Documente Academic
Documente Profesional
Documente Cultură
WHEEL LOADER
821E
TIER 3
84299244
(Replaces 87364100)
SECTION INDEX
GENERAL
Section Title
Section Number
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A.
Bur 5-3090
1001
Section
1001
GENERAL TORQUE SPECIFICATIONS
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A.
Bur 8-71603
1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 8-71603
Revised 7-05
3
4
5
6
Printed in U.S.A.
1001-3
PoundInches
Newton
metres
1/4 inch
144 to 180
16 to 20
5/16 inch
288 to 348
33 to 39
3/8 inch
540 to 648
61 to 73
Size
PoundInches
Newton
metres
Size
PoundFeet
Newton
metres
1/4 inch
108 to 132
12 to 15
7/16 inch
70 to 84
95 to 114
5/16 inch
204 to 252
23 to 28
1/2 inch
110 to 132
149 to 179
3/8 inch
420 to 504
48 to 57
9/16 inch
160 to 192
217 to 260
5/8 inch
220 to 264
298 to 358
Newton
metres
3/4 inch
380 to 456
515 to 618
Size
PoundFeet
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
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
Size
Bur 8-71603
Revised 7-05
Printed in U.S.A.
1001-4
Size
PoundInches
Size
PoundInches
Newton
metres
M4
36 to 48
4 to 5
M5
84 to 96
9 to 11
M6
132 to 156
15 to 18
M8
324 to 384
37 to 43
PoundFeet
Newton
metres
Newton
metres
M4
24 to 36
3 to 4
Size
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
Newton
metres
M24
780 to 940
1050 to 1275
Size
PoundFeet
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
M16
160 to 200
217 to 271
M20
320 to 380
434 to 515
M24
500 to 600
675 to 815
M30
920 to 1100
1250 to 1500
M36
1600 to 1950
2175 to 2600
Bur 8-71603
Revised 7-05
Printed in U.S.A.
1001-5
Tube OD
Hose ID
Thread
Size
PoundInches
Newton
metres
Tube OD
Hose ID
Thread
Size
PoundInches
Newton
metres
1/4 inch
6.4 mm
7/16-20
72 to 144
8 to 16
1/4 inch
6.4 mm
7/16-20
144 to 228
16 to 26
5/16 inch
7.9 mm
1/2-20
96 to 192
11 to 22
5/16 inch
7.9 mm
1/2-20
192 to 300
22 to 34
3/8 inch
9.5 mm
9/16-18
120 to 300
14 to 34
3/8 inch
9.5 mm
9/16-18
300 to 480
34 to 54
1/2 inch
12.7 mm
3/4-16
180 to 504
20 to 57
1/2 inch
12.7 mm
3/4-16
540 to 804
57 to 91
5/8 inch
15.9 mm
7/8-14
300 to 696
34 to 79
Tube OD
Hose ID
Thread
Size
PoundFeet
Newton
metres
Tube OD
Hose ID
Thread
Size
PoundFeet
Newton
metres
5/8 inch
15.9 mm
7/8-14
58 to 92
79 to 124
3/4 inch
19.0 mm
1-1/16-12
40 to 80
54 to 108
3/4 inch
19.0 mm
1-1/16-12
80 to 128
108 to 174
7/8 inch
22.2 mm
1-3/16-12
60 to 100
81 to 135
7/8 inch
22.2 mm
1-3/16-12
100 to 160
136 to 216
1.0 inch
25.4 mm
1-5/16-12
75 to 117
102 to 158
1.0 inch
25.4 mm
1-5/16-12
117 to 187
159 to 253
1-1/4 inch
31.8 mm
1-5/8-12
125 to 165
169 to 223
1-1/4 inch
31.8 mm
1-5/8-12
165 to 264
224 to 357
1-1/2 inch
38.1 mm
1-7/8-12
210 to 250
285 to 338
1-1/2 inch
38.1 mm
1-7/8-12
250 to 400
339 to 542
Newton
metres
5/16-18
180 to 240
20 to 27
3/8-16
240 to 300
27 to 34
7/16-14
420 to 540
47 to 61
Size
PoundFeet
Newton
metres
1/2-13
55 to 65
74 to 88
5/8-11
140 to 150
190 to 203
Size
Bur 8-71603
Revised 7-05
Printed in U.S.A.
1001-6
Tube OD
Thread
Size
PoundInches
Newton
metres
Thread
Size
PoundInches
Newton
metres
-4
1/4 inch
6.4 mm
9/16-18
120 to 144
14 to 16
7/16-20
204 to 240
23 to 27
-6
3/8 inch
9.5 mm
11/16-16
216 to 240
24 to 27
9/16-18
300 to 360
34 to 41
-8
1/2 inch
12.7 mm
13/16-16
384 to 480
43 to 54
3/4-16
540 to 600
61 to 68
Thread
Size
PoundFeet
Newton
metres
7/8-14
60 to 65
81 to 88
1-1/16-12
85 to 90
115 to 122
-10
Nom.
SAE
Dash
Size
5/8 inch
15.9 mm
Tube OD
1-14
552 to 672
62 to 76
Thread
Size
PoundFeet
Newton
metres
1-3/16-12
95 to 100
129 to 136
-12
3/4 inch
19.0 mm
1-3/16-12
65 to 80
90 to 110
1-5/16-12
115 to 125
156 to 169
-14
7/8 inch
22.2 mm
1-3/16-12
65 to 80
90 to 110
1-5/8-12
150 to 160
203 to 217
-16
1.0 inch
25.4 mm
1-7/16-12
92 to 105
125 to 140
1-7/8-12
190 to 200
258 to 271
-20
1-1/4 inch
31.8 mm
1-11/16-12
125 to 140
170 to 190
-24
1-1/2 inch
38.1 mm
2-12
150 to 180
200 to 254
Bur 8-71603
Revised 7-05
Printed in U.S.A.
1002
Section
1002
FLUIDS AND LUBRICANTS
Bur 5-3100
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 821E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3100
Issued 8-06
3
4
5
5
5
5
6
6
7
7
Printed in U.S.A.
1002-3
Bur 5-3100
Issued 8-06
Printed in U.S.A.
1002-4
RH99K130
BD03A102
BC02N250
Bur 5-3100
Issued 8-06
Printed in U.S.A.
1002-5
BC04F193
Fuel Storage
If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
tank. Many engine problems are caused by water in
the fuel.
Keep the fuel storage tank outside and keep the fuel
as cool as possible. Remove water from the storage
container at regular periods of time.
Fill the fuel tank at the end of the daily operating
period to prevent condensation in the fuel tank.
Bur 5-3100
Issued 8-06
Printed in U.S.A.
1002-6
MAINTENANCE SCHEDULE
Model 821E
Variable
Periodic
(*)
13
14
Tires
19
Hydraulic Filter
22
29
Air cleaner
XX
Fire extinguisher
Every 10 Hours 1
10
50
50
50
5&6
18
Every 500
Hours
Every 1000
Hours
Every 2000
Hours
Every 6000
hours
Bur 5-3100
50
50
100
18 & 26
100
19
100
21
100
100
100
10
100
11
100
12 & 23
13
14
22
XX
250
250
4
250
250
1000
250
15
500
16
500
17
500
17
500
18
26
500
19
1000
20
21
ADJUST
REPLACE
LUBRICATE
DRAIN
CHANGE
CLEAN
17
Every 250
Hours
*
*
*
*
*
*
Every 50 Hours 4
SERVICE POINTS
CHECK
ITEM
NUMBER
SERVICE
INTERVAL
Initial Service
FREQUENCY IN HOURS
500
1000
1000
22
23
1000
25
XX
XX
1000
XX
1000
1000
1000
1000
27
2000
28
Change Coolant
2000
29
XX
2000
XX
6000
XX
6000
2000
6000
Issued 8-06
Printed in U.S.A.
1002-7
MAINTENANCE POINTS
Model 821E
1
29
12 23
17
11
10
26
18
14
21 15
19 25 24
10
21 15
13
16
22
11
5
17
20
18
17
28
27
BC06F531
Bur 5-3100
Issued 8-06
Printed in U.S.A.
1002-8
NOTES
Bur 5-3100
Issued 8-06
Printed in U.S.A.
1003
Section
1003
METRIC CONVERSION CHART
Bur 7-52590
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bur 7-52590
Issued 4-03
Printed in U.S.A.
1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY
BY
TO OBTAIN
Area:
sq. meter
hectare
10.763 91
2.471 05
square foot
acre
Force:
newton
newton
3.596 942
0.224 809
ounce force
pound force
Length:
millimeter
meter
kilometer
0.039 370
3.280 840
0.621 371
inch
foot
mile
Mass:
kilogram
2.204 622
pound
Mass/Area:
kilogram/hectare
0.000 466
ton/acre
Mass/Energy:
gr/kW/hr.
0.001 644
lbs/hp/hr.
Mass/Volume:
kg/cubic meter
1.685 555
lb/cubic yd.
Power:
kilowatt
1.341 02
horsepower
Pressure:
kilopascal
bar
0.145 038
14.50385
lb/sq. inch
lb/sq. inch
Temperature:
degree C
1.8 x C +32
degree F
Torque:
newton meter
newton meter
8.850 748
0.737 562
lb/inch
lb/foot
Velocity:
kilometer/hr.
0.621 371
miles/hr.
Volume:
cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre
0.061 024
35.314 66
1.307 950
0.033 814
1.056 814
0.879 877
0.264 172
0.219 969
cubic inch
cubic foot
cubic yd.
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US liquid)
gallon (Imperial)
Volume/Time:
litre/min.
litre/min.
0.264 172
0.219 969
Bur 7-52590
Issued 4-03
Printed in U.S.A.
1003-4
U.S. to Metric
MULTIPLY
BY
TO OBTAIN
Area:
square foot
acre
0.092 903
0.404 686
square meter
hectare
Force:
ounce force
pound force
0.278 014
4.448 222
newton
newton
Length:
inch
foot
mile
25.4 *
0.304 8 *
1.609 344 *
millimeter
meter
kilometer
Mass:
pound
ounce
0.453 592
28.35
kilogram
gram
Mass/Area:
ton/acre
2241 702
kilogram/hectare
Mass/Energy:
lb/hp/hr
608.277 4
gr/kW/hr
Mass/Volume:
lb/cubic yd.
0.593 276
kg/cubic meter
Power:
horsepower
0.745 700
kilowatt
Pressure:
lbs/sq. in.
lbs/sq. in.
lbs/sq. in.
6.894 757
0.069
0.070 303
kilopascal
bar
kg/sq. cm
Temperature:
degree F
1.8 F - 32
degree C
Torque:
pound/inch
pound/foot
0.112 985
1.355 818
newton meter
newton meter
Velocity:
miles/hr.
1.609 344 *
kilometer/hr.
Volume:
cubic inch
cubic foot
cubic yard
ounce (US fluid)
quart (US liquid)
quart (Imperial)
gallon (US)
gallons (Imperial)
16.387 06
0.028 317
0.764.555
29.573 53
0.946 353
1.136 523
3.785 412
4.546 092
cubic centimeter
cubic meter
cubic meter
milliliter
litre
litre
litre
litre
Volume/Time:
gallon/min.
3.785 412
litre/min.
* = exact
Bur 7-52590
Issued 4-03
Printed in U.S.A.
SECTION INDEX
ENGINES
Section Title
Section Number
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A.
Bur 5-3110
Section
2000
Bur 5-2700
2000
2000-2
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2700
Issued 8-06
3
3
10
18
18
20
Printed in U.S.A.
2000-3
ENGINE
Removal
STEP 5
STEP 1
BD02N160
STEP 2
STEP 6
BD03A040
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD02N160
BD06F108
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-4
STEP 7
STEP 10
BD03A231
BD06F109
STEP 8
STEP 11
1
BD03A230
BD03A227
STEP 9
2
BD03A226
BD03A228
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-5
STEP 12
STEP 15
BD03A232
BD06F110
STEP 16
STEP 13
BD06F110
BD03A224
STEP 17
STEP 14
BD03A115
BD03A225
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-6
STEP 18
STEP 21
BD06F111
BD06F112
STEP 22
STEP 19
BD06F113
BD03A118
STEP 20
BD06F114
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-7
STEP 23
STEP 26
BD06F115
BD06F118
STEP 24
STEP 27
BD06F116
BD06F119
STEP 25
STEP 28
1
1
2
BD06F117
BD06F120
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-8
STEP 29
STEP 32
1
3
BD06F121
BD06F111
STEP 33
STEP 30
BD03A142
STEP 34
STEP 31
3
2
1
BD06F123
Issued 8-06
Printed in U.S.A.
2000-9
STEP 35
STEP 38
BD06F127
BD06F124
STEP 39
STEP 36
BD03A172
BD06F125
STEP 40
STEP 37
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
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-10
Installation
1
2
2
3
4
5
6
6
7
7
8
4
5
6
7
BS03B035
3. INSOLATOR UPPER
4. INSOLATOR LOWER
STEP 42
5. WASHER
6. WASHER
7. NUT
8. REMOTE OIL DRAIN HOSE
STEP 47
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
Tighten engine mounting bolts to a torque of 244 to
298 Nm (180 to 220 lb-ft).
STEP 45
Disconnect lifting equipment from engine lifting
brackets.
STEP 46
Connect engine oil drain hose to frame bracket.
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-11
STEP 48
STEP 51
BD06F127
BD06F124
STEP 49
STEP 52
BD06F126
BD06F123
STEP 53
STEP 50
BD03A142
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-12
STEP 54
STEP 57
1
2
BD06F111
BD06F121
STEP 55
STEP 58
3
1
2
2
BD06F122
STEP 56
BD06F120
STEP 59
BD06F146
BD06F119
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-13
STEP 60
STEP 63
BD06F118
BD06F115
STEP 64
STEP 61
1
2
BD06F113
BD06F117
STEP 62
BD06F114
BD06F116
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-14
STEP 65
STEP 68
BD06F112
BD06F111
STEP 69
STEP 66
BD03A115
BD06F110
STEP 70
STEP 67
BD06F110
BD03A118
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-15
STEP 71
STEP 74
BD06F110
STEP 72
BD03A232
STEP 75
BD03A225
BD03A227
STEP 73
BD03A226
BD03A224
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-16
STEP 76
STEP 78
1
BD03A228
BD03A221
Install the pin from the top of the lifting motor, lower
and remove lifting equipment.
STEP 77
BD06F109
Bur 5-2700
Y
X
(MM) (MM)
Y
X
(MM) (MM)
Y
X
(MM) (MM)
19
21
14
41
61
19
22
14
42
62
18
23
14
43
63
18
24
13
44
64
18
25
13
45
65
18
26
13
46
66
17
27
13
47
67
17
28
12
48
68
17
29
12
49
69
10
17
30
12
50
70
11
16
31
12
51
71
12
16
32
12
52
72
13
16
33
11
53
73
14
16
34
11
54
74
15
16
35
11
55
75
16
15
36
11
56
76
17
15
37
10
57
77
18
15
38
10
58
78
19
15
39
10
59
79
20
14
40
10
60
80
Issued 8-06
Printed in U.S.A.
2000-17
STEP 79
STEP 85
BD02N160
BD06F108
STEP 80
STEP 86
STEP 81
If hydraulic reservoir was drained, fill reservoir with
105.7 liters (27.9 gallons) of Case AKCELA Hy-Tran
Ultra fluid.
STEP 82
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 36.9 liters (9.75 gallons). Install the
radiator cap. Fill the coolant reservoir up to the FULL
mark on the reservoir.
STEP 83
Connect the batteries, install battery covers, put
master disconnect switch in ON position.
STEP 84
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
an d wat er. Wh en the coo lan t is at o pe ra ting
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.
Bur 5-2700
Issued 8-06
Printed in U.S.A.
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
STEP 6
BD03A040
STEP 3
Put master disconnect switch in OFF position.
STEP 4
BD02N160
STEP 7
BD03A120
BD03A109
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-19
STEP 8
STEP 11
1
2
BD03A108
BD03A106
STEP 9
BD06F129
STEP 10
BD03A113
Bur 5-2700
Issued 8-06
Printed in U.S.A.
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
STEP 16
BD03A106
STEP 14
BD03A108
STEP 17
BD03A113
BD06F130
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-21
STEP 18
STEP 21
BD06F131
BD03A120
STEP 19
STEP 22
BD06F132
Align the slots in the fender with the tabs on the body
of the machine.
STEP 20
BD02N160
STEP 23
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 36.9 liter (9.75 gallon). Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
DSC00105.TIF
Bur 5-2700
Issued 8-06
Printed in U.S.A.
2000-22
STEP 24
Put master disconnect switch in ON position.
STEP 25
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 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.
Bur 5-2700
STEP 26
Put articulation lock in OPERATING position.
Issued 8-06
Printed in U.S.A.
2002
Section
2002
STALL TEST
Bur 5-3120
2002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3120
Issued 8-06
3
3
3
3
5
5
5
6
7
7
7
7
7
8
8
Printed in U.S.A.
2002-3
SPECIFICATIONS
Low idle ..............................................................................................................................................875 to 925 rpm
Alternate low idle .................................................................................................................................575 to 625 rpm
Cold low idle ....................................................................................................................................1175 to 1225 rpm
In gear low idle when in boost or auto power modes (see note) .....................................................1050 to 1150 rpm
Full throttle (no load)........................................................................................................................2090 to 2225 rpm
Temperature of the torque converter oil....................................................................... 82 to 104 C (180 to 220 F)
Temperature of the hydraulic oil....................................................................................... 54 to 57C (129 to 134F)
NOTE: This low idle will be held after the engine has accelerated over 1400 rpm while in gear. It will remain at this
accelerated level until the transmission is placed back into neutral for two seconds.
Stall Speeds
Torque converter..............................................................................................................................1750 to 1895 rpm
Hydraulic system .............................................................................................................................1860 to 2175 rpm
Torque converter and hydraulic system together.............................................................................1500 to 1800 rpm
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
BD06F183
BD06F188
Bur 5-3120
Issued 8-06
Printed in U.S.A.
2002-4
BD06F169
BD06F027
BD06F170
BD06F184
Bur 5-3120
Issued 8-06
Printed in U.S.A.
2002-5
Hydraulic System
Bur 5-3120
Issued 8-06
Printed in U.S.A.
2002-6
BD06H038
Bur 5-3120
Issued 8-06
Printed in U.S.A.
2002-7
Bur 5-3120
Issued 8-06
Printed in U.S.A.
2002-8
Bur 5-3120
Issued 8-06
Printed in U.S.A.
2003
Section
2003
AFTER COOLER
Bur 6-49850
2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-49850
Issued 2-04
3
4
4
6
6
Printed in U.S.A.
2003-3
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
(rpm). Record pressure readings for both gauges. If
the pressure difference is greater than 60 mBar
(0.87 psi), inspect cooler components for damaged
or missing parts.
BD03A118
STEP 6
STEP 4
BD03A119
BD03A116
STEP 7
STEP 5
BD03A109
BD03A115
Bur 6-49850
Issued 2-04
Printed in U.S.A.
2003-4
AFTERCOOLER REMOVAL
Removal
STEP 4
STEP 1
BD03A118
STEP 5
STEP 2
BD03112
BD03A115
STEP 6
STEP 3
BD03A111
BD03A119
Bur 6-49850
Issued 2-04
Printed in U.S.A.
2003-5
STEP 7
STEP 10
BD03A109
BD03A113
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
STEP 9
BD03A111
BD03A117
Bur 6-49850
Issued 2-04
Printed in U.S.A.
2003-6
Leak Test
Installation
STEP 1
BD03A111
BS03B028
Check the core for leaks by closing off the outlet tube
and attaching regulated air pressure 550kPa (80psi)
to the inlet tube. Submerge the cooler in water and
watch for air leakage.
NOTE: If leakage is detected replace the after
cooler.
STEP 2
BD03A113
STEP 3
BD03A117
Bur 6-49850
Issued 2-04
Printed in U.S.A.
2003-7
STEP 4
STEP 7
BD03A107
BD03A116
STEP 8
STEP 5
BD03A115
BD03112
STEP 9
STEP 6
BD03A119
Bur 6-49850
Issued 2-04
Printed in U.S.A.
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
Bur 6-49850
Issued 2-04
Printed in U.S.A.
SECTION INDEX
FUEL SYSTEM
Section Title
Section Number
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A.
Bur 5-3130
4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND
ALTERNATOR
Bur 5-2740
4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
With Out Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
With Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2740
Issued 8-06
3
3
4
5
5
6
8
8
8
Printed in U.S.A.
4001-3
STARTER
Removal
STEP 4
STEP 1
Park machine on a level surface and lower bucket to
ground.
STEP 2
BD06F135
BD06F133
STEP 3
BD06F134
Bur 5-2740
Issued 8-06
Printed in U.S.A.
4001-4
Installation
STEP 7
STEP 5
1
BD06F134
STEP 8
BC05G047
1. STUDS
2. NUTS
STEP 6
2
BD06F135
Bur 5-2740
Issued 8-06
Printed in U.S.A.
4001-5
ALTERNATOR
Removal
STEP 4
STEP 1
Park machine on a level surface and lower bucket to
ground.
STEP 2
BD06F137
BD06F133
STEP 3
BD06F138
STEP 5
BD06F136
BD06F139
Bur 5-2740
Issued 8-06
Printed in U.S.A.
4001-6
Installation
STEP 6
STEP 7
BD06F140
BD06F140
STEP 8
BD06F139
Bur 5-2740
Issued 8-06
Printed in U.S.A.
4001-7
STEP 9
STEP 10
BD06F137
BD06F136
STEP 11
BD06F138
BD06F133
Bur 5-2740
Issued 8-06
Printed in U.S.A.
4001-8
BELT INSTALLATION
BC05G045
BC05G046
Bur 5-2740
Issued 8-06
Printed in U.S.A.
4002
Section
4002
ELECTRICAL SPECIFICATIONS AND
TROUBLESHOOTING
Bur 5-2750
4002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltmeter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Relay Module A, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Relay Module B, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Relay Module C, For Fuel Filter Heater and Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . .
Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit breaker Cab B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Relay Module D, Accessory Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2750
Issued 8-06
7
8
38
38
38
39
40
40
40
41
41
41
42
42
43
43
44
44
45
46
46
46
47
47
47
47
48
48
49
50
50
51
52
53
53
54
54
55
55
55
56
56
56
57
58
58
59
59
60
60
60
61
61
61
Printed in U.S.A.
4002-3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for
Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-4
Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Power Relay Module E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-5
Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Recirculation Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOOD RAISE AND LOWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2750
Issued 8-06
117
118
118
118
118
119
120
120
120
120
120
121
121
121
121
121
122
123
124
124
124
125
126
Printed in U.S.A.
4002-6
NOTES
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage................................................................................................................................................24 volts
Batteries
Group Size ..........................................................................................................................................................31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17 C (0 F) for 60 Seconds At 6.0 Volts................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Alternator ..................................................................................................................................... 24 volt, 65 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20 C (68 F) (Nominal)................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20 C (68 F) (Nominal) ........... 305 ohms
Fuel Level Sender............................................................................................................................... 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20 C (68 F) ......................................... 3521 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Set point ............................................................................................................................ 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig)
A/C Trinary Pressure Switch (Closed With Normal System Pressure)
Opens With Pressure ............................................................................ Above 28.5 2.5 bar (413.3 36,25 psi)
Below 2.5 0.25 bar (36.25 3.6 psi)
Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi)
Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi)
Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Set point........................ 5 to 6 bar increasing (75 to 85 psi)
Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi)
Fuel Filters Heater Resistance At 20 C (68 F) (Nominal) .......................................................................... 1.9 ohms
Parking Brake Solenoid DC Resistance At 20 C (68 F) (Nominal) .......................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20 C (68 F) (Nominal) .......................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20 C (68 F) (Nominal) ..................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20 C (68 F) (Nominal)............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20 C (68 F) (Nominal) .............................................................. 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20 C (68 F) (Nominal) ................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20 C (68 F) (Nominal).......................................................... 39.3 ohms
Fan PWM Solenoid DC Resistance At 20 C (68 F) (Nominal) ..................................................................xx.x ohms
Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi)
Fuel Temperature Sensor At 20 C (68 F) (Nominal) ............................................................................... 2500 ohms
Grid Heater .................................................................................................................................................. 500 ohms
Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)
Analog Throttle ..................................................................................Idle Validation Switch Closes At 0.775V 0.1V
Throttle Position Potentiometer.................................................................................................. 5V Reference 0.2V
Low Idle Position .............................................................................................................................. 0.4V 0.025V
High Idle Position ................................................................................................................................. 4.0V 0.1V
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-8
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
14
Alternator D+
42
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
AD, Alternator D+
26
SPL-WL, Ultrasonic
23
44
T 1.0 SXL
23
49
Back Lt Power
DU1.0 GXL
D-OR, Diode OR
52
W 0.8 TXL
23
B8
56
W 0.8 TXL
23
26
57
W 1.0 SXL
20
58
W 1.0 SXL
64
Horn Power
Or 1.0 SXL
13
0 29
RTT/Float Ground
Bk 0.8 GXL
0 AA
Bk 1.0 SXL
SPL-A2, Ultrasonic
0 AB
Bk 1.0 SXL
SPL-A2, Ultrasonic
GND-FC, Ground A
0 AC
Bk 1.0 SXL
PXF, RTD
SPL-A2, Ultrasonic
0 AD
Bk 1.0 SXL
SPL-A1, Ultrasonic
0 AE
Bk 1.0 SXL
SPL-A1, Ultrasonic
0 AF
Horn Ground
Bk 1.0 SXL
SPL-A1, Ultrasonic
0 AG
Bk 2.0 SXL
SPL-A1, Ultrasonic
GND-FC, Ground A
0 AH
Bk 1.0 SXL
SPL-A1, Ultrasonic
LRF, Lights RH
0 AJ
Bk 1.0 SXL
SPL-A1, Ultrasonic
LLF, Lights LH
0 AK
Bk 1.0 SXL
SPL-A4, Ultrasonic
GND-FC, Ground A
0 AL
Bk 1.0 SXL
SPL-A4, Ultrasonic
0 AM
RTD Grnd
Bk 1.0 SXL
PXM, RTD
PXT, RTD
0 AN
Bk 1.0 SXL
SPL-A4, Ultrasonic
0 AP
Bk 5.0 SXL
GND-S1, Ground A
GND-S2, Ground A
0 AQ
Bk 1.0 SXL
SPL-A4, Ultrasonic
0 AR
0B
Bk 1.0 SXL
0 B1
Bk 0.8 GXL
Bur 5-2750
Lg 1.0 SXL
Issued 8-06
Printed in U.S.A.
4002-9
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
K = Pink
U = Blue
Y = Yellow
To Connector
Connector
Cavity
Connector
Cavity
0 B2
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
0 B3
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
0 B4
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
0 B5
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
0 B6
Cab2 Ground
Bk 1.0 GXL
GND-CAB2, Ground A
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
0 B7
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
0 B8
Bk 0.8 GXL
SPL-BCK-LT-GD, Spl Bk Lt
Grnd
0 B9
Bk 0.8 GXL
Bk 1.0 GXL
SPL-HOOD-GRND, Hood
Grnd 6 Pck
GND-CAB2, Ground A
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
Bk 1.0 GXL
SPL-HOOD-GRND, Hood
Grnd 6 Pck
C4
Bk 1.0 GXL
SPL-BCK-LT-GD, Spl Bk Lt
Grnd
GND-CAB2, Ground A
Bk 0.8 GXL
Bk 0.8 GXL
Bk 1.0 GXL
SPL-HOOD-GRND, Hood
Grnd 6 Pck
B4
Bk 0.8 GXL
Bk 0.8 GXL
Bk 0.8 GXL
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
Bk 1.0 GXL
Bk 1.0 GXL
SPL-HOOD-GRND, Hood
Gnd 6 Pck
Bur 5-2750
Issued 8-06
C2
Printed in U.S.A.
4002-10
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Bk 0.8 GXL
Bk 0.8 GXL
Bk 1.0 GXL
SPL-HOOD-GRND, Hood
Gnd 6 Pck
B2
Bk 0.8 GXL
SPL-BUZ, Ultrasonic
SPL-BCK-LT-GD2, Spl Bk Lt
Grnd
Bk 0.8 GXL
SPL-BUZ, Ultrasonic
Bk 0.8 TXL
10
SPL-BUZ, Ultrasonic
Bk 0.8 GXL
Bk 0.8 GXL
0 BA
Bk 5.0 SXL.
GND-PDST, Ground A
GND-PDST2, Ground A
Bk 2.0 SXL
SPL-EDC1, Ultrasonic
Bk 1.0 SXL
Bk 1.0 SXL
Bk 1.0 SXL
0 BAG
Hood Grounds (NA)
N
Bk 1.0 SXL
Bk 0.8 GXL
SPL-EDC1, Ultrasonic
29
0 BAI
QSM11 Ground
Bk 0.8 GXL
SPL-EDC1, Ultrasonic
30
Bk 0.8 GXL
SPL-EDC1, Ultrasonic
39
Bk 0.8 GXL
SPL-EDC1, Ultrasonic
40
Bk 0.8 GXL
SPL-EDC1, Ultrasonic
41
Bk 1.0 SXL
Bk 1.0 SXL
Bk 0.8 GXL
SPL-EDC1, Ultrasonic
50
Bk 1.0 SXL
GND-ENG6, Dedicated
Bk 1.0 SXL
0 BB
Bk 1.0 SXL
SPL-FAN, Ultrasonic
0 BC
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
11
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-11
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0 BD
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
10
0 BE
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
0 BF
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
0 BG
Bk 0.8 GXL
19
GND-ENG6, Dedicated
0 BH
Bk 0.8 GXL
20
GND-ENG6, Dedicated
0 BJ
Bk 0.8 GXL
17
GND-ENG6, Dedicated
0 BK
Bk 1.0 GXL
0 BL
Bk 1.0 SXL
0 BM
Bk 1.0 SXL
0 BN
Bk 0.8 GXL
13
0 BP
Bk 1.0 SXL
0 BQ
Bk 1.0 SXL
SPL-FAN, Ultrasonic
0 BR
Bk 1.0 SXL
Bk 1.0 SXL
SPL-J1, Ultrasonic
Bk 1.0 SXL
SPL-FAN, Ultrasonic
0 BT
Bk 1.0 SXL
Bk 1.0 SXL
SPL-J1, Ultrasonic
Bk 1.0 SXL
0 BV
Bk 0.8 TXL
75
0 BW
Bk 2.0 SXL
0 BX
Bk 2.0 SXL
0 BY
Bk 1.0 SXL
0 BZ
Bk 1.0 SXL
0 CA
Bk 1.0 SXL
11
0 CB
Bk 1.0 SXL
12
0 CC
Bk 1.0 SXL
0 CD
Bk 1.0 SXL
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-12
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0 CE
Bk 1.0 SXL
0 CF
Bk 1.0 SXL
0 DA
Bk 0.8 TXL
GND-PDST1, Ground A
22
S 0.8 GXL
Bk 0.8 GXL
GND-CAB3D, Ground A
0 DB
Bk 0.8 TXL
20
15
0 DC
Bk 0.8 GXL
0 DD
Bk 0.8 GXL
B2
0 DE
Bk 0.8 GXL
B4
0 DF
Bk 0.8 GXL
B6
0 DG
Bk 1.0 GXL
GND-CAB3, Ground C
0 DH
Bk 0.8 GXL
DIA, Diagnostic
0 DJ
Bk 0.8 GXL
B10
0 DK
Bk 0.8 GXL
0 DL
Bk 0.8 GXL
0 DM
Bk 0.8 TXL
11
TECM, Trans
0 DN
Bk 0.8 TXL
28
TECM, Trans
0 DP
Bk 0.8 TXL
GND-CAB3D, Ground A
TECM, Trans
0 DQ
Bk 0.8 TXL
GND-CAB3D, Ground A
TECM, Trans
0 DR
Bk 1.0 GXL
GND-CAB1, Ground A
0 DS
Bk 1.0 GXL
GND-CAB1, Ground A
0 DT
Bk 0.8 GXL
0 DU
Bk 0.8 GXL
0 DV
Bk 3.0 SXL
GND-CAB3, Ground C
0 DW
Bk 0.8 TXL
19
12
0 DX
Bk 0.8 TXL
17
0 DY
Bk 1.0 GXL
GND-CAB3D, Ground A
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-13
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0 EA
Bk 0.8 GXL
0 EB
Bk 0.8 GXL
0 EC
Bk 0.8 GXL
0 ED
HVAC Grounds
Bk 3.0 SXL
HVAC2, HVAC2
GND-CAB4, Ground C
0 EE
Bk 0.8 GXL
0 EF
Bk 0.8 GXL
B6
0 EG
Bk 0.8 GXL
0 EH
Bk 0.8 GXL
0 EJ
Bk 1.0 GXL
GND-CAB4, Ground C
0 EK
Bk 1.0 GXL
GND-CAB5, Ground C
0 EL
Bk 1.0 GXL
GND-CAB5, Ground C
0 EM
Radio Ground
Bk 0.8 GXL
0 EN
Radio Ground
Bk 0.8 GXL
0 EP
Bk 0.8 GXL
31
0 EQ
Bk 0.8 GXL
0 ER
Bk 1.0 GXL
GND-CAB4, Ground C
0 ES
Bk 19.0 SXL
0 GB
Bk 1.0 SXL
SRC-1, Relay
0 HC
Bk 1.0 SXL
0 HD
Bk 1.0 SXL
11
SPL-H2, Ultrasonic
0 HE
Bk 1.0 SXL
28
0 HF
Bk 0.8 GXL
Twist
SPL-H2, Ultrasonic
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-14
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0 HG
Bk 0.8 GXL
Twist
SPL-H2, Ultrasonic
0 HH
Bk 0.8 GXL
Twist
SPL-H2, Ultrasonic
0 HL
Bk 1.0 SXL
0 HM
Bk 1.0 SXL
0 HP
Bk 1.0 SXL
0 HV
Bk 1.0 SXL
0 HW
Hot Ground
Bk 1.0 SXL
0 JA
Bk 1.0 SXL
SPL-J1, Ultrasonic
Bk 1.0 SXL
SPL-J1, Ultrasonic
Bk 1.0 SXL
SPL-J1, Ultrasonic
0 JC
Bk 1.0 SXL
SPL-J1, Ultrasonic
0 LA
Bk 1.0 SXL
SPL-B1, Ultrasonic
0 LB
Bk 1.0 SXL
SPL-B1, Ultrasonic
0 LC
Bk 1.0 SXL
SPL-B1, Ultrasonic
0 LD
Bk 1.0 SXL
SPL-B1, Ultrasonic
0 MA
Bk 1.0 GXL
0 MB
Bk 0.8 GXL
0 MC
Bk 1.0 GXL
0 MD
Bk 1.0 GXL
0 ME
Bk 1.0 GXL
0 MF
Bk 1.0 GXL
0 MJ
Bk 1.0 GXL
0 MK
Roof Grounds
Bk 1.0 GXL
0 MN
Roof Grounds
Bk 1.0 GXL
0 MU
Bk 1.0 GXL
0 NB
Bk 62.0 SGR
0 NC
Battery Disconnect
Bk 62.0 SGR
0 ND
SSM Ground
Bk 62.0 SGR
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-15
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
0 PA
Bk 0.8 GXL
SPK, Speaker
0 PB
Bk 0.8 GXL
SPK, Speaker
W 0.8 GXL
SPL-ACC, Ultrasonic
12ACC
ACC PRM control Power
B
W 0.8 GXL
SPL-ACC, Ultrasonic
W 0.8 GXL
SPL-ACC, Ultrasonic
Or 1.0 GXL
AA4
Or 1.0 GXL
AA5
Or 1.0 GXL
AA6
Or 2.0 GXL
SPL-12V, Ultrasonic
Or 1.0 GXL
SPL-12V, Ultrasonic
A4
Or 1.0 GXL
SPL-12V, Ultrasonic
A5
Or 1.0 GXL
SPL-12V, Ultrasonic
A6
Or 1.0 GXL
SPL-12V, Ultrasonic
A7
Or 0.8 GXL
SPL-RAD, Ultrasonic
12V
12V
HA
Or 0.8 GXL
SPL-RAD, Ultrasonic
12V
HB
Or 0.8 GXL
SPL-RAD, Ultrasonic
13C
Or 1.0 SXL
Or 1.0 SXL
21
Or 1.0 SXL
21
A9
13D
Or 1.0 SXL
13H
Or 3.0 GXL
SPL-DLY-RL, Ultrasonic
Or 0.8 GXL
SPL-DLY-RL, Ultrasonic
A3
Or 0.8 GXL
SPL-DLY-RL, Ultrasonic
A1
Or 3.0 GXL
SPL-DLY-RL, Ultrasonic
A2
Or 1.0 GXL
Or 1.0 GXL
Or 1.0 GXL
Or 1.0 GXL
D1
13K
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-16
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
13M
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Or 1.0 SXL
Or 0.8 TXL
40
Or 1.0 GXL
38
D2
13V
Or 0.8 TXL
14 A
Alternator D+
LG 0.8 GXL
26
25
3
Or 1.0 SXL
LLF, Lights LH
Or 0.8 GXL
Or 1.0 SXL
16
LRF, Lights RH
Or 0.8 GXL
16
Or 1.0 SXL
14
LLF, Lights LH
Or 0.8 GXL
14
Or 1.0 SXL
15
LRF, Lights RH
Or 0.8 GXL
15
Or 1.0 SXL
LLF, Lights LH
Or 0.8 GXL
SPL-POS-L, Ultrasonic
Or 1.0 SXL
Or 1.0 SXL
Or 1.0 SXL
Or 1.0 GXL
SPL-POS-L, Ultrasonic
Or 0.8 GXL
SPL-POS-L, Ultrasonic
Or 1.0 SXL
Or 1.0 GXL
SPL-POS-R, Ultrasonic
Or 1.0 SXL
LRF, Lights RH
Or 1.0 SXL
SPL-POS-NA, Ultrasonic
Or 1.0 SXL
SPL-POS, Ultrasonic
Or 0.8 GXL
Or 1.0 SXL
SPL-POS-NA, Ultrasonic
18C
18D
18E
18F
18F
AN
18F
BN
18G
18G
CN
18G
EN
Bur 5-2750
AA3
3
AA4
2
AA6
2
AA5
4
AA7
AA8
Issued 8-06
Printed in U.S.A.
4002-17
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Or 0.8 GXL
SPL-POS-R, Ultrasonic
Or 0.8 GXL
SPL-POS-R, Ultrasonic
Or 1.0 SXL
SPL-POS, Ultrasonic
Or 1.0 SXL
Or 1.0 SXL
LRR-E, RH Rear
Combination Light
SPL-POS, Ultrasonic
Or 1.0 SXL
SPL-POS-NA, Ultrasonic
Or 1.0 SXL
SPL-P9, Ultrasonic
Or 1.0 SXL
SPL-P9, Ultrasonic
Or 1.0 SXL
SPL-P9, Ultrasonic
Or 2.0 GXL
18
SPL-D2, Ultrasonic
Or 2.0 GXL
18
SPL-EDC2, Ultrasonic
Or 1.0 GXL
SPL-EDC2, Ultrasonic
Or 1.0 GXL
SPL-EDC2, Ultrasonic
Or 1.0 GXL
SPL-EDC4, Ultrasonic
Or 1.0 GXL
SPL-EDC4, Ultrasonic
18J F
Or 2.0 SXL
14
SPL-EDC4, Ultrasonic
Or 2.0 GXL
14
SPL-D2, Ultrasonic
SPL-EDC4, Ultrasonic
Or 3.0 GXL
SPL-D2, Ultrasonic
18J L
Or 0.8 GXL
SPL-EDC4, Ultrasonic
17
Or 0.8 GXL
SPL-EDC2, Ultrasonic
Or 0.8 GXL
SPL-EDC2, Ultrasonic
Or 0.8 GXL
SPL-EDC4, Ultrasonic
18
Or 0.8 GXL
SPL-EDC4, Ultrasonic
28
Or 0.8 GXL
DIA, Diagnostic
A9
Or 0.8 GXL
SPL-CSTR, Ultrasonic
A2
Or 0.8 GXL
SPL-CSTR, Ultrasonic
D9
Or 0.8 GXL
SPL-CSTR, Ultrasonic
B9
18G
HN
18G
JN
18J
Bur 5-2750
Issued 8-06
AA2
Printed in U.S.A.
4002-18
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
Or 0.8 GXL
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
2
Connector
Cavity
SPL-CSTR, Ultrasonic
18M
Or 0.8 GXL
C5
B9
18N
Or 3.0 GXL
SPL-BLWR, Ultrasonic
C1
Or 0.8 GXL
SPL-BLWR, Ultrasonic
HVAC1, HVAC1
Or 3.0 GXL
SPL-BLWR, Ultrasonic
HVAC2, HVAC2
Or 2.0 SXL
13
Or 2.0 GXL
13
B1
29
18R
19A
Or 1.0 SXL
27
Or 0.8 GXL
SPL-FNR, Ultrasonic
Or 0.8 GXL
Or 0.8 GXL
SPL-D15, Ultrasonic
Or 0.8 GXL
10
SPL-D15, Ultrasonic
Or 0.8 GXL
SPL-D15, Ultrasonic
Or 0.8 GXL
SPL-FNR, Ultrasonic
Or 0.8 GXL
Or 0.8 GXL
SPL-PB1, Ultrasonic
Or 0.8 TXL
SPL-TRANS-PWR, Trans
Pwr
TECM, Trans
45
Or 0.8 GXL
SPL-PB1, Ultrasonic
29
Or 1.0 GXL
SPL-TRANS-PWR, Trans
Pwr
A1
Bk 1.0 GXL
SPL-TRANS-PWR, Trans
Pwr
AA10
Or 0.8 GXL
Or 0.8 GXL
Or 0.8 GXL
SPL-TRANS-PWR, Trans
Pwr
SPL-PB1, Ultrasonic
Or 0.8 GXL
27
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-19
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Or 0.8 GXL
SPL-FNR, Ultrasonic
Or 0.8 GXL
SPL-FNR, Ultrasonic
Or 0.8 GXL
Or 0.8 GXL
49a
A8
Or 1.0 GXL
SPL-D24, Ultrasonic
A5
Or 1.0 GXL
SPL-D24, Ultrasonic
B5
Or 0.8 GXL
SPL-D24, Ultrasonic
D5
Or 1.0 GXL
SPL-D24, Ultrasonic
Or 1.0 GXL
SPL-PBS, Ultrasonic
A6
Or 0.8 GXL
SPL-PBS, Ultrasonic
D9
Or 1.0 GXL
SPL-PBS, Ultrasonic
B9
Or 0.8 TXL
21
A3
19B
19H
Or 1.0 GXL
C4
A10
19J
Or 0.8 GXL
C2
Or 0.8 GXL
Or 0.8 GXL
Or 0.8 GXL
SPL-FW, Ultrasonic
Or 0.8 GXL
SPL-FW, Ultrasonic
D1
Or 0.8 GXL
SPL-FW, Ultrasonic
B1
Or 0.8 GXL
SPL-FW, Ultrasonic
D3
Or 0.8 GXL
SPL-FW, Ultrasonic
86
Or 1.0 GXL
SPL-RWW, Ultrasonic
C3
Or 1.0 GXL
SPL-RWW, Ultrasonic
Or 0.8 GXL
SPL-RWW, Ultrasonic
Or 1.0 GXL
SPL-RWW, Ultrasonic
Or 1.0 SXL
Or 2.0 GXL
SPL-CNV, Ultrasonic
Or 2.0 GXL
SPL-CNV, Ultrasonic
19J F
19L
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-20
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
K = Pink
U = Blue
Y = Yellow
To Connector
Connector
Cavity
Or 2.0 GXL
SPL-CNV, Ultrasonic
Or 0.8 GXL
C7
Or 1.0 SXL
Or 1.0 SXL
Connector
Cavity
19N
Or 1.0 GXL
C6
19P
Or 0.8 GXL
A7
Or 0.8 GXL
Or 0.8 GXL
Or 0.8 GXL
D7
Or 0.8 GXL
B7
19R
Or 0.8 GXL
DM, Diode OR
SPL-2 Ultrasonic
19RR
Or 0.8 GXL
DM, Diode OR
A4
Or 1.0 SXL
Or 1.0 SXL
Or 0.8 GXL
SPL-2, Ultrasonic
Or 0.8 GXL
SPL-2, Ultrasonic
19S1
Or 1.0 GXL
26
Or 1.0 SXL
26
R 1.0 SXL
Or 0.8 GXL
SPL-DKY3, Ultrasonic
Or 0.8 TXL
SPL-DKY3, Ultrasonic
20
Or 0.8 TXL
SPL-DKY3, Ultrasonic
14
Or 0.8 TXL
TECM, Trans
23
AA1
Or 0.8 GXL
SPL-HRN, Ultrasonic
A6
Or 0.8 GXL
SPL-HRN, Ultrasonic
B7
Or 1.0 GXL
SPL-LT, Ultrasonic
A1
Or 0.8 GXL
19U
Bur 5-2750
Issued 8-06
AA3
Printed in U.S.A.
4002-21
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Or 0.8 GXL
SPL-LT, Ultrasonic
Or 0.8 GXL
SPL-HRN, Ultrasonic
D7
Bk 0.8 GXL
Or 0.8 GXL
SPL-LT, Ultrasonic
Or 1.0 GXL
SPL-LT, Ultrasonic
19W
Or 3.0 GXL
A8
19Y
Or 1.0 GXL
SPL-HOOD, Ultrasonic
A7
Or 1.0 GXL
SPL-HOOD, Ultrasonic
D2
Or 1.0 GXL
SPL-HOOD, Ultrasonic
D4
Or 1.0 GXL
35
SPL-HOOD, Ultrasonic
Or 1.0 GXL
35
Or 1.0 GXL
A3
Or 1.0 GXL
Or 1.0 GXL
Or 1.0 GXL
56d
19Z
1A
R 1.0 GXL
SPL-DLY, Ultrasonic
1CB
R 19.0 SXL
R 19.0 SXL
P-A3, B+ Power
1DM
R 1.0 GXL
SPL-DLY, Ultrasonic
A5
1DN
R 1.0 GXL
SPL-DLY, Ultrasonic
1NC
R 19.0 SXL
CB2B, Cab B+ CB
1 AA
Brake Lt Sw Pwr
R 1.0 SXL
22
1 B9
PRM C Power
R 8.0 SXL
CB3B, Cab B+ CB
1 BA
Alternator B+
R 13.0 SXL
AB+, Alternator B+
B2 Starter Power
1 BB
R 8.0 SXL
1 BC
Cab CB Power
R 19.0 SXL
CB1B, Cab B+ CB
1 BE
R 19.0 SXL
1C
R 8.0 GXL
P-A1, B+ Power
cs01
R 1.0 GXL
22
SPL-FLSHR-PWR, Ultrasonic
1 DR
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-22
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
To Connector
Wire
Circuit
1 DU
R 1.0 GXL
SPL-FLSHR-PWR, Ultrasonic
1 DV
R 2.0 GXL
SPL-FLSHR-PWR,
Ultrasonic
A4
1 DW
R 1.0 GXL
SPL-FLSHR-PWR,
Ultrasonic
B5
R 19.0 SXL
1 GA
R 3.0 SXL
SPL-HTR, Ultrasonic
1 GB
R 2.0 SXL
SPL-HTR, Ultrasonic
1 GC
R 2.0 SXL
SPL-HTR, Ultrasonic
1 KA
R 1.0 GXL
SPL-FLSHR-PWR, Ultrasonic
1 NA
Battery Crossover
R 62.0 SGR
1 NB
Battery Starter
R 62.0 SGR
1 NC
B+ Power PRMC
R 19.0 SXL
1 ND
SSM Power
R 62.0 SGR
1Y
R 19.0 SXL
1Z
R 8.0 SXL
W 0.8 TXL
31
89
W 0.8 GXL
31
DIA, Diagnostic
W 0.8 GXL
SPL-CR, Ultrasonic
D4
W 0.8 GXL
SPL-CR, Ultrasonic
D5
W 0.8 GXL
SPL-CR, Ultrasonic
A10
W 0.8 GXL
SPL-CR, Ultrasonic
W 1.0 SXL
W 1.0 SXL
SRC-1, Relay
15
W 0.8 GXL
SPL-4, Ultrasonic
W 0.8 GXL
SPL-4, Ultrasonic
W 0.8 GXL
15
SPL-4, Ultrasonic
W 0.8 GXL
27
D6
W 0.8 TXL
27
32
W 0.8 GXL
11
B5
W 0.8 GXL
11
SPL-EDC3, Ultrasonic
1E
21C
21D
21E
21F
Bur 5-2750
Connector
K = Pink
U = Blue
Y = Yellow
Cavity
Connector
Issued 8-06
Cavity
AA9
Printed in U.S.A.
4002-23
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
W 0.8 TXL
SPL-EDC3, Ultrasonic
29
W 0.8 TXL
SPL-EDC3, Ultrasonic
W 0.8 GXL
W 0.8 TXL
37
W 0.8 GXL
A9
W 0.8 TXL
17
W 0.8 GXL
SPL-CRK, Ultrasonic
W 0.8 TXL
SPL-CRK, Ultrasonic
17
W 0.8 GXL
SPL-CRK, Ultrasonic
B3
Throttle Signal
W 0.8 TXL
79
W 0.8 TXL
47
21G
21H
21K
24B
AA10
24L
Low Idle Sw
W 0.8 TXL
48
24R
W 0.8 TXL
78
W 0.8 TXL
49
Throttle Supply
W 0.8 TXL
77
W 0.8 TXL
48
W 0.8 GXL
Twist
LU 0.8 TXL
TECM, Trans
19
W 0.8 GXL
Twist
LU 0.8 TXL
TECM, Trans
42
W 0.8 GXL
Twist
LU 0.8 TXL
TECM, Trans
41
LU 1.0 SXL
10
LU 0.8 TXL
10
TECM, Trans
62
24S
25A
25B
25C
25D
25F
Forward Signal
LU 0.8 TXL
TECM, Trans
43
25G
LU 1.0 SXL
28
LU 0.8 GXL
28
SPL-DC, Ultrasonic
LU 0.8 GXL
SPL-DC, Ultrasonic
LU 0.8 TXL
SPL-DC, Ultrasonic
TECM, Trans
66
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-24
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
25H
LU 0.8 TXL
TECM, Trans
29
25J
LU 0.8 TXL
21
LU 0.8 TXL
21
TECM, Trans
51
LU 0.8 TXL
16
LU 0.8 TXL
16
LU 0.8 TXL
16
TECM, Trans
56
25K
25L
LU 0.8 TXL
17
25L 9
LU 0.8 TXL
17
LU 0.8 TXL
17
TECM, Trans
10
25M
LU 0.8 TXL
18
LU 0.8 TXL
18
TECM, Trans
32
LU 0.8 TXL
19
LU 0.8 TXL
19
TECM, Trans
55
LU 0.8 TXL
20
LU 0.8 TXL
20
TECM, Trans
25N
25P
25R
Reverse Signal
LU 0.8 TXL
TECM, Trans
64
25S
LU 0.8 TXL
22
LU 0.8 TXL
22
LU 0.8 TXL
TECM, Trans
12
LU 0.8 TXL
TECM, Trans
13
Neutral Signal
LU 0.8 GXL
SPL-NEU, Ultrasonic
D3
LU 0.8 GXL
SPL-NEU, Ultrasonic
LU 0.8 TXL
SPL-NEU, Ultrasonic
TECM, Trans
67
25W
LU 0.8 TXL
TECM, Trans
65
25Y
LU 0.8 GXL
LU 0.8 TXL
TECM, Trans
22
LU 0.8 GXL
LU 0.8 GXL
25T
25Z
LU 0.8 TXL
TECM, Trans
63
26E
LU 0.8 TXL
TECM, Trans
31
LU 0.8 GXL
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-25
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
LU 0.8 TXL
TECM, Trans
20
LU 0.8 GXL
LU 0.8 GXL
LU 0.8 TXL
TECM, Trans
44
LU 0.8 GXL
LU 0.8 TXL
TECM, Trans
30
26J
28E
W 1.0 SXL
16
28F
W 0.8 TXL
PRM-C2,PRM Signal
36
28G
W 1.0 GXL
12
28H
W 0.8 GXL
16
28J
W 0.8 GXL
19
28P
W 1.0 SXL
31D
Y 1.0 SXL
Y 0.8 TXL
26
31F
Y 1.0 SXL
28
Y 0.8 TXL
28
Y 1.0 SXL
23
Y 0.8 GXL
23
31H
31L
Y 0.8 TXL
18
32F
Y 1.0 SXL
31
Y 0.8 TXL
31
TECM, Trans
17
Y 0.8 GXL
Y 0.8 GXL
SPL-D16, Ultrasonic
Y 0.8 TXL
SPL-D16, Ultrasonic
TECM, Trans
Y 0.8 GXL
SPL-D16, Ultrasonic
Y 1.0 SXL
26
Y 0.8 TXL
26
Y 0.8 TXL
33P
33R
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-26
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Y 1.0 SXL
SPL-RD, Ultrasonic
Y 1.0 SXL
SPL-RD, Ultrasonic
Y 1.0 SXL
SPL-RD, Ultrasonic
Y 0.8 TXL
Y 1.0 SXL
E-HD9, Transmission-Hood
Y 0.8 GXL
Y 0.8 GXL
Y 0.8 GXL
Y 0.8 GXL
Y 0.8 SXL
SPL-D8-C1, Ultrasonic
Y 0.8 SXL
40
SPL-D8-C1, Ultrasonic
Y 0.8 SXL
40
Y 1.0 SXL
40
Y 1.0 SXL
Y 1.0 SXL
K 1.0 SXL
SPL-A1A, Ultrasonic
K 1.0 SXL
SPL-A1A, Ultrasonic
K 1.0 SXL
SPL-A1A, Ultrasonic
K 1.0 SXL
SPL-REV, Ultrasonic
K 1.0 SXL
SPL-REV, Ultrasonic
K 1.0 SXL
SPL-REV, Ultrasonic
Y 1.0 SXL
33U
35A
GN
35A
HN
AA9
35B
W 0.8 TXL
13
35C
Y 0.8 TXL
TECM, Trans
A9
Y 0.8 GXL
SPL-D8-C1, Ultrasonic
W 0.8 TXL
42
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-27
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
35X
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Y 0.8 TXL
11
Y 1.0 SXL
SPL-C3, Ultrasonic
Y 1.0 SXL
Y 1.0 SXL
SPL-C3, Ultrasonic
Y 1.0 SXL
SPL-C3, Ultrasonic
P 0.8 TXL
32
P 1.0 SXL
32
P 0.8 TXL
P 1.0 SXL
P 1.0 SXL
34
W 0.8 TXL
34
11
P 1.0 SXL
33
P 0.8 TXL
33
P 1.0 SXL
13
P 0.8 TXL
13
TECM, Trans
49
P 1.0 SXL
30
P 0.8 TXL
30
P 1.0 SXL
12
P 1.0 SXL
P 0.8 TXL
P 1.0 SXL
P 0.8 TXL
12
TECM, Trans
46
P 0.8 TXL
P 0.8 TXL
TECM, Trans
39
P 0.8 TXL
TECM, Trans
15
P 0.8 TXL
TECM, Trans
18
Or 1.0 GXL
56a
Or 0.8 GXL
A3
Or 0.8 GXL
A4
36A
36B
36C
36F
36G
36H
36T
37E
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-28
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
Or 0.8 TXL
Or 1.0 GXL
56
Or 1.0 GXL
56b
Or 0.8 GXL
SPL-LB, Ultrasonic
A6
Or 0.8 GXL
SPL-LB, Ultrasonic
A5
K 1.0 GXL
A8
A7
K 1.0 GXL
D-OR, Diode OR
SPL-D, Ultrasonic
K 0.8 TXL
SPL-D, Ultrasonic
K 1.0 SXL
SPL-D, Ultrasonic
DU 1.0 GXL
DU 1.0 GXL
DU 1.0 GXL
D-OR, Diode OR
DU 0.8 TXL
DU 1.0 GXL
SPL-WRKF, Ultrasonic
SPL-WRKF, Ultrasonic
SPL-WRKF, Ultrasonic
42FS
DU 1.0 GXL
A1
42RS
DU 1.0 GXL
A2
DU 1.0 GXL
AA2
DU 1.0 GXL
SPL-WRKR, Ultrasonic
DU 1.0 SXL
SPL-WRKR, Ultrasonic
DU 1.0 SXL
SPL-WRKR, Ultrasonic
41J
41T
SPL-LB, Ultrasonic
A
AA1
42 A
R 2.0 GXL
SPL-WL, Ultrasonic
42 B
R 2.0 GXL
SPL-WL, Ultrasonic
W 0.8 GXL
SPL-DS, Ultrasonic
W 0.8 GXL
W 0.8 TXL
SPL-DS, Ultrasonic
W 0.8 TXL
SPL-DS, Ultrasonic
DU 0.8 TXL
43 A
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-29
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
43 B
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
DU 0.8 GXL
T 0.8 GXL
SPL-BRK, Ultrasonic
D6
T 0.8 TXL
SPL-BRK, Ultrasonic
15
T 0.8 GXL
SPL-BRK, Ultrasonic
T 1.0 SXL
SPL-B8, Ultrasonic
T 1.0 SXL
T 1.0 SXL
SPL-B8, Ultrasonic
T 1.0 SXL
SPL-J2-N, Ultrasonic
T 1.0 SXL
SPL-B8, Ultrasonic
44A
DN
44A
EN
44A
FN
T 1.0 SXL
SPL-J2-N, Ultrasonic
44A
GN
T 1.0 SXL
SPL-J2-N, Ultrasonic
T 1.0 SXL
SPL-L1, Ultrasonic
T 1.0 SXL
SPL-L1, Ultrasonic
T 1.0 SXL
SPL-L1, Ultrasonic
44 A
T 0.8 GXL
23
D5
N 0.8 GXL
N 0.8 GXL
10
45H
N 0.8 GXL
11
45L
N 1.0 SXL
LLF, Lights LH
45L 9
N 1.0 SXL
N 1.0 SXL
10
N 1.0 SXL
10
N 0.8 GXL
10
N 1.0 SXL
N 0.8 GXL
N 0.8 GXL
N 0.8 TXL
N 0.8 GXL
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-30
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
N 0.8 GXL
12
N 1.0 SXL
LRF, Lights RH
N 1.0 SXL
N 1.0 SXL
12
N 1.0 SXL
12
N 0.8 GXL
12
N 1.0 SXL
N 0.8 TXL
10
N 0.8 GXL
N 0.8 GXL
46 C
K 1.0 GXL
46 D
K 1.0 GXL
46 E
K 1.0 GXL
49A
S 0.8 GXL
HVAC1, HVAC1
49S
S 0.8 GXL
49U
S 0.8 GXL
49 A
S 0.8 GXL
49 B
S 0.8 GXL
49 C
S 0.8 GXL
49 D
S 0.8 GXL
49 E
S 0.8 GXL
49 F
S 0.8 GXL
10
49 G
S 0.8 GXL
49 H
S 0.8 GXL
49 J
S 0.8 GXL
45R
45R
AN
45R
BN
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-31
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
K = Pink
U = Blue
Y = Yellow
To Connector
Connector
Cavity
Connector
Cavity
49 K
S 0.8 GXL
49 L
S 0.8 GXL
49 M
S 0.8 GXL
49 N
S 0.8 GXL
49 P
S 0.8 GXL
49 Q
S 0.8 GXL
49 R
S 0.8 GXL
49 S
S 0.8 GXL
49 T
S 0.8 GXL
49 U
S 0.8 GXL
49 V
S 0.8 GXL
W 0.8 GXL
SPL-CSS, Ultrasonic
W 0.8 GXL
SPL-CSS, Ultrasonic
W 0.8 GXL
SPL-CSS, Ultrasonic
W 1.0 SXL
D10
51C
W 0.8 TXL
21
B10
51CS
W 0.8 TXL
17
W 1.0 SXL
W 0.8 TXL
16
51 A
W 1.0 SXL
SPL-SS, Ultrasonic
51 B
W 1.0 SXL
SPL-SS, Ultrasonic
51 C
W 1.0 SXL
SPL-SS, Ultrasonic
52AU
W 0.8 TXL
W 1.0 GXL
22
W 1.0 SXL
22
Bur 5-2750
Issued 8-06
D8
1
Printed in U.S.A.
4002-32
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
52C
W 0.8 TXL
14
52J
W 0.8 GXL
52M
W 0.8 TXL
52P
W 1.0 SXL
24
W 0.8 GXL
24
SPL-PB, Ultrasonic
W 0.8 GXL
SPL-PB, Ultrasonic
D10
W 0.8 TXL
SPL-PB, Ultrasonic
TECM, Trans
21
B10
53A
W 0.8 GXL
53B
RTD Signal
W 1.0 SXL
12
PXF, RTD
W 1.0 SXL
PXM, RTD
PXT, RTD
W 0.8 GXL
12
W 0.8 TXL
20
B6
W 0.8 GXL
SPL-D25, Ultrasonic
W 0.8 GXL
SPL-D25, Ultrasonic
W 1.0 GXL
SPL-D25, Ultrasonic
D6
W 0.8 GXL
SPL-D25, Ultrasonic
W 0.8 GXL
SPL-D25, Ultrasonic
W 0.8 GXL
19
SPL-D25, Ultrasonic
W 1.0 SXL
19
SPL-A3, Ultrasonic
W 1.0 SXL
SPL-A3, Ultrasonic
PXF, RTD
53P I
W 1.0 SXL
PXM, RTD
PXT, RTD
W 1.0 SXL
SPL-A3, Ultrasonic
54A
W 0.8 GXL
54B
W 1.0 SXL
11
W 0.8 GXL
11
SPL-D1, Ultrasonic
W 0.8 GXL
SPL-D1, Ultrasonic
W 0.8 GXL
SPL-D1, Ultrasonic
W 0.8 GXL
SPL-RTT, Ultrasonic
W 0.8 GXL
SPL-RTT, Ultrasonic
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-33
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
K = Pink
U = Blue
Y = Yellow
To Connector
Connector
Cavity
Connector
Cavity
W 0.8 GXL
SPL-RTT, Ultrasonic
55B
W 0.8 GXL
56 A
W 1.0 SXL
23
57 A
W 0.8 GXL
20
SPL-PINE, Ultrasonic
57 B
W 0.8 GXL
SPL-PINE, Ultrasonic
57 C
W 0.8 TXL
SPL-PINE, Ultrasonic
16
58C
W 0.8 GXL
W 0.8 TXL
TECM, Trans
D7
Bk 0.8 TXL
TECM, Trans
57
B8
W 1.0 SXL
21
W 0.8 GXL
B7
58 A
W 1.0 SXL
58 B
W 1.0 SXL
21
58 C
W 0.8 GXL
21
SPL-D26, Ultrasonic
58 D
W 0.8 GXL
SPL-D26, Ultrasonic
58 E
W 0.8 GXL
SPL-D26, Ultrasonic
D8
58 F
W 0.8 GXL
SPL-D26, Ultrasonic
59D
W 1.0 GXL
37
D3
W 1.0 SXL
37
W 1.0 GXL
39
D1
W 1.0 SXL
39
W 1.0 GXL
36
B3
W 1.0 SXL
36
W 1.0 GXL
38
B1
W 1.0 SXL
38
W 1.0 SXL
30
W 0.8 GXL
30
HVAC1, HVAC1
AC Relay Out
Or 0.8 GXL
Or 1.0 SXL
Or 1.0 SXL
W 1.0 SXL
29
59U
60D
60U
61A
61C
61R
AC Relay Control
Bur 5-2750
Issued 8-06
D10
Printed in U.S.A.
4002-34
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
W 0.8 GXL
29
D9
63C
W 0.8 GXL
C4
63C2
W 0.8 GXL
D4
C2
63C3
W 0.8 GXL
87a
B3
63HC
W 0.8 GXL
SPL-HC, Ultrasonic
63HC
Wiper Cutout Relay Control
A
W 0.8 GXL
SPL-HC, Ultrasonic
85
63HC
Front Wiper High Speed Rly Ctrl
B
W 0.8 GXL
SPL-HC, Ultrasonic
B2
W 0.8 GXL
SPL-WHS, Ultrasonic
W 0.8 GXL
SPL-WHS, Ultrasonic
D2
W 0.8 GXL
SPL-WHS, Ultrasonic
63LC
W 0.8 GXL
B4
W 0.8 GXL
SPL-WLS, Ultrasonic
W 0.8 GXL
30
SPL-WLS, Ultrasonic
W 0.8 GXL
SPL-WLS, Ultrasonic
63W
W 0.8 GXL
25
W 1.0 SXL
25
64C
Or 0.8 GXL
31b
B8
64 A
Horn Power
Or 0.8 GXL
13
D8
65L
Left Speaker
Or 0.8 GXL
SPK, Speaker
65R
Right Speaker
Or 0.8 GXL
SPK, Speaker
68C
Or 1.0 GXL
Or 1.0 GXL
Or 1.0 GXL
SPL-3, Ultrasonic
Or 1.0 GXL
Or 1.0 GXL
SPL-3, Ultrasonic
Or 1.0 GXL
SPL-3, Ultrasonic
68W
W 0.8 GXL
24
W 1.0 SXL
24
Y 0.8 TXL
TWIST
35
68L
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-35
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
K = Pink
U = Blue
Y = Yellow
To Connector
Connector
Cavity
Connector
Cavity
CAN
HA
CAN High
Y 0.8 TXL
TWIST
SPL-CAN-HVAC, Ultrasonic
CAN
HB
CAN High
Y 0.8 TXL
TWIST
SPL-CAN-DIAG, Ultrasonic
DIA, Diagnostic
CAN
HC
CAN High
Y 0.8 TXL
TWIST
SPL-CAN-TRANS, Ultrasonic
SPL-CAN-DIAG, Ultrasonic
CAN
HD
CAN High
Y 0.8 TXL
TWIST
SPL-CAN-TRANS, Ultrasonic
TECM, Trans
25
CAN
HE
CAN High
Y 0.8 TXL
TWIST
SPL-CAN, Ultrasonic
SPL-CAN-TRANS, Ultrasonic
CAN
HF
CAN High
Y 0.8 TXL
TWIST
SPL-CAN, Ultrasonic
CAN
HG
CAN High
Y 0.8 TXL
TWIST
SPL-CAN, Ultrasonic
CAN
HJ
Y 0.8 TXL
TWIST
46
CAN
HK
CAN High
Y 0.8 TXL
TWIST
SPL-CAN-HVAC, Ultrasonic
CAN
HM
CAN High
Y 0.8 TXL
TWIST
SPL-CAN-HVAC, Ultrasonic
SPL-CAN-DIAG, Ultrasonic
G 0.8 TXL
TWIST
34
CAN
LA
CAN Low
G 0.8 TXL
TWIST
SPL-CAN-HVAC-L,
Ultrasonic
CAN
LB
CAN Low
G 0.8 TXL
TWIST
SPL-CAN-DIAG-L, Ultrasonic
DIA, Diagnostic
CAN
LC
CAN Low
G 0.8 TXL
TWIST
SPL-CAN-TRANS-L,
Ultrasonic
SPL-CAN-DIAG-L, Ultrasonic
CAN
LD
CAN Low
G 0.8 TXL
TWIST
SPL-D5, Ultrasonic
SPL-CAN-TRANS-L, Ultrasonic
CAN
LE
CAN Low
G 0.8 TXL
TWIST
SPL-CAN-L, Ultrasonic
SPL-CAN-TRANS-L, Ultrasonic
CAN
LF
CAN Low
G 0.8 TXL
TWIST
SPL-CAN-L, Ultrasonic
CAN
LG
CAN Low
G 0.8 TXL
TWIST
SPL-CAN-L, Ultrasonic
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-36
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
CAN
LJ
CAN Low
G 0.8 TXL
TWIST
SPL-D5, Ultrasonic
TECM, Trans
27
CAN
LK
CAN Low
G 0.8 TXL
TWIST
SPL-D5, Ultrasonic
TECM, Trans
26
CAN
LL
CAN Low
G 0.8 TXL
TWIST
SPL-CAN-HVAC-L,
Ultrasonic
CAN
LM
G 0.8 TXL
TWIST
37
CAN
LN
CAN Low
G 0.8 TXL
TWIST
SPL-CAN-HVAC-L,
Ultrasonic
SPL-CAN-DIAG-L, Ultrasonic
ECC
L1
BUSS
cs01
J1
ECA-BUSS
ECA-L1, B+ Power
cs01
L1
J2
ECA-BUSS
L1
L1
J3
ECA-BUSS
L1
L1
J4
ECA-BUSS
L1
L1
J5
ECA-BUSS
L1
L1
J6
ECA-BUSS
L1
L1
J7
ECA-BUSS
L1
L1
J8
ECA-BUSS
L1
L1
J9
ECA-BUSS
L1
L1
J11
ECA-BUSS
ECA-L2, B+ Power
cs01
L2
J12
ECA-BUSS
L2
L2
J13
ECA-BUSS
L2
L2
J14
ECA-BUSS
L2
L2
J15
Backup AC
ECA-BUSS
L2
L2
J16
AC Seat Compressor
ECA-BUSS
L2
L2
J18
ECA-BUSS
L2
L2
J2
ECC
ECA-BUSS
L1-1
L1-2
J3
ECC
ECA-BUSS
L1-2
L1-3
Bur 5-2750
Issued 8-06
L1-1
Printed in U.S.A.
4002-37
21C Bk - 1.0
Wire Size (mm2) 0.8 mm
Wire Color
Wire Name
Bk = Black
T = Tan
LU = Light Blue
Wire Identification
Wire
Circuit
S = Gray
N = Brown
R = Red
LG = Light Green
G = Green
P = Purple
From Connector
Color, Size,
and Material
Connector
K = Pink
U = Blue
Y = Yellow
To Connector
Cavity
Connector
Cavity
J4
ECC
ECA-BUSS
L1-3
L1-4
J5
ECC
ECA-BUSS
L1-4
L1-5
J6
ECC
ECA-BUSS
L1-5
L1-6
J7
ECC
ECA-BUSS
L1-6
L1-7
J8
ECC
ECA-BUSS
L1-7
L1-8
J9
ECC
Diagnostic Power
ECA-BUSS
L1-9
L1-8
BUSS
BUSS
BUSS
BUSS
W 0.8 GXL
W 0.8 GXL
12
W 0.8 GXL
W 0.8 GXL
RAD-J2, Speaker
W 0.8 GXL
10
RAD-J2, Speaker
W 0.8 GXL
RAD-J2, Speaker
W 0.8 GXL
11
RAD-J2, Speaker
W 0.8 GXL
RAD-J2, Speaker
W 0.8 GXL
RAD-J2, Speaker
W 0.8 GXL
RAD-J2, Speaker
W 0.8 GXL
RAD-J2, Speaker
PRM
PWR
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-38
Check Points
Correct
Reading
Good
12 volts
Bad fuse.
Check wire 1A between the starter terminal (21) and the
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter.
6
1.
2.
3.
4.
5.
6.
This title is the number and component name on the Electrical Schematic.
This column shows the location of the check point.
This column shows the indication of the check.
This column shows the possible cause of a bad test indication.
The numbers in the parentheses show the number of the component on the Electrical Schematic.
This statement assumes that all other problems are solved at this point in the test.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-39
10
5
1
7
4 11
6 12
BS06H241 / BS06H242
1.
2.
3.
4.
5.
6.
STARTING RELAY
RESISTOR 75 OHM
ALTERNATOR
CRANK CONTROL RELAY
BATTERIES
CRANK REQUEST RELAY
7.
8.
9.
10.
11.
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-40
1 Starting Relay
Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access.
Check Points
Terminal for wire 0-GB to ground
Correct
Reading
Continuity
24 volts
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
24 volts
2 Resistor
Located in the cab access panel for fuses and relays.
NOTE: Turn master disconnect switch off, disconnect terminals from resistor.
Check Points
Between terminals of resistor
Correct
Reading
75 ohms
3 Alternator
Located on left side of engine, open engine compartment to gain access.
Check Points
Between housing of alternator and
ground
Correct
Reading
Continuity
24 volts
24 volts
24 volts
20 volts
Check circuit 14, 75 ohm resistor, and diode module. Bad fuse
ECA-F4. Check power relay module A, and 105 ampere circuit
breaker in engine compartment of machine.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-41
Correct
Reading
Continuity
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
24 volts
24 volts
5 Batteries
Located on right and left rear sides of the machine.
NOTE: See Section 4003 and check the batteries.
Correct
Reading
Continuity
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
24 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-42
Check Points
Terminal for wire 0-DC to ground
Continuity
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 30 seconds time
delay an audible click will be heard.
Within 30 seconds of putting the
ignition switch in the OFF position,
check terminal for wire 13D to
ground
24 volts
Key OFF
0 volt after 30
seconds
0 volt
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
disconnect switch
Continuity
Open Circuit
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-43
9 Starter Motor
Located on left side of engine, open engine compartment to gain access.
Check Points
Between housing of starter and
ground
Correct
Reading
Continuity
24 volts
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Terminal S to ground
24 volts
Bad starting relay (1). Also check wire 1-BB between starter
and starting relay (1).
10 Ignition Switch
Located on steering column.
Check Points
Correct
Reading
24 volts
NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON.
Between Bat and Ign
Continuity
Continuity
Continuity
Continuity
Bur 5-2750
Continuity
Issued 8-06
Printed in U.S.A.
4002-44
Correct
Reading
Continuity
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
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21K-B to ground
24 volts
24 volts
12 Voltmeter Relay
Located in the cab access panel for fuses and relays.
Check Points
Terminal for wire 0-DB to ground
Correct
Reading
Continuity
24 volts
24 volts
24 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-45
20
21
17
15 19
16
13
14
18
BS06H241 / BS06H242
13.
14.
15.
16.
17.
18.
19.
20.
21.
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-46
Correct
Reading
Continuity
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
24 volts
24 volts
Correct
Reading
Continuity
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire PRM-B BUSS to
ground
24 volts
24 volts
24 volts
15 Power Relay Module C, For Fuel Filter Heater and Water Separator Heater
Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access.
Check Points
Correct
Reading
Continuity
24 volts
24 volts
24 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-47
Correct
Reading
Continuity
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
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
24 volts
17 Grid Heater
Located in the right side of the engine in intake manifold, open engine compartment to gain access.
Check Points
Correct
Reading
Continuity
Resistance
Correct
Reading
Continuity
Correct
Reading
Continuity
1.9 ohms
Bad heater.
NOTE: If the readings are good, check circuit 1-G between water separator heater connector WSH and power
relay module C connector PRM-C1.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-48
Correct
Reading
Continuity
1.9 ohms
Bad heater.
NOTE: If the readings are good, check circuit 1-G between fuel filter heater connector FFH and power relay
module C connector PRM-C1.
Correct
Reading
Continuity
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Accessory or the ON
position.
Terminal for wire PRM-D BUSS to
ground
24 volts
24 volts
24 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-49
ENGINE CONTROLLER
24
22
23
BS06H241 / BS06H242
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-50
Check Points
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
24 volts
23 Throttle Potentiometer
Located below cab under throttle pedal.
Check Points
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
Terminal for wire 24R to ground
5 volts
Continuity
0.4 0.025
volts
Bad potentiometer.
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.
1000 400
ohms at 20 C
(68 F)
Bad potentiometer.
1200 400
ohms at 20 C
(68 F)
Bad potentiometer.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-51
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
ground
Continuity
Continuity
Continuity
Continuity
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
ground
24 volts
24 volts
24 volts
24 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-52
30
25 26 31 32
29
27
33
34
BS06H241 / BS06H242
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-53
25 Return-To-Travel/Float Switch
Located on right side console.
Check Points
Correct
Reading
Continuity
Continuity
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch. Put the return-totravel/float switch in FLOAT position.
Between switch terminals 1 and 2
Continuity
Continuity
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.
24 volts
Correct
Reading
Continuity
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
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-54
27 Electromagnetic Detents
Located under right side console.
Check Points
Correct
Reading
74 ohms @
20 C (68 F)
74 ohms @
20 C (68 F)
74 ohms @
20 C (68 F)
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
to ground
24 volts
24 volts
24 volts
Correct
Reading
NOTE: Disconnect the connector from the return-to-dig proximity switch. Put the master disconnect switch and
the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the return to dig
switch in the ON position.
Terminal B for wire 0-AC to ground
Continuity
24 volts
24 volts
NOTE: If the readings are good, replace the return-to-dig proximity switch.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-55
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
0 volt
24 volts
24 volts
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
24 volts
24 volts
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch.
Correct
Reading
Continuity
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
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-56
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF
position.
Terminal for wire 19P-A to ground
Terminal for wire 57-B to ground
24 volts
0 volt
24 volts
24 volts
Check the driving lamp switch (95). Also check circuit 49. If
LED in pin engage switch is not ON with 24 volts at check point,
replace pin engage switch.
Correct
Reading
Continuity
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
NOTE: If the readings are good, replace the pilot pressure solenoid.
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch
(32) in the ON position.
Terminal for wire 57 to ground
24 volts
NOTE: If the readings are good, replace the pin engage solenoid.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-57
43 44
35 37 39
36
38
40
41
42
BS06H241 / BS06H242
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-58
Correct
Reading
Continuity
Continuity
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.
Terminal for wire 19C-D to ground
Terminal for wire 58C to ground
24 volts
0 volt
24 volts
24 volts
Check driving lamp switch (95). Also check circuit 49. If LED in
ride control switch is not ON with 24 volts at check point,
replace ride control switch.
Correct
Reading
Continuity
Continuity
Continuity
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
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-59
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19P-C to ground
24 volts
24 volts
24 volts
24 volts
Correct
Reading
24 volts
NOTE: Put the fan reverse switch in the manual reverse position.
Terminals for wire 52A-A to ground
Bur 5-2750
24 volts
Bad fan reverse solenoid, bad fan reverse switch (37), bad
advanced instrument cluster (62).
Issued 8-06
Printed in U.S.A.
4002-60
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19C to ground
24 volts
24 volts
24 volts
Check driving lamp switch (95) and fuse ECC-F3. Also check
circuit 49.
NOTE: If the readings are correct replace the pilot control switch.
Correct
Reading
Continuity
20 to 26 ohms
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
switch
Terminal for wire 58S to ground
Continuity
37 to 43 ohms
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.).
Bur 5-2750
24 volts at
5 km/hr
(3 m.p.h.)
Bad ride control relay (36) or ride control switch (35). Also
check circuit 58.
Issued 8-06
Printed in U.S.A.
4002-61
Correct
Reading
Continuity
Correct
Reading
NOTE: Disconnect wiring harness connector YFN from fan PWM solenoid.
Between pins 1and 2 of fan PWM
solenoid
26 to 32 ohms
Continuity
NOTE: In the options menu of the instrument cluster select auto for the fan. Stall the transmission to raise
transmission temperature to high operating range.
Pin 1 of wiring harness connector
YFN to ground
24 volts
Correct
Reading
NOTE: Disconnect wiring harness connector YFR from fan reversing solenoid.
Between pins 1and 2 of fan
reversing solenoid
Pin 2 of wiring harness connector
YFR to ground
36 to 42 ohms
Continuity
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
YFR to ground
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-62
TRANSMISSION
46
48
52
55 56 57 60
49 50
51
45 53 54
47 61 58
BS06H241 / BS06H242
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-63
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 45 through 61.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-64
66
62 63
67
69
65
68
64
BS06H241 / BS06H242
62.
63.
64.
65.
66.
67.
68.
69.
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-65
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
ground
Open Circuit
Bad air filter restriction switch (66). Also check circuit 31F-A.
Open Circuit
Continuity
130 to 9500
ohms
33 to 240 ohms
Bad fuel level sender (65). Also check circuit 36F-A and ground
circuit at sender.
130 to 9500
ohms
Continuity
Open Circuit
Continuity
Continuity
Continuity
24 volts
Bad parking brake switch. Also check fuse ECA-F6 and circuit
19D and 52C.
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Connector terminal 10 to ground
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-66
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1to
ground
24 volts
24 volts
24 volts
Bad pilot control relay or fuse ECA-F5. Also check circuits 53C
and 19C.
63 Warning Buzzer
Located on steering column under instrument cluster.
Check Points
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
24 volts
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
to ground
Terminal for wire 52C to ground
Terminal for wire 52P-B to ground
24 volts
0 volt
24 volts
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-67
Check Points
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 36F to ground
Approximately
5 volts
NOTE: Put the ignition switch and the master disconnect switch in the OFF position. Tag and disconnect the wires
from the fuel level sender.
Between terminals of fuel level
sender
33 to 240
ohms
Check Points
NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig).
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 31F to ground
Approximately
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch.
Correct
Reading
Continuity
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
NOTE: If the readings are good, replace the parking brake solenoid.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-68
Correct
Reading
Continuity
NOTE: Disconnect the connector from the radiator coolant temperature sender.
Between terminals of radiator
coolant temperature sender
3521 ohms
at 20 C (68 F)
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal A for wire 36C to ground
Approximately
5 volts
Correct
Reading
NOTE: Brake warning pressure switch opens at 110.3 bar (1600 psi).
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal 2 for wire 0-AL to ground
Continuity
Approximately
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
switch
Continuity
Bur 5-2750
Open Circuit
Issued 8-06
Printed in U.S.A.
4002-69
75
76
72
73
BS06H241 / BS06H242
70.
71.
72.
73.
SWITCH PAD
INSTRUMENT CLUSTER CONNECTOR 2
HYDRAULIC FILTER RESTRICTION SWITCH
HYDRAULIC OIL TEMPERATURE SENDER
74.
75.
76.
77.
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-70
70 Switch Pad
Located on steering column.
Check Points
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
Bur 5-2750
Continuity
Issued 8-06
Printed in U.S.A.
4002-71
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
ground
Continuity
Continuity
Bad coolant level sender (77). Also check circuit 31D-A and
ground circuit at coolant level sender.
Continuity
Open Circuit
Bad air filter restriction switch (66). Also check circuit 31F-A.
Open Circuit
Continuity
Open Circuit
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Connector terminal AIC-2 14 and 20
to ground
24 volts
Bad fuse ECD-F3. Also check circuit 19S-C and 19S-D. Also
check power relay module B (14).
24 volts
Bad fuse ECA-F3. Also check circuit 19E-A. Also check power
relay module A (13).
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Connector terminal 10 to ground
24 volts
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1to
ground
24 volts
NOTE: Put the turn signal switch in the LEFT TURN position.
Connector terminal AIC-2 9to
ground
24 volts on and
off every 1-2
seconds
NOTE: Put the turn signal switch in the RIGHT TURN position.
Connector terminal AIC-2 10to
ground
24 volts on and
off every 1-2
seconds
Bur 5-2750
24 volts
Bad pilot control switch or fuse ECA-F1. Also check wire 31L
and circuit 19A.
Issued 8-06
Printed in U.S.A.
4002-72
]
Correct
Reading
NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi).
Check between the housing of the
hydraulic filter restriction switch and
ground
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 31H to ground.
Approximately
11.5 volts
NOTE: If the readings are correct replace the hydraulic filter restriction switch.
Correct
Reading
Continuity
NOTE: Disconnect the connector from the hydraulic oil temperature sender.
Between terminals of hydraulic oil
temperature sender
3521 ohms
at 20 C (68 F)
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal A for wire 36H to ground
Bur 5-2750
Approximately
5 volts
Issued 8-06
Printed in U.S.A.
4002-73
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19A-L to ground
24 volts
24 volts
24 volts
Bad driving lamp switch. Also check fuse ECC-F3 and circuits
41 and 19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal A for wire 33R-C to ground
Approximately
11.5 volts
NOTE: If the readings are good, replace the redundant brake pressure switch(es).
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal A for wireS 33R-B to
ground
Approximately
11.5 volts
NOTE: If the readings are good, replace the redundant brake pressure switch(es).
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-74
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal A for wire 31D to ground
Approximately
1.6 volts AC
NOTE: If the readings are correct replace the coolant level sender.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-75
79
78
BS06H241 / BS06H242
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-76
Correct
Reading
NOTE: Disconnect the transmission electronic control module (53) connector TECM.
Terminal for wire 35C to terminal 7 of
connector TECM
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19A-P to ground
24 volts
Bad fuse ECA-F1, also check wires 19A-P, power relay module
A, Ignition power (13).
24 volts
Bad fuse ECA-F14, also check wires 19H, power relay module
D, accessory power (21).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A-A to ground
24 volts
Correct
Reading
Continuity
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
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
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-77
LIGHTS - 01
87
82 85
81
86
88
83
80 84
89
BS06H241 / BS06H242
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-78
Correct
Reading
Continuity
24 volts
NOTE: Put the work lamps switch in position 2 for front work lamps.
Terminal for wire 42FS to ground
24 volts
NOTE: Put the wok lamps switch in position 3 for rear work lamps.
Terminal for wire 42RS to ground
24 volts
81 Door Switch
Located above door in cab.
Check Points
Correct
Reading
24 volts
Continuity
Open circuit
Correct
Reading
Bulb
Continuity
Bad bulb.
Continuity
NOTE: Put master disconnect switch and beacon switch (84) in ON position.
Terminal for wire 46-D to ground
24 volts
Bad circuit between the beacon and the beacon switch (84).
Also check the beacon switch (84).
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-79
83 Dome Lamp
Located in top of cab.
Correct
Reading
Check Points
Bulb
Continuity
Bad bulb.
Continuity
NOTE: Put master disconnect switch in ON position. Put dome lamp switch in ON position.
24 volts
24 volts
3 to 5 seconds
Correct
Reading
Continuity
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
24 volts
Correct
Reading
NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector.
Flood lamp connector pin A to pin B
Continuity
NOTE: Connect wiring harness connector LLFW to LH front work lamp connector.
Terminal for wire 0-MU to ground
Continuity
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
Bur 5-2750
24 volts
Check fuse ECB-F1 and driving lamp switch (95). Also check
circuit 42C from flood lamp to lamp switch (95) and wire 42-A
to fuse ECC-F2.
Issued 8-06
Printed in U.S.A.
4002-80
Correct
Reading
NOTE: Disconnect wiring harness connector LRFW from RH front work lamp connector.
Flood lamp connector pin A to pin B
Continuity
NOTE: Connect wiring harness connector LRFW to RH front work lamp connector.
Terminal for wire 0-MJ to ground
Continuity
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
24 volts
Check fuse ECB-F1 and driving lamp switch (95). Also check
circuit 42C from flood lamp to lamp switch (95) and wire 42-A
to fuse ECC-F2.
Correct
Reading
NOTE: Disconnect wiring harness connector LLRW from LH rear work lamp connector.
Flood lamp connector pin A to pin B
Continuity
NOTE: Connect wiring harness connector LLRW to LH rear work lamp connector.
Terminal for wire 0-ME to ground
Continuity
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 4 or 5.
24 volts
Check fuse ECB-F2 and driving lamp switch (95). Also check
circuit 42R from flood lamp to lamp switch (95) and wire 42-B
to fuse ECC-F2.
Correct
Reading
NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector.
Flood lamp connector pin A to pin B
Continuity
NOTE: Connect wiring harness connector LRRW to RH rear work lamp connector.
Terminal for wire 0-MF to ground
Continuity
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
Bur 5-2750
24 volts
Check fuse ECB-F2 and driving lamp switch (95). Also check
circuit 42R from flood lamp to lamp switch (95) and wire 42-B
to fuse ECC-F2.
Issued 8-06
Printed in U.S.A.
4002-81
89 Lights Diodes
Located in the cab access panel for fuses and relays, rear of compartment.
Check Points
Correct
Reading
None
Bad diode.
None
Bad diode.
Continuity
Bad diode.
Continuity
Bad diode.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-82
LIGHTS - 02
93 94
95
92 91 90
BS06H241 / BS06H242
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-83
Correct
Reading
24 volts
0 volt
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44 to ground
24 volts
Correct
Reading
Continuity
24 volts
0 volt
0 volt
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44A to ground
24 volts
24 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-84
92 Flasher Module
Located in the cab access panel for fuses and relays, rear of compartment.
Check Points
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
Continuity
Continuity
24 volts
NOTE: Put ignition switch in the ON position. Put the hazard switch (93) ON.
Terminal for wire 45H to ground
24 volts
Intermittent 24
volts
Intermittent 24
volts
NOTE: Put hazard switch (93) in OFF position. Put turn signal switch (94) in RIGHT turn position.
Terminal for wire 45B-A to ground
24 volts
Intermittent 24
volts
Bad turn signal switch (94) or fuse ECA-F8. Also check wires
45B-A and 45B.
Bad flasher module.
24 volts
Intermittent 24
volts
Bur 5-2750
Bad turn signal switch (94) or fuse B. Also check wire 45A-A.
Bad flasher module.
Issued 8-06
Printed in U.S.A.
4002-85
93 Hazard Switch
Located on steering column.
Check Points
Terminal for wire 0-B24 to ground
Correct
Reading
Continuity
24 volts
24 volts
24 volts
Correct
Reading
Continuity
Check fuse ECC-F6 and horn relay (98). Also check wires 64C
and circuit 19U.
24 volts
24 volts
Check fuse ECA-F8 and power relay module A (13). Also check
wire 19B.
24 volts
24 volts
Bur 5-2750
Continuity
Issued 8-06
Printed in U.S.A.
4002-86
Correct
Reading
24 volts
24 volts
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-87
97
98
BS06H241 / BS06H242
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-88
Correct
Reading
NOTE: Disconnect wiring harness connector LF from LH front combination lamp connector.
Combination lamp connector pin 3 to
pin 1
Continuity
Continuity
Continuity
Continuity
Continuity
NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 2.
Terminal for wire 18F to ground
24 volts
Check fuse ECB-F7 and driving lamp switch (95). Also check
circuit 18F.
24 volts
24 volts
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Terminal for wire 45L to ground
Intermittent 24
volts
Check the turn signal switch (94) and flasher module (92). Also
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-89
Correct
Reading
NOTE: Disconnect wiring harness connector RF from RH front combination lamp connector.
Combination lamp connector pin 3 to
pin 1
Continuity
Continuity
Continuity
Continuity
Continuity
NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3.
Terminal for wire 18G-A to ground
24 volts
Check fuse ECB-F8 and driving lamp switch (95). Also check
circuit 18G and wire 41T-A.
24 volts
24 volts
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R to ground
Intermittent 24
volts
Check the turn signal switch (94) and flasher module (92). Also
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-90
98 Horn Relay
Located in the cab access panel for fuses and relays.
Check Points
Correct
Reading
24 volts
24 volts
24 volts
NOTE: Have another person push and hold the horn switch.
Terminal for wire 64C to ground
0 volt
24 volts
99 Horn
Located on the left front of the machine with combination lamps.
Check Points
Terminal for wire 0-AF to ground
Correct
Reading
Continuity
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-91
101
103
100
102
BS06H241 / BS06H242
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-92
Correct
Reading
NOTE: Disconnect wiring harness connector LRR-N from RH rear combination lamp connector.
Combination lamp connector pin A
to pin D
Continuity
Continuity
Continuity
NOTE: Connect wiring harness connector LRR-N to RH rear combination lamp connector.
Terminal for wire 0-BT to ground
Continuity
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
Terminal for wire 44A-GN to ground
24 volts
Intermittent 24
volts
Check the turn signal switch (94) and flasher module (92). Also
check circuit 45R to flasher module.
24 volts
Check fuse ECB-F8 and lamp switch (95). Also check circuit
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-93
Correct
Reading
NOTE: Disconnect wiring harness connector LRR-E from RH rear combination lamp connector.
Combination lamp connector pin 1 to
pin 5
Continuity
Continuity
Continuity
Continuity
NOTE: Connect wiring harness connector LRR-E to RH rear combination lamp connector.
Terminal for wire 0-BR to ground
Continuity
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
Terminal for wire 44A-F to ground
24 volts
24 volts
NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R-A to ground
Intermittent 24
volts
Check the turn signal switch (94) and flasher module (92). Also
check circuit 45R to flasher module.
24 volts
Check fuse ECB-F8 and lamp switch (95). Also check circuit
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-94
Correct
Reading
NOTE: Disconnect wiring harness connector LLR-N from LH rear combination lamp connector.
Combination lamp connector pin A
to pin D
Continuity
Continuity
Continuity
NOTE: Connect wiring harness connector LLR-N to LH rear combination lamp connector.
Terminal for wire 0-BR-N to ground
Continuity
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
Terminal for wire 44A-FN to ground
24 volts
Intermittent 24
volts
Check the turn signal switch (94) and flasher module (92). Also
check circuit 45L to flasher module.
24 volts
Check fuse ECB-F7 and lamp switch (95). Also check circuit
18F.
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-95
Correct
Reading
NOTE: Disconnect wiring harness connector LLR-E from LH rear combination lamp connector.
Combination lamp connector pin 1 to
pin 5
Continuity
Continuity
Continuity
Continuity
NOTE: Connect wiring harness connector LLR-E to LH rear combination lamp connector.
Terminal for wire 0-BT to ground
Continuity
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
Terminal for wire 44A-E to ground
24 volts
24 volts
NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.
Terminal for wire 45L-A to ground
Intermittent 24
volts
Check the turn signal switch (94) and flasher module (92). Also
check circuit 45L to flasher module.
Correct
Reading
Bulb
Continuity
Bad bulb.
Continuity
NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2.
Terminal for wire 18G-E to ground
Bur 5-2750
24 volts
Check fuse ECB-F8 and five driving lamp switch (95). Also
check circuit 18G.
Issued 8-06
Printed in U.S.A.
4002-96
Correct
Reading
Bulb
Continuity
Bad bulb.
Continuity
NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2.
Terminal for wire 18G-E to ground
24 volts
Check fuse ECB-F8 and five driving lamp switch (95). Also
check circuit 18G.
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
Terminal for wire 35A to ground
24 volts
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
Terminal for wire 35A to ground
24 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-97
109
111
107 108
112
104 106
113
105
BS06H241 / BS06H242
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-98
Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J-D and 19J-E to
ground
24 volts
Bad fuse ECA-F12, check circuit 19J, also check power relay
module D (21).
Continuity
24 volts
24 volts
Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J-G to ground
24 volts
Check fuse ECA-F12, check circuit 19J, also check power relay
module D (21).
24 volts
Bur 5-2750
Continuity
0 volts
Issued 8-06
Printed in U.S.A.
4002-99
Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J-F to ground
24 volts
Bad fuse ECA-F12, check circuit 19J, also check power relay
module D (21).
24 volts
Continuity
24 volts
Correct
Reading
Continuity
24 volts
24 volts
NOTE: Put the rear wiper and washer switch in the ON position.
Terminal for wire 68L to ground
24 volts
NOTE: Press and hold the rear wiper and washer switch in the WASH position.
Terminal for wire 68W to ground
24 volts
Bur 5-2750
24 volts
Check rotary lamp switch (95) and circuit 49. If LEDs in rear
wiper and washer switch are not ON with 24 volts at check
point, replace rear wiper and washer switch.
Issued 8-06
Printed in U.S.A.
4002-100
Correct
Reading
Continuity
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.
Terminal for wire 19J-B to ground
24 volts
Check fuse ECA-F12, check circuit 19J, also check power relay
module D (21).
NOTE: Put the front wiper and washer switch in the LOW position.
Terminal for wire 63LC to ground
Continuity
NOTE: Put the front wiper and washer switch in the HIGH position.
Terminal for wire 63HC to ground
Continuity
NOTE: Put the front wiper and washer switch in the wash position.
Terminal for wire 63W to ground
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-101
Correct
Reading
Continuity
NOTE: Make sure the front wiper and washer switch (108) is in the OFF position.
Between terminals B and D for wires
63C and 63L
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19J to ground
24 volts
NOTE: Put the front wiper and washer switch (108) in the LOW position.
Terminal for wire 63L-A to ground
Terminal for wire 63C to ground
24 volts
0 volt
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
and washer switch (108), low speed relay or cut out relay.
Bad front wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (108) in the HIGH position.
Terminal for wire 63H-A to ground
Terminal for wire 63C to ground
24 volts
0 volt
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
and washer switch (108), high speed relay or cut out relay.
Bad front wiper and washer switch (108).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L to ground
24 volts pulse
24 volts pulse
NOTE: If the readings