machine BD06G202
is equipped with air ride seat make sure to pull the Install and torque the four bolts to 73 to 87 Nm (55 to
wiring up above the mat for the seat. 65 pound-feet).
STEP 73
Install the remainder of the floor mat.
9004-18
STEP 77 STEP 79
Connect the wiring connector to the operator’s seat Charge the air conditioning system according to the
(if equipped with air seat option). instructions in Section 9003.
STEP 78
Ethylene Glycol and 50% water. Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
9004-19
CONDENSER AND RECIEVER DRIER
Removal STEP 85
STEP 80
bucket to the ground.
STEP 81
position.
STEP 82
Discharge the air conditioning system according to
BS03A107
STEP 83 Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the condenser.
1 STEP 86
Install plugs in the hoses and caps on the fittings.
2 STEP 87
BD01D142
1. COVER 2. CONDENSER
Open the cover (1) to gain access to the condenser
(2).
STEP 84
BS03A109
Loosen the bolts that fasten the condenser to the

bracket, pivot the condenser and remove the bolts
and condenser.
BD03A109
The condenser is connected to a bracket which

pivots on the cooling frame. Pivot the condenser to
gain access to the hoses.
9004-20
STEP 91
Put the condenser in position on the bracket.
STEP 92
BD06G211
Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d
disconnect the hoses from the receiver drier.
STEP 89
Install plugs in the hoses and caps on the fittings. BS03A109
Install the bolts that fasten the condenser to the

STEP 90 bracket, pivot the condenser down and tighten the
Disconnect the trinary switch, remove the mounting bolts.
bolt, remove the receiver drier and bracket.
STEP 93
BS03A107
Pivot the condenser to gain access to the hoses.
STEP 94
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings and connect the
hoses to the fittings. Remove and discard
identification tags that were used during
disassemble.
STEP 95
Pivot the condenser down and close the cover.
STEP 96
Mount the receiver drier and bracket, install and
tighten the mounting bolt.
9004-21
STEP 97 STEP 98
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 99
position.
BD06G211
Remove plugs from the hoses and caps from the

fittings, install new O-rings and connect the hoses to
the fittings, connect the trinary switch. Remove and
discard identification tags that were used during
disassemble.
9004-22
NOTES
Section
9006
LOADER
9006
9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth ........................................................................1315 to 1480 Nm (970 to 1090 pound-feet)
BUCKET TEETH
Replacement of the Tooth Points

1. Use a hammer and punch to drive the retaining 3 5
pin (1) for the tooth point (2) out of the tooth
4
shank (3), refer to the illustration on this page. 2 1
2. Remove the tooth point (2).
3. Install a new tooth point (2) on the tooth shank
(3).
4. Install the retaining pin (1) into the tooth point (2)
7
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
6
8 10
a hammer to hit the retaining pin (1) until the 3
retaining pin (1) is even with the outside of the
tooth shank (3).
2 1
Replacement of the Bucket Teeth
1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth. 9
NOTE: If wear of the bolt or nut makes removal 7
difficult, the bolt or nut can be cut off.
2. Remove the tooth.
B0740A88J
3. Install the new tooth on the bucket cutting edge 1. RETAINING RING 6. BOLT
(7). 2. TOOTH POINT 7. CUTTING EDGE
3. TOOTH SHANK 8. PLOW BOLT
4. Use new nuts (4), hardened washers (5), and
4. NUT 9. NUT
bolts (6) for the tooth being installed.
5. HARDENED WASHER 10. CORNER TOOTH
5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to
1090 pound-feet). BUCKET TEETH ILLUSTRATION
Replacement of the Bucket Corner

Teeth
1. Loosen and remove the nuts (9) and bolts (8)
from the bucket corner teeth (10).
NOTE: If wear of the bolt or nut makes removal
difficult, the bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket
cutting edge (7).
4. Use new nuts (9) and bolts (8) for the corner
tooth being installed.
5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to
1090 pound-feet).
9006-4
RETURN TO DIG ADJUSTMENT
6
1
3
4
5
BS01C083
1. TARGET MOUNTING BRACKET 3. TARGET BAR 5. PROXIMITY SWITCH

2. BUCKET CYLINDER 4. PROXIMITY SWITCH MOUNTING BRACKET 6. PROXIMITY SWITCH GUARD
RETURN TO DIG ADJUSTMENT ILLUSTRATION
IMPORTANT: Before adjusting the return-to-dig, 7. Loosen the bolts holding the target bar (3) to the
make sure that the target bar on the bucket linkage is target mounting bracket (1). Slide the target bar
not damaged. Slowly roll back and dump the bucket (3) towards the proximity switch (5) until the face
and make sure that the target bar stays the same of the proximity switch (5) is completely covered.
distance from the switch. The switch mounting 8. Align the target bar (3) parallel to the tilt cylinder
bracket protects the switch. Make sure the target bar (2) and tighten the bolts.
cannot touch the switch when the bucket is dumped.
9. Turn the ignition switch to the ON position. Do
1. Park the machine on a level surface. Raise the lift NOT start the engine.
arms until they are approximately horizontal and
dump the bucket. Lower the bucket until the 10. Place the bucket control lever in the ROLLBACK
bucket edge is on the ground. position.
2. Apply the parking brake and stop the engine. 11. Loosen the bolts holding the target bar (3) to the
target mounting bracket (1).
3. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target 12. Slide the target bar (3) slowly away from the
mounting bracket (1) parallel to the tilt cylinder proximity switch (5), until the control lever returns
(2). Tighten the bolts, refer to the illustration on to the center position. Tighten the bolts holding
this page. the target bar (3).
4. Loosen the bolts holding the proximity switch 13. Check to make sure that the 3.2 to 5.0 mm (1/8
mounting bracket (4) to the tilt cylinder (2). to 3/16 inch) gap is still maintained.
Position the proximity switch (5) parallel to the 14. Start the engine.
target bar (3) and tighten the bolts. 15. Place the detent switch in the ON position and
5. Adjust the proximity switch (5) out towards the place the return to travel/float detent switch to the
target bar (3), until an air gap of 3.2 to 5.0 mm TRAVEL position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 16. Raise the lift arms approximately horizontal, and
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). put the bucket in the fully dumped position.
NOTE: The proximity switch (5) must not protrude 17. Place the loader control lever in the ROLLBACK
past the proximity switch guard (6). position, and verify that the electromagnet holds
6. Start the engine, position the bucket to the it in that position until the end of the target bar (3)
correct digging angle and stop the engine. passes in front of the proximity switch (5).
18. Lower the lift arms and verify that the bucket is at
the correct digging angle.
9006-5
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
5
6
3
2
1
BS01C081
1. TARGET MOUNTING PLATE 3. PROXIMITY SWITCH 5. RETURN TO TRAVEL TARGET

2. HEIGHT CONTROL TARGET 4. LIFT ARM 6. FRONT CHASSIS (TOP LEFT HAND SIDE)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
1. Park the machine on a level surface. 6. Adjust the proximity switch (3) out towards the
return to travel target (5) until an air gap of 3.2 to
2. Start the engine and apply the parking brake.
5.0 mm (1/8 to 3/16 inch) is obtained.
3. Lower the lift arms and place the bucket flat on
7. Lock the proximity switch (3) in this position with
the ground.
the jam nut. Torque the jam nut to 6 to 7.5 Nm
4. Stop the engine. (4.5 to 5.5 pound-feet).
NOTE: To avoid damage to the proximity switch (3),
it must be adjusted back to clear everything on the lift
arm as it passes. Refer to the illustration on this
page.
WARNING: Raised equipment on the machine

without an operator can cause injury or death.
Before you leave the operators compar tment,
always suppor t or lower the equipment
(backhoe, blade, boom, bucket, etc.) to the
ground and stop the engine.
CSM105
5. Position the return to travel target (5) opposite

the proximity switch (3) and tighten it to the target
mounting plate (1).
9006-6
2
A
B
1
BS01C082
1. HEIGHT CONTROL TARGET 2. RETURN TO TRAVEL TARGET 3. TARGET MOUNTING PLATE
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
821F Z-Bar 56 mm (2.2 inches) 414 mm (16.3 inches) 42 mm (1.6 inches) 3302 mm (130 inches)
821F XR 70 mm (2.76 inches) 587 mm (23.11inches) 61 mm (2.4 inches) 4000 mm (157.48 inches)
921F Z-Bar 56 mm (2.2 inches) 414 mm (16.3 inches) 42 mm (1.6 inches) 3302 mm (130 inches)
921F XR 70 mm (2.76 inches) 587 mm (23.11inches) 61 mm (2.4 inches) 4000 mm (157.48 inches)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
8. Refer to the table and the illustration on this 13. Place the detent switch in the ON position, and
page. Position the height control target (1) on the set the return to travel/float detent switch to the
target mounting plate (3) using the table above. return to travel position.
NOTE: The higher the height control target (1) is 14. Place the loader control lever in the raise position
positioned in its slot in the target mounting plate (3), and verify that the electromagnet holds it in that
the lower the lift arms will stop as they are raised. position until the height control target (2) passes
in front of the proximity switch (3). Refer to the
9. Tighten the height control target (1).
10. Position the return to travel target (2) using the
15. With the lift arms still raised, place the loader
table above.
control lever in the lower position and verify that
NOTE: The higher the return to travel target (2) is the electromagnet holds it in that position until
positioned in its slot in the target mounting plate (3), the return to travel target (5) passes in front of
the lower the lift arms will stop as they are lowered. the proximity switch (3). Refer to the illustration
on page 5.
11. Check to make sure the proximity switch (3) and
all of the mounting bolts are tight. Refer to the 16. Repeat steps 8 through 15 until the desired
illustration on page 5. heights are reached.
12. Start the engine. 17. Lower the bucket to the ground and stop the
engine.
9006-7
REMOVING THE LOADER FRAME

1. Park the machine on a level surface and apply 17. Loosen and remove the bolt (19), flat washer
the parking brake. Roll the bucket all the way (20) and spacer (21) that fasten the pivot pin (9
forward and lower the bucket to the floor. Stop or 10) to the front frame.
the engine.
18. Raise the loader frame slightly. Use an
2. Loosen the filler plug in the reservoir to release acceptable driver and drive the pivot pin (9 or 10)
the air in the reservoir. out of the front frame. Do not lose the washers
(18) and wipers (22) between the front frame and
3. Fasten a chain hoist to the cross member (1) of
the loader frame (2).
the loader frame (2), refer to the illustration on
page 8.
4. Loosen and remove the bolt (12), flat washer
(13), and spacer (14) that fasten the pivot pin (3)
to the piston rod yoke of the right lift cylinder (4).
5. Use an acceptable driver and drive the pivot pin
(3) out of the piston rod yoke of the right lift
cylinder (4). Do not remove the driver.
6. Repeat Steps 4 and 5 for the left lift cylinder (6).
7. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor
and fasten the chain hoist to a lift cylinder (4 or
6). BD01G009
19. Remove the proximity switch cover. Left-hand

8. Raise the lift cylinder (4 or 6) slightly and remove side of the machine only.
the driver.
9. Repeat steps 7 and 8 for the other lift cylinder (4
or 6).
10. Connect the chain hoist to the bucket cylinder
(8).
11. Loosen and remove the bolt (15), flat washer 1
(16), and spacer (17) that fasten the pivot pin (7)
for the piston rod eye of the bucket cylinder (8) to
the bell crank (11).
2
12. Use an acceptable driver and drive the pivot pin
(7) out of the piston rod eye of the bucket cylinder
(8).
BD01G010
13. Raise the bucket cylinder (8) and use a chain or 1. ELECTRICAL CONNECTION 2. PROXIMITY SWITCH
other acceptable holding equipment to hold the
bucket cylinder (8) in place. 20. Disconnect the electrical connector (1), remove
the lock nut from the proximity switch (2) and
14. If the machine is equipped with auxiliary remove the proximity sw itch (2) fr om the
hydraulics, disconnect the two hoses from the machine. Left-hand side of the machine only.
tubes at the bracket on the right side of the
loader frame (2). Install caps on the hoses and 21. Repeat Steps 17 and 18 for the other pivot pin (9
plugs in the tube fittings. or 10).
15. If the machine is equipped with front lamps, 22. Raise the loader frame (2) out of the front frame.
loosen and remove the cap screws and lock Carefully move the machine out of the loader
washers that fasten the lamp brackets to the front frame (2).
frame. Put the lamp brackets on the fenders.
16. Connect the chain hoist to the loader frame (2).
9006-8
10
18 8
20 18 22
16
17 15
19 9 6 7
2
1 11
21
5
5 4
14
12 5
3
13
23
BS01G022
1. CROSS MEMBER 7. PIVOT PIN 13. WASHER 19. BOLT

2. LOADER FRAME 8. BUCKET CYLINDER 14. SPACER 20. WASHER
3. PIVOT PIN 9. PIVOT PIN 15. BOLT 21. SPACER
4. LIFT CYLINDER 10. PIVOT PIN 16. WASHER 22. WIPER
5. PIVOT PIN 11. BELL CRANK 17. SPACER 23. DUMP LINK
6. LIFT CYLINDER 12. BOLT 18. WASHER
LOADER FRAME ILLUSTRATION

9006-9
INSTALLING THE LOADER FRAME

1. Apply antiseize compound to the inner bores and 17. Disconnect the chain hoist from the bucket
outer bores for the pivot pins of the front frame, cylinder (8).
refer to the illustration on page 8.
18. Fasten the chain hoist to one of the lift cylinders
2. Move the machine into alignment with the loader (4 or 6).
frame (2).
19. Raise the piston rod yoke of the lift cylinder (4 or
3. Lower the loader frame (2) into alignment with 6) so the piston rod yoke is aligned with the
the front frame. loader frame (2).
4. Apply antiseize compound to the pivot pins (9 20. Install a driver in the piston rod yoke and the
and 10) that fasten the loader frame (2) to the loader frame (2).
front frame.
21. Repeat Steps 18, 19, and 20 for the other lift
5. Start the pivot pins (9 and 10) into the front cylinder (4 or 6).
frame. Install the washers (18) and new wipers
22. Disconnect the chain hoist from the lift cylinder (4
(22) between the loader frame (2) and the front
or 6).
frame.
23. Start the engine. Raise the loader frame and roll
6. Install the pivot pins (9 and 10) all the way.
the bucket all the way forward. Lower the bucket
7. Install the bolt (19), washer (20) and spacer (21) to the floor. Stop the engine.
that fasten the pivot pins (9 and 10). Tighten the
24. Fasten the chain hoist to the cross member (1) of
bolt.
the loader frame (2).
8. Install the proximity switch and cover. Left-hand
side of the machine only.
26. Have another person help you at this time. Move
9. Disconnect the chain hoist from the loader frame
the lift control lever as required to align the piston
(2).
rod yoke of one of the lift cylinders (4 or 6) with
10. If the machine is equipped with front lamps, hold the loader frame (2).
the front lamps in place and install the cap
screws and lock washers that fasten the front IMPORTANT: D o n o t u s e yo u r f i n g e r s t o
lamps to the front frame. Tighten the cap screws. check the alignment of the cylinder rod.
11. If the machine is equipped with auxiliary Personal injury can be the result.
48-88
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses. Connect the 27. Remove the driver and install the pivot pin (3).
hoses to the tubes.
28. Install the bolt (12), washer (13), and spacer(14)
12. Connect the chain hoist to the bucket cylinder (8) that fasten the pivot pin (3). Tighten the bolt.
and lower the bucket cylinder (8).
29. Repeat Steps 26, 27, and 28 for the other lift
13. Start the engine and run the engine at low idle. cylinder (4 or 6). Stop the engine.
14. Have another person help you at this time. Move 30. Lubricate the pivot pins with molydisulfide
the bucket control lever as required to align the grease.
piston rod eye of the bucket cylinder (8) with the
bell crank (11). Stop the engine. 31. Disconnect the chain hoist from the cross
member (1) of the loader frame (2).
IMPORTANT: D o n o t u s e yo u r f i n g e r s t o 32. Tighten the filler plug in the reservoir.
check the alignment of the cylinder rod.
33. If the machine is equipped with auxiliary
Personal injury can be the result.
48-88
hydraulics, start the engine and run the engine at
low idle.
15. Install the pivot pin (7) in the bell crank (11) and
34. Slowly extend and retract the clam cylinders four
the piston rod eye of the bucket cylinder (8).
times to remove air from the auxiliary circuit.
16. Install the bolt (15), washer (16), and spacer (17)
35. Stop the engine, check the level of the oil in the
that fasten the pivot pin (7). Tighten the bolt.
reservoir, and check for leaks. Add oil to the
reservoir as required.
9006-10
NOTES
Section
9007
ROLLOVER PROTECTIVE STRUCTURE (ROPS)

CAB STRUCTURAL FRAME (CSF)
9007
9007-2
TABLE OF CONTENTS
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3
CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9007-3

CAB STRUCTURAL FRAME (CSF)
After an accident, fire or rollover, the following MUST
be performed before returning the machine to field or
Attention
job site operation:
● The ROPS or CSF structure MUST be replaced.
The Rollover Protective Structure (ROPS) or Cab ● The ROPS or CSF mounting or suspension,
S t r u c t u r a l Fr a m e ( C S F ) i s a s p e c i a l s a fe t y operator seat and suspension, seat belts and
component of your machine. mounting components and wiring within the
DO NOT attach any device to the ROPS or CSF for operator’s protective system MUST be carefully
pulling purposes. inspected for damage.
● All damaged parts MUST be replaced.
The ROPS or CSF is a certified structural support
and any damage, fire, corrosion or modification will DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
weaken the structure and reduce your protection. If REPAIR THE ROPS OR CAB STRUCTURAL
this occurs, the ROPS or CSF MUST be replaced so FRAME.
that it will provide the same protection as a new
ROPS or CSF.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following: WARNING: Do not install attachments that
will make the total weight of the machine
1. Check the torque on the CSF cab or ROPS more than the weight shown in the maximum
canopy mounting bolts; torque should be 773 to gross vehicle weight section of the ROPS
854 Nm (570 to 630 lb-ft). If necessary, tighten serial number plate. 47-26
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight WARNING: Do not change the ROPS in any
and seat belt is not cut or frayed. Check the way. Changes made to the ROPS which are
torque on operators seat mounting bolts; torque not authorized, such as welding, drilling or
should be 73 to 87 Nm (54 to 64 lb-ft). If cutting will make the ROPS weaker and
necessary, tighten the bolts to the correct torque. decrease your protection. Replace the
Replace parts that are worn or damaged. ROPS if it becomes damaged in any way.
DO NOT TRY TO MAKE REPAIRS TO THE
WARNING: Grade 8 hardware is used to ROPS. 47-25
mount and anchor the ROPS. Parts used for
replacement must be those shown in the
parts catalog. 47-27A
9007-4
CSF CAB AND ROPS CANOPY
Removal STEP 5
NOTE: Procedures and photos in following steps
cover in detail removal and installation of CSF
structure. Removal and installation of ROPS is
similar to removal and installation of CSF structure.
STEP 1
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position. BD06G191
Remove skirting under each side and front of cab.

STEP 2
STEP 6
BD01F143
Put articulation lock in LOCKED position. BD06G186
Remove the ducts from the machine.

STEP 3
Put battery disconnect switch in OFF position. STEP 7
STEP 4
BD06G189
At RH rear, bottom of cab, disconnect ground strap

BD01F184 from rear chassis.
If machine is equipped with a heater, put a 40 liters
(10 Gallons) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.
9007-5
STEP 8 STEP 11
BD06G194 BD06G192
If machine is equipped with windshield washers, Identify, tag, and disconnect hoses from steering
identify, tag, and disconnect front and rear windshield control valve. Plug hoses and cap steering control
washer nozzle hoses from supply hoses. valve fittings to prevent entry of foreign matter into
hydraulic system.
STEP 9
STEP 12
2 3
BD06G205
2. AIR CONDITIONING HOSES BD06F207
3. HEATER HOSES
Unlatch and open the window on the right hand side.
If machine is equipped with a heater disconnect
heater hoses (3), if machine is equipped with air STEP 13
conditioning discharge the air conditioning system,
see section 9003, and disconnect the air conditioning
hoses (2), cap and plug lines and fittings.
STEP 10
BD06F208
Open and remove the access panel.
BD06G193
Disconnect throttle connector and the air duct.

9007-6
STEP 14 STEP 19
BD06F209 BD06G187
Remove the front access panel. Disconnect the electrical connectors, push
connectors out of the bottom of the cab with the
STEP 15 rubber gromment
STEP 20
BD06F210
Disconnect the electrical connectors for the remote

control valve.
BD06G188
Raise floor mat up and away from brake pedal to gain

STEP 16 access to mounting hardware.
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the STEP 21
STEP 17
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.
STEP 18
Push the hoses out of the bottom of the cab with the
rubber gromment.
BD06G185
Remove hardware securing brake valve to cab floor.

Let brake valve rest on the frame.
9007-7
STEP 22 STEP 25
Slowly raise cab from rear chassis. Check that all tie
straps and clamps have been removed and all hoses,
tubes, and wires are disconnected and free. Check
that brake valve with hoses attached are free and
clear of cab. Remove the ROPS or CSF from the
machine. Lower ROPS or CSF onto wooden blocks
to prevent damaging cab or canopy.
BD06G184
Install lifting eyes in threaded holes at top of the cab.
STEP 23
Connect lifting equipment to cab at lifting eyes. Take
up all slack in lifting equipment.
STEP 24
Remove nuts, bolts, and washers securing cab to
rear chassis.
9007-8
2 1
4
4
5
5
6
6
BC06G031
1. NUT 4. RUBBER MOUNT

2. WASHER 5. WASHER
3. RUBBER MOUNT 6. BOLT
9007-9
STEP 26
Check rubber mounts (3 an 4) for deterioration, tears,
defor mation, or other damage; replace rubber
mounts as necessary.
STEP 27
BD06G188
Position floor mat.
STEP 33
BD01D388
Position cab over rear chassis then put wood blocks

under brake valve. Slowly lower cab onto rear
chassis making sure that brake valve is positioned so
that brake pedal enters into cab. Remove wood
blocks as cab is lowered onto brake valve.
STEP 28
Install washers, bolts, and nuts to secure cab to rear BD06G192
chassis. Tighten bolts to a torque of 773 to 854 Nm
Remove plugs from hoses and caps from fittings.
(570 to 630 pound feet)
Connect hoses to steering control valve following
tags installed during removal. Remove and discard
STEP 29 tags.
Disconnect lifting equipment from cab.
STEP 34
STEP 30
Remove lifting eyes.
STEP 31
BD06G193
Connect throttle connector and mount air duct.
BD06G185
Align mounting holes in brake valve with associated

holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
9007-10
STEP 35 STEP 38
2 3
BD06G186 BD06G205
Install the ducts on the machine.
3. HEATER HOSES
STEP 36
If machine is equipped with a heater, remove plugs
from hoses and caps from fittings, connect heater
hoses (3), if machine is equipped with air
conditioning, remove plugs from hoses and caps
from fittings, connect air conditioning hoses (2),
charge the air conditioning system, see section 9003.
STEP 39
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
shown on pages 11, 12, and 13.
BD06G189
At RH rear, bottom of cab, connect ground strap to

rear chassis.
STEP 37
BD06G194
If machine is equipped with windshield washers,

connect front and rear windshield washer nozzle
hoses following tags installed during removal.
9007-11
3
8
6
7
1
5
7 8
7 5
1 2
8 3
6 4
BC05M092
1. PILOT TANK HOSE 4. ORANGE BLACK GREEN 7. GREEN WHITE GREEN

2. PILOT PRESSURE HOSE 5. GREEN BLACK GREEN 8. RED WHITE GREEN
3. YELLOW BLACK GREEN 6. RED BLACK GREEN
JOYSTICK AND 2 LEVER HOSE COLOR CODING
9007-12
5 5
7 1 4 7
3
4
6 3
2 1
6
2
7 7
7 7
1 1
2 2
6 6
3 3
4 5 4 5
BC05M091

7. RED WHITE GREEN 7. RED WHITE GREEN
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING
9007-13
1
5
4 5 4 6
6 3 2
3 1
2
2 1 2 1
6 6
3 3
4 5 4 5
BC05M090

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING
9007-14
STEP 40 STEP 43
BD06F210 BD06F208
Connect the electrical connectors for the remote Install and close the access panel.
control valve.
STEP 44
STEP 41
BD06F209 BD06F207
Place the access panel into position, install and Close the right hand window.
tighten the screw.
STEP 42 STEP 45
BD06G187
BD06G191
Connect wiring harness connectors.
Install skirting under each side and front of cab.
9007-15
STEP 46 STEP 49
Start engine and run engine at low idle. Run engine
at operating temperature for approximately five
minutes to completely mix Ethylene Glycol and water.
When coolant is at operating temperature, stop
engine. When engine has cooled, check coolant level
at reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: let system cool,
radiator cap.
BD01F184
STEP 50
If machine is equipped with a heater and coolant was
drained, check that coolant drain cap is tight. Put articulation lock in OPERATING position.
STEP 47
capacity is 36.9 liters (9.75 U.S. Gallons). Install
radiator cap. Fill coolant reservoir up to FULL mark
on reservoir.
STEP 48
Put battery disconnect switch in ON position.
9007-16
NOTES
Section
9010
CAB GLASS INSTALLATION
9010
9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9010-3
PREPARATION FOR GLASS REPLACEMENT

1. Remove all of the damaged glass section and 5. Clean the new glass section. Apply a 25 mm (1
the silicone sealant from the window frame inch) wide band of glass primer (349-110) to the
black ceramic painted edges of the window.
2. Remove all the adhesive from the window frame.
6. When replacing a front window section, a
3. The window frame recesses must be free of oil
silicone forming tool is needed, refer to Figure 2.
and dust. Clean the frame with rubbing alcohol
Use the template and instructions provided to
with a clean rag. Do not reuse the rag.
make the tool.
4. Apply a 25 mm (1 inch) wide band of metal
primer (349-108) to the window recesses.
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must 3. For front glass installations install a glass spacer
be installed within 5 minutes. If the glass is not 12 mm (1/2 inch) from each corner on bottom
installed within the 5 minute period, the adhesive edge of each glass section, refer to Figure 3.
must be removed and applied again.
4. Install the glass. The glass edges must not
1. Apply a 10 mm (3/8 inch) diameter bead of contact the metal frame at any point.
adhesive (345-135) to the pr imed surface
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the
front glass apply extra adhesive in corners, refer to
Figure 3.
SILICONE SEALANT APPLICATION - FRONT WINDOWS

1. Clean the edges of the front center and front side 6. Fill the joint with the clear silicone sealant
windows. Use glass cleaning primer. (114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
2. Apply masking tape to the inside edge of each
glass sections. The sealant must extend at least
glass section next to the gap.
1.5 mm (1/16 inch) above the outside surface of
3. Apply the polyester tape on top of the masking the glass section for the length of the gap. Be
tape across the inside side gap. Do not push the sure the sealant fills against the adhesive at each
tape into the gap. end of the joint.
4. Apply masking tape to the outside edge of each 7. Remove the polyester tape from the inside joint.
glass section. Align the edge of the tape with
8. Remove the extra silicone from the outside joint
edge of glass on both sections.
by carefully sliding the forming tool down the
5. The tape must be smooth to get the best result length of the joint. The tool must remain in
when using the silicone forming tool. contact with the glass sections during this
process. Refer to Figure 2 for for ming tool
template.
9010-4
9. Remove all the silicone from the forming tool
1 2 immediately after use.
10. Remove the outside tape from the glass
sections.
11. Remove the extra silicone sealant from the inside
joint by carefully sliding the forming tool down the
length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.
3 13. Remove the inside joint masking tape.
4 14. If two or more glass sections are being replaced,

498L93
use the procedure on the second joint.
1. FRONT RH SIDE GLASS 3. SILICONE BEFORE 15. Apply the gray silicone sealant above the front
SMOOTHING center, front side or rear windows for additional
2. FRONT CENTER GLASS 4. SILICONE AFTER leak protection.
SMOOTHING
FIGURE 1. SILICONE APPLICATION 16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
NOTE: Make the forming tool from 10 mm (3/8 inch)
each front side window replaced, refer to Figure
plexiglass, or wood. Sand all radius and edges
3.
smooth.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.
6 MM 120°
(1/2 INCH) R
120°
4 MM
(3/16 INCH) R
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE
9010-5
2
1
3
4
2
1
497L93
1. SIDE GLASS ADHESIVE 4. RIGHT HAND SIDE GLASS SPACER LOCATIONS

2. CENTER GLASS ADHESIVE 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS CENTER GLASS
FIGURE 3 SILICONE APPLICATION
NOTE: After completing the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
9010-6
NOTES
Section
9020
REAR VIEW CAMERA INSTALLATION AND REMOVAL
9020
9020-2
TABLE OF CONTENTS
Rear view camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation - Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation - Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9020-3
REAR VIEW CAMERA
Installation - Camera STEP 5
STEP 1
CAMERA TO EXTENSION CABLE
Route the camera cable down through the grill

SAFETY LOCK
screen hole and connect to the extension cable.
ground. Put articulation lock in LOCKED position.
STEP 6
STEP 2
EXTENSION CABLE ROUTING 1
Route the extension cable on the left side of the hood

RAISE HOOD
and tie wrap to the existing harness.
Raise the engine hood and turn the master switch to
the off position.
STEP 7
STEP 3
Drill the camera bracket mounting holes in the screen
per Camera mounting - Illustration 1. (3 holes, 6.6
mm in screen if necessary)
STEP 4
Assemble and mount the camera brackets as shown
in Camera mounting - Ilustration 1. Route the camera
harness through the screen.
EXTENSION CABLE ROUTING 2
Route cable down left side and under fan to the right
side of the Wheel Loader. Pull cable and tie wrap
through firewall to the bottom of the fuse box.
9020-4
STEP 8 STEP 11
EXTENSION CABLE TO FUSE BOX CAMERA TO MONITOR CONNECTORS
Pull cable up through existing hole into the fuse box. In the fuse box connect the extension cable from the
camera to the CA1 cable from the monitor. Tie wrap
STEP 9 to secure cable.
STEP 12
MONITOR MOUNTING
Attach the mounting bar to Cab right post per Monitor

mounting - Illustration 2. Install the display arm and POWER TO SYSTEM
monitor as shown and tighten all nuts. Connect the remaining monitor connector to the
“MON” connector in the fuse box. Tie wrap to secure
cable.
STEP 10 STEP 13
Install the 5A fuse to F19 in the ECA fuse panel.
Always install the correct fuse size.
For additional information see the camera manual

included with the camera kit.
JUNCTION BOX UNDER SEAT
Install the access plate and route the cable with the
engine harness. The monitor cable will run through
the grommet on the access plate and up to the
monitor per Plate access mounting - Illustration 3.
9020-5
Installation - Monitor
Camera mounting - Illustration 1
84336466(1)
Monitor mounting - Illustration 2
84336466(2)
9020-6
Plate access mounting - Illustration 3
84336466(3)
Parts List - Illustration 4
84336466(4)
9020-7
Removal STEP 4
STEP 1
CAMERA ON GRILL BOTTOMVIEW
Remove the mounting bolts holding the bracket to the

SAFETY LOCK
grill screen, and remove the camera.
ground. Put articulation lock in LOCKED position.
STEP 2 STEP 5
RAISE HOOD MONITOR MOUNTING BACKSIDE
Raise the engine hood and turn the master switch to Unplug the monitor cable and loosen the handle on
the off position. display arm. Remove monitor.
STEP 3
CAMERA TO EXTENSION CABLE
Disconnect camera from the extension cable.

9020-8
ECD
INDEX OF FUNCTIONS SHT SHT SHT SHT
SHEET SHEET SHEET SHEET
BACKUP ALARM 6
, 14
COLOR ABBREVIATIONS
70
62
SHT SHT SHT SHT SHT
SHT
71
SHT
LARGE CONNECTOR LIST

SHEET
INDEX / WIRE INFORMATION 1 CONNECTOR LIST 2
SHEET SHEET SHEET
3 18
21 13 14 15
20
2
8
158
1
10
Relay in
4 location F5/F6
160
Relay in
location
F3\F4
6 11
16 17
159
CONNECTOR LIST 3 COLD START POWER DISTRIBUTION IGNITION SWITCH 4

ELECTRICAL SCHEMATIC SIDE 1
721F, 821F, 921F TIER 4 WHEEL LOADER
Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419913
22
24
92
90
CONNECT FOR NA OPERATION,

OPP SIDE STEADY ON.
DISCONNECT FOR EUROPEAN OPERATION,
162 OPP SIDE OFF.
161
Relay in
location F7\F8 Relay in
Relay in location
location 93 F9\F10
F1/F2
95
78
CAN_L3 G-0.8
CAN_H3 Y-0.8
91
North American models

European and International models
101 100 101 100
23 Turn
Signal
163
Driving
Lights
Light/
Horn
79
Horn
169 94
164
168
103
165 96 97
167
166 102
ENGINE CONTROL 5 LIGHTING 1 BACKUP ALARM 6
89 172
54
173 171
57
81 55
59
56
88
87
174
80
86
46
47
45
61
48
58
49
85
50
84
51
52
170
53
83
60
82
LIGHTING 2 7 TRANSMISSION CONTROLS 8

25
35
36
26
63 29
33
64
31
32
68 98
74
27
72
37
67
65
99
75
69
73 39
28
76
40
38 34 30
66
41
42
44
43
INSTRUMENT CLUSTER 9 MACHINE CONTROLS 10
121
113
122
155 129
154 122
104 126
128
108
105 130
114
106 125
124 123
115 119
107
117
109
156
111
116
BLUE BROWN
112
DOWN
LIMIT
UP
LIMIT
113 Note: Telematics for future models
SWITCH SWITCH
127
157
110
NO
COM 118
NC
R R
S S
HOOD LIFT 11 HVAC AIR SEAT RADIO POWER/CONVERTER 12

145
144
143
146
184
177
175
147
8
8
148
185
176
179
153
149 150
152
151
178
181
182
180
183
186
JOYSTICK STEERING (FOR PL18 & PL23 ONLY) 13 STANDARD HVAC 14

COMPONENT NUMBERS
# SHT COMPONENT # SHT COMPONENT # SHT COMPONENT # SHT COMPONENT
1 4 STARTING RELAY 61 8 DIAGNOSTIC CONNECTOR 119 12 DIAGNOSTIC CONNECTOR 177 13 ARM POS
2 4 RESISTOR - 75 OHM 62 1 INSTRUMENT CLUSTER CONNECTOR 1 121 12 POWER CONVERTER - 24 TO 12 VOLT 178 13 FNR SWITCH (OPTION)
3 4 ALTERNATOR 63 9 WARNING BUZZER 122 12 12 VOLT POWER OUTLETS (OPTION) 179 13 FNR RELAY
4 4 CRANK CONTROL RELAY 64 9 PARKING BRAKE RELAY 123 12 RADIO 180 13 PILOT DUMP VALVE
5 4 BATTERIES 65 9 FUEL LEVEL SENDER 124 12 RIGHT SPEAKER 181 13 JSS VALVE
6 4 CRANK REQUEST RELAY 66 9 AIR FILTER RESTRICTION SWITCH 125 12 LEFT SPEAKER 182 13 LOAD SENSE PRESSURE SENSOR
8 4 MASTER DISCONNECT SWITCH 67 9 PARKING BRAKE SOLENOID 126 12 AIR SEAT 183 13 PILOT PRESSURE SWITCH
9 4 STARTER 68 9 RADIATOR COOLANT TEMPERATURE SENDER 127 12 CIGAR LIGHTER 184 13 JSS RELAY
10 4 IGNITION SWITCH 69 9 BRAKE PRESSURE WARNING SWITCH 128 12 AIR CONDITIONING CLUTCH RELAY 185 13 JOYSTICK STR SWITCH (OPTION)
11 4 NEUTRAL START RELAY 70 1 SWITCH PAD 129 12 AIR CONDITIONING HIGH-LOW PRESSURE SWITCH 186 13 JSS CONTROLLER
13 4 POWER RELAY MODULE A 71 1 INSTRUMENT CLUSTER CONNECTOR 2 130 12 AIR CONDITIONING COMPRESSOR CLUTCH
14 4 POWER RELAY MODULE B 72 9 HYDRAULIC FILTER RESTRICTION SWITCH 131 NA ELECTRONIC PANEL
15 4 POWER RELAY MODULE C 73 9 HYDRAULIC OIL TEMPERATURE SENDER 132 NA EXTERNAL AIR TEMPERATURE SENSOR
16 4 GRID HEATER RELAY 74 9 PARK BRAKE SWITCH 133 NA INTERNAL AIR TEMPERATURE SENSOR
17 4 GRID HEATER 75 9 REDUNDANT BRAKE PRESSURE SWITCH 1 134 NA SUN SENSOR
18 4 POWER RELAY MODULE D 76 9 REDUNDANT BRAKE PRESSURE SWITCH 2 135 NA BLOWER FAN RESISTOR
20 4 WATER SEPARATOR HEATER 78 6 BACKUP ALARM RELAY 136 NA BLOWER MOTORS
21 4 FUEL FILTER HEATER 79 6 BACKUP ALARM DISABLE SWITCH 137 NA THERMOCOUPLE SENSOR
22 5 WATER IN FUEL SENSOR 80 7 WORK LAMPS SWITCH 138 NA MIXED AIR SENSOR
23 5 THROTTLE POTENTIOMETER 81 7 DOOR SWITCH 139 NA COMPRESSOR RELAY
24 5 ENGINE CONTROLLER 82 7 ROTATING BEACON (OPTIONAL) 140 NA RECYCLING MOTOR
25 10 RETURN TO TRAVEL FLOAT SWITCH 83 7 DOME LAMP 141 NA ELECTRONIC WATER VALVE
721F, 821F, 921F Tier 4 Wheel Loader 26 10 HEIGHT CONTROL SWITCH 84 7 ROTATING BEACON SWITCH (OPTIONAL) 142 NA 24 TO 12 VOLT CONVERTER
27 10 ELECTROMAGNETIC DETENTS 85 7 LEFT HAND FRONT WORK LAMP 143 14 ACTUATOR
ELECTRICAL SCHEMATIC 28 10 RETURN TO DIG PROXIMITY SWITCH 86 7 RIGHT HAND FRONT WORK LAMP 144 14 DRIVER
29 10 PILOT CONTROL RELAY ECD-K3 87 7 LEFT HAND REAR WORK LAMP 145 14 ELECTRONIC WATER VALVE
30 10 HEIGHT CONTROL AND RETURN TO TRAVEL PROXIMITY SW 88 7 RIGHT HAND REAR WORK LAMP 146 14 BLOWER FAN RESISTOR
31 10 RETURN TO DIG SWITCH 89 7 DIODES 147 14 BLOWER MOTOR
32 10 PIN ENGAGE SWITCH (OPTION) 90 6 BRAKE LAMP SWITCH 148 14 THERMOSTAT
LEGEND 33 10 PILOT PRESSURE SOLENOID
PIN ENGAGE SOLENOID (OPTION)
91 6 BRAKE LAMP RELAY 149 14 FAN SPEED SWITCH
34 10 92 6 FLASHER MODULE 150 14 AIR CONDITIONING SWITCH
35 10 RIDE CONTROL SWITCH (OPTION) 93 6 HAZARD SWITCH 151 14 CONTROL PANEL LAMPS
36 10 RIDE CONTROL RELAY (OPTION) 94 6 TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 152 14 WATER VALVE POTENTIOMETER
INDICATES CONSTANT POWER 37 10 FAN CONTROL SWITCH (OPTION) 95 6 DRIVING LAMPS SWITCH 153 14 AIR RECIRCULATING SWITCH
38 10 FAN REVERSE RELAY (OPTION) 96 6 LEFT HAND FRONT COMBINATION LAMPS 154 11 HOOD UP RELAY
INDICATES POWER WHEN KEY 39 10 PILOT CONTROL SWITCH 97 6 RIGHT HAND FRONT COMBINATION LAMPS 155 11 HOOD DOWN RELAY
40 10 RIDE CONTROL SOLENOID (OPTION) 98 10 HORN RELAY 156 11 HOOD SWITCH
SWITCH IS ON 41 10 ROLLBACK PRESSURE SW (XT WITH RIDE CONTROL ONLY) 99 10 HORN RELAY 157 11 HOOD MOTOR
INDICATES POWER WHEN KEY 42 10 ROLLBACK JUMPER
FAN PWM SOLENOID
100 6 RIGHT HAND REAR COMBINATION LAMPS 158 4 IGNITION POWER LATCH
43 10 101 6 LEFT HAND REAR COMBINATION LAMPS 159 4 IGNITION POWER CONTROL
SWITCH IS IN START POSITION 44 10 FAN REVERSE SOLENOID (OPTION) 102 6 LICENSE PLATE LAMP 160 4 START LOCKOUT
45 8 OUTPUT SPEED SENSOR 103 6 BACKUP ALARM 161 5 NOX SENSOR
46 8 TRANSMISSION SOLENOID VALVE AND TEMP SENDER 104 11 FRONT WIPER HIGH SPEED RELAY 162 5 HUMIDITY AND AMBIENT TEMPERATURE SENSOR
POWER RELAY A 47 8 FILTER MAINTENANCE SWITCH 105 11 WIPER CUTOUT RELAY 163 5 NOX SENSOR (NOXS)
POWER RELAY B 48 8 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 106 11 FRONT WIPER LOW SPEED RELAY 164 5 TANK HEATER CONTROL VALVE
49 8 ENGINE SPEED SENSOR 107 11 REAR WIPER AND WASHER SWITCH 165 5 DEF LEVEL AND TANK TEMPERATURE
POWER RELAY C 50 8 INTERMEDIATE SPEED SENSOR 108 11 FRONT WIPER AND WASHER SWITCH 166 5 UPSTREAM TEMPERATURE SENSOR
51 8 TURBINE SPEED SENSOR 109 11 FRONT WIPER MOTOR 167 5 DOWNSTREAM TEMPERATURE SENSOR
POWER RELAY D 52 8 TRANSMISSION SHIFTER 110 11 REAR WIPER MOTOR 168 5 DOSER METERING VALVE
53 8 TRANSMISSION ELECTRONIC CONTROL MODULE 111 11 REAR WASHER MOTOR 169 5 DNOX CONTROLLER
ILLUMINATION 54 8 TRANSMISSION ENABLE SWITCH 112 11 FRONT WASHER MOTOR 170 7 REAR VIEW CAMERA/MONITOR
55 8 FNR SWITCH FOR JOYSTICK CONTROLS 113 11 DIODES 171 8 DIFFERENTIAL LOCK SWITCH (MANUAL)
56 8 TRANSMISSION KICK DOWN SWITCH 114 11 SECONDARY STEERING DIODES 172 8 DIFFERENTIAL LOCK SWITCH
57 8 FNR SWITCH FOR SINGLE AXIS CONTROLS 115 11 SECONDARY STEERING SOLENOID 173 8 DIFFERENTIAL LOCK SOLENOID
58 8 TRANSMISSION AUTO SWITCH 116 11 SECONDARY STEERING MODULE 174 8 LOCKUP SOLENOID
59 8 BRAKE DECLUTCH PRESSURE SWITCH 117 11 SECONDARY STEERING MOTOR 175 13 JOYSTICK PVRES
60 8 DECLUTCH SWITCH 118 11 SECONDARY STEERING PRESSURE SWITCH 176 13 TRANSMISSION KICK DOWN SWITCH
ELECTRICAL WIRING INFORMATION 15 COMPONENT NUMBERING INFORMATION 16

9
1 2 19
15 18
16
21
11 YPP
A1
UNLOCK
20
P
T X1
LOCK
8 16B
MX
16A B1
20D
12 T 20A
280 bar
14
16C
20C
R R1 F
4 13A 13
2 20B
X 13F
16D
3
1
13E
5 P
2 B A
3 13D 16E
13B 1
T1
T1'
N B
240±8% L/min
240±8% L/min
280±8% L/min
20±8% L/min
B1 280±8% L/min
OPTION
22K
BOOM
BUCKET
22K
a3
a2
6 13C
T2
868050
868050
ø0.8
ø2.0
ø2.0
ø0.8
pst
22A
0.6
R2
a1
A1
A3
A2
B3
B2
P
17
765876
LS
Mp
1.2
Pst
22F
11
R901075585
898999
7
528789
528789
528789
30 bar
22C
T
22C )( 22H
22C
22G
847160
224±3 bar
R901007569
R901075587
859551
TP10: FRONT BRAKE TO AXLE 22J
22D
8-10.8 bar
329140
MT1
22B
S1
TP3: STEERING LOAD SENSE
737012
290 bar
290 bar
936718
936718
290 bar
290 bar
936718
936718
TP2: IMPLEMENT LOAD SENSE
936725
22D
TP1: UNLOADING PUMP PRESSURE 22E 22E 22D 22E
22E
S2
22
A2
280±8% A1
b1
B2
899039
868050
ø2.0
ø2.0
ø0.8
ø0.8
L/min
45C
M2 P
22K 22K
b3
b2
45B
44 45A
45
43
42 234
M2 162 bar IN bar
35 LS EF LS IMPL 24
23cc 234
M1 TANK CF
bar .64
L
.8 24A
P 24B
46
45B 45D
Note 2 T 24C
35A T 30 LS 23
M1 LS SLS ST CF 32
G1
0.7
35B 35C 27
G2 X2
R
34 X1 30A 2
33 T
240 bar 0.31 1 46
0.31
34A 33A 30B
36 29
R L
34B 33B 3
30C
40 28
Note 1 0.75 LS
23cc 34C 33C T P
P T
28A
41 P
34D 33D
1.8
28B 28C
L1 L2 S1 S2 L4 L3 p
31 26
39 11 cc
T
25
38
COMPONENTS
1 Rear Axle Brakes 11 Redundant Accumulator Pressure Switches 16C Lift Pilot Control 22F Pilot Pressure Reducing Valve 30A Auxiliary Steering Activation Solenoid 35A Priority Spool 44 Standard Fan Valve
Modulation Pressure Electrical Connectors PRB1, PRB2 16D Auxiliary Hydraulics Pilot Control 1 29 to 40 bar (420 to 580 PSI) Electrical Connector YSS 35B Differential Pressure Relief 162 bar (2350 PSI)
68 to 75 bar (985 to 1090 PSI) Rising < 91 bar (< 1320 PSI) 16E Auxiliary Hydraulics Pilot Control 2 22G Pilot Pressure Relief 30B Relief Valve 40 bar (580 PSI) 45 Fan Reversing and Variable Valve
2 Front Axle Brakes Falling 70 to 84 bar (1015 to 1220 PSI) 17 Pilot Control Accumulator 22H Load Sense Signal Bleed Down Orifice 240 bar (3480 PSI) 35C Steering Relief 45A Crossover Relief 234 bar (3395 PSI)
Modulation Pressure 12 Low Brake Pressure Warning Switch 0.75 liter (0.79 quart) 22J Loader Main Relief 30C Priority Spool 216 bar (3130 PSI) 45B Reversing Spools
70 to 77 bar (1015 to 1115 PSI) Alarm OFF 138 bar (2000 PSI) Increasing 13.8 bar (200 PSI) Precharge 22K Shuttle Check Valve 31 Auxiliary Steering Pump 36 Brake Pump 45C Pulse Width Modulation (PWM) Relief Valve
37 37 3 Brake Damping Accumulators Alarm ON 115 to 129 bar (1670 to 1870 PSI) Decreasing 18 Bucket Cylinder Z-Bar 23 Steering Cylinders 32 Auxiliary Steering Pressure Switch 37 100 Mesh Strainers 165 bar (2390 PSI)
0.16 liter (0.17 quart) 13 Brake Valve 19 Lift Cylinders 24 Steering Control Valve Electrical Connector PSS 38 Hydraulic Reservoir 45D ON/OFF Reversing Solenoid
7 bar (102 PSI) Precharge 13A Parking Brake Solenoid 20 Ride Control Valve 24A Steering Spool 33 Second Pump (Farthest from Transmission) 90 liter Electrical Connector YFR
4 Parking Brake Electrical Connector YPB 20A Ride Control Solenoid 24B Gerotor Pump 120 LPM (31.6 GPM) 39 Reservoir Vent 46 Steering Cylinder Relief Valves
5 Brake Signal, 5-speed transmission 13B Front Brake Valve Electrical Connector YRC 24C Circuit Relief Valve Cut Off 280 bar (4060 PSI) 100 mesh 345 bar (5000 PSI)
6 Brake Declutch Switch, 4-speed transmission 13C Rear Brake Valve 20B Ride Control Spool Valve 25 Steering Back Pressure Valve Delta 24 to 26 bar (350 to 375 PSI) 0.03 bar check
Electrical Connector PBD 13D Accumulator Isolation Check Valve 20C Manual Bleed Valve 8 to 10 bar (115 to 145 PSI) 33A Compensator Differential Pressure Spool 0.35 bar relief
24 bar (350 PSI) 13E Accumulator Charging Spool 20D Pressure Relief Valve 26 Steering Back Pressure Sensor 33B Compensator High Pressure Cutoff Spool 40 Filter
7 Brake Light Switch 13F Priority Valve 280 bar (4060 PSI) Joystick Steering Only 33C Control Piston with Spring Electrical Connector PHF
4.1 bar (60 PSI) Increasing Cut-In Pressure 21 Ride Control Accumulator 27 Joystick Steering Load Sense Resolver 33D Rotating Group with Swash Plate 10 micron media
8 Parking Brake Accumulator 157 to 167 bar (2275 to 2420 PSI) 3.78 liter (4 quart) 28 Joystick Steering Valve 34 First Pump (Closest to Transmission) Bypass 3.4 bar (50 PSI)
0.16 liter (0.17 quart) Cut-Out Pressure 14.5 bar (210 PSI) Precharge 28A Control Spool 120 LPM (31.6 GPM) Warning Switch 2.7 bar (40 PSI)
96 bar (1390 PSI) Precharge 190 to 196 bar (2755 to 2845 PSI) 22 Loader Valve 28B Pressure Reducer Cut Off 280 bar (4060 PSI) 41 Oil Cooler Thermal Valve
9 Front Brake Accumulator 14 Coupler Locking Valve 22A Load Sense Shuttle Valve 28C Pilot Dump Valve Delta 28 to 30 bar (405 to 435 PSI) 2.4 to 3.6 bar (35 to 52 PSI) Bypass
3.5 liter (3.7 quart) 15 Coupler Locking Cylinders 22B Regeneration Relief Valve 29 Auxiliary Steering Accumulator 34A Compensator Differential Pressure Spool 42 Hydraulic Oil Cooler
70 bar (1015 PSI) Precharge 16 Pilot Control Valve 22C Flow Compensator Spool 0.32 liter (0.34 quart) 34B Compensator High Pressure Cutoff Spool 43 Oil Cooler Fan
10 Rear Brake Accumulator, 3.5 liter, 70 bar precharge 16A Pilot ON/OFF Solenoid 22D Regeneration Check Valve 60 bar (870 PSI) Precharge 34C Control Piston with Spring
3.5 liter (3.7 quart) Electrical Connector YPP 22E Circuit Relief Valve with Anti-Cavitation 30 Auxiliary Steering Control Valve 34D Rotating Group with Swash Plate
70 bar (1015 PSI) Precharge 16B Bucket Pilot Control 35 Priority Valve
CIRCUIT DIAGRAM LEGEND NOTES CONVERSION INFORMATION

HYDRAULIC SCHEMATIC
PUMP SUPPLY
Note 1 : Optional Check Valve for Ride Control Only 1 bar = 14.5 pounds per square inch (PSI) 821F WHEEL LOADER
# CIRCUIT LOAD SENSE Note 2 : Check and Relief Valves not used with Fan Reverser 1 liter per minute = .264 gallons per minute
Additional copies of this Schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419918.
SHOWS CIRCUIT COMPONENT PILOT
CROSSING SHOWS CIRCUIT COMPONENT
NOT CONNECTED CONNECTED NUMBER CHECK VALVE RESTRICTOR FILTER OR SCREEN OIL COOLER LINE TYPES
9 19
1 2 18
15
16 21
11 A1
UNLOCK
P 20 T X1
LOCK
16B
8
MX
16A B1
20D
12 T
20A 280 bar
14
16C
20C
R R1 F
4 13
13A 2
20B
X 13F 16D
3
1
13E
5 P
2 B A
3 13D 16E
13B 1
T1
T1'
N B
B1 280±8% L/min
B3 240±8% L/min
B2 280±8% L/min
A3 240±8% L/min
20±8% L/min
22K 22K
BOOM
BUCKET
a3
a2
OPTION
6
13C
T2
868050
868050
ø0.8
ø2.0
ø2.0
ø0.8
pst
0.6 22A
R2
A1
A2
a1
17
P
765876
LS
Mp
1.2
Pst
22F
11
R901075585
7
898999
528789
528789
528789
30 bar
22C
T
)( 22H 22C
22C
22G
847160
224±3 bar
R901075587
R901007569
859551
TP10: FRONT BRAKE TO AXLE
22D 22J
8-10.8 bar
329140
MT1
22E
S1
TP3: LOAD SENSE SIGNAL
737012
290 bar
290 bar
290 bar
290 bar
936718
936718
936718
936718
936725
TP1: UNLOADING PUMP PRESSURE
22D
22E 22E 22D 22E
22E
S2
22
A2
280±8% A1
b1
B2
899039
868050
ø2.0
ø2.0
ø0.8
ø0.8
L/min
M2 45C
P
22K 22K
b3
b2
45B
44 45A 45
42 43
M2 IN 234
162 BAR bar
23cc 35 LS EF LS IMPL 24
234 CF
M1 TANK bar 0.64
L
0.47
LS1 24A
P 24B 46
LS2
45B 45D
Note 2
T 35A 24C
T 30 LS
M1 23
G1 LS SLS ST CF 32
35B 0.7
35C 27
X1 G2 X2
R
34 30A 2 T
33
240 bar 0.31 1 46
0.31
34A 33A 30B
36 29
R L
34B 33B
30C 3
40 28
Note 1 0.75 LS
23cc 34C 33C T P
P T
28A
41 P
34D 33D
1.8
28B 28C
p
L1 L2 S1 S2 L4 L3
31 26
39 11 cc
25 T
38
COMPONENTS
1 Rear Axle Brakes 11 Redundant Accumulator Pressure Switches 16C Lift Pilot Control 22F Pilot Pressure Reducing Valve 30 Auxiliary Steering Control Valve 35 Priority Valve 42 Hydraulic Oil Cooler
Modulation Pressure Electrical Connectors PRB1, PRB2 16D Auxiliary Hydraulics Pilot Control 1 29 to 40 bar (420 to 580 PSI) 30A Auxiliary Steering Activation Solenoid 35A Priority Spool 43 Oil Cooler Fan
68 to 75 bar (985 to 1090 PSI) Rising < 91 bar (< 1320 PSI) 16E Auxiliary Hydraulics Pilot Control 2 22G Pilot Pressure Relief Electrical Connector YSS 35B Differential Pressure Relief 44 Standard Fan Valve
2 Front Axle Brakes Falling 70 to 84 bar (1015 to 1220 PSI) 17 Pilot Control Accumulator 22H Load Sense Signal Bleed Down Orifice 30B Relief Valve 40 bar (580 PSI) 162 bar (2350 PSI)
Modulation Pressure 12 Low Brake Pressure Warning Switch 0.75 liter (0.79 quart) 22J Loader Main Relief 240 bar (3480 PSI) 35C Steering Relief 45 Fan Reversing and Variable Valve
37 37 70 to 77 bar (1015 to 1115 PSI) Alarm OFF 138 bar (2000 PSI) Increasing 13.8 bar (200 PSI) Precharge 22K Shuttle Check Valve 30C Priority Spool 216 bar (3130 PSI) 45A Crossover Relief 234 bar (3395 PSI)
3 Brake Damping Accumulators Alarm ON 115 to 129 bar (1670 to 1870 PSI) Decreasing 18 Bucket Cylinder Z-Bar 23 Steering Cylinders 31 Auxiliary Steering Pump 36 Brake Pump 45B Reversing Spools
0.16 liter (0.17 quart) 13 Brake Valve 19 Lift Cylinders 24 Steering Control Valve 32 Auxiliary Steering Pressure Switch 37 100 Mesh Strainers 45C Pulse Width Modulation (PWM) Relief Valve
7 bar (102 PSI) Precharge 13A Parking Brake Solenoid 20 Ride Control Valve 24A Steering Spool Electrical Connector PSS 38 Hydraulic Reservoir 165 bar (2390 PSI)
4 Parking Brake Electrical Connector YPB 20A Ride Control Solenoid 24B Gerotor Pump 33 Second Pump (Farthest from Transmission) 108.5 liter 45D ON/OFF Reversing Solenoid
5 Brake Signal, 5-speed transmission 13B Front Brake Valve Electrical Connector YRC 24C Circuit Relief Valve 120 LPM (31.6 GPM) 39 Reservoir Vent Electrical Connector YFR
6 Brake Declutch Switch, 4-speed transmission 13C Rear Brake Valve 20B Ride Control Spool Valve 25 Steering Back Pressure Valve Cut Off 280 bar (4060 PSI) 100 mesh 46 Steering Cylinder Relief Valves
Electrical Connector PBD 13D Accumulator Isolation Check Valve 20C Manual Bleed Valve 8 to 10 bar (115 to 145 PSI) Delta 21 to 23 bar (305 to 335 PSI) 0.03 bar check 345 bar (5000 PSI)
24 bar (350 PSI) 13E Accumulator Charging Spool 20D Pressure Relief Valve 26 Steering Back Pressure Sensor 33A Compensator Differential Pressure Spool 0.35 bar relief
7 Brake Light Switch 13F Priority Valve 280 bar (4060 PSI) Joystick Steering Only 33B Compensator High Pressure Cutoff Spool 40 Filter
4.1 bar (60 PSI) Increasing Cut-In Pressure 21 Ride Control Accumulator 27 Joystick Steering Load Sense Resolver 33C Control Piston with Spring Electrical Connector PHF
8 Parking Brake Accumulator 157 to 167 bar (2275 to 2420 PSI) 3.78 liter (4 quart) 28 Joystick Steering Valve 33D Rotating Group with Swash Plate 10 micron media
0.16 liter (0.17 quart) Cut-Out Pressure 14.5 bar (210 PSI) Precharge 28A Control Spool 34 First Pump (Closest to Transmission) Bypass 3.4 bar (50 PSI)
96 bar (1390 PSI) Precharge 190 to 196 bar (2755 to 2845 PSI) 22 Loader Valve 28B Pressure Reducer 162 LPM (42.7 GPM) Warning Switch 2.7 bar (40 PSI)
9 Front Brake Accumulator 14 Coupler Locking Valve 22A Load Sense Shuttle Valve 28C Pilot Dump Valve Cut Off 280 bar (4060 PSI) 41 Oil Cooler Thermal Valve
3.5 liter (3.7 quart) 15 Coupler Locking Cylinders 22B Regeneration Relief Valve 29 Auxiliary Steering Accumulator Delta 24 to 26 bar (350 to 380 PSI) 2.4 to 3.6 bar (35 to 52 PSI) Bypass
70 bar (1015 PSI) Precharge 16 Pilot Control Valve 22C Flow Compensator Spool 0.32 liter (0.34 quart) 34A Compensator Differential Pressure Spool
10 Rear Brake Accumulator, 3.5 liter, 70 bar precharge 16A Pilot ON/OFF Solenoid 22D Regeneration Check Valve 60 bar (870 PSI) Precharge 34B Compensator High Pressure Cutoff Spool
3.5 liter (3.7 quart) Electrical Connector YPP 22E Circuit Relief Valve with Anti-Cavitation 34C Control Piston with Spring
70 bar (1015 PSI) Precharge 16B Bucket Pilot Control 34D Rotating Group with Swash Plate
CIRCUIT DIAGRAM LEGEND NOTES CONVERSION INFORMATION

HYDRAULIC SCHEMATIC
PUMP SUPPLY
Note 1 : Optional Check Valve for Ride Control Only 1 bar = 14.5 pounds per square inch (PSI) 921F WHEEL LOADER
# CIRCUIT LOAD SENSE Note 2 : Check and Relief Valves not used with Fan Reverser 1 liter per minute = .264 gallons per minute
Additional copies of this Schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419921.
SHOWS CIRCUIT COMPONENT PILOT
CROSSING SHOWS CIRCUIT COMPONENT
NOT CONNECTED CONNECTED NUMBER CHECK VALVE RESTRICTOR FILTER OR SCREEN OIL COOLER LINE TYPES

84487565-SM-821F 921F Tier4

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84487565-SM-821F 921F Tier4

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821F

Printed in U.S.A. Part number 84487565

GENERAL TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Pound- Newton Pound- Newton

TORQUE SPECIFICATIONS - METRIC HARDWARE

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

Pound- Newton M24 780 to 940 1050 to 1275

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-ring

Split Flange Mounting Bolts

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Boss End

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

FLUIDS AND LUBRICANTS

821F - CAPACITIES AND LUBRICANTS

921F - CAPACITIES AND LUBRICANTS

ENGINE OIL RECOMMENDATIONS

TRANSMISSION TEMPERATURE CHART

DIESEL FUEL SYSTEM

The diesel fuel used in this machine must meet the

Specifications for Acceptable No. 2 Diesel Fuel

What is Selective Catalytic Reduction (SCR)?

SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS

2 Radiator Coolant Level *

13 Check Engine Coolant Level 50

Every 250 14 Check Tire Pressure & Wheel Torque 4 250

Every 500 16 Change Engine Oil and Filter 500

20 Replace Hydraulic Oil filter 1000

Every 6000 XX Engine Injectors (Engine Manual) 6000

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

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

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

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

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

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

Volume: cubic centimeter 0.061 024 cubic inch

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

Area: square foot 0.092 903 square meter

Force: ounce force 0.278 014 newton

Length: inch 25.4 * millimeter

Mass: pound 0.453 592 kilogram

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

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

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

Power: horsepower 0.745 700 kilowatt

Pressure: lbs/sq. in. 6.894 757 kilopascal

Temperature: degree F 1.8 F - 32 degree C

Torque: pound/inch 0.112 985 newton meter

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

Volume: cubic inch 16.387 06 cubic centimeter

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

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

Put a 30 liter (32 U.S. quart) container below radiator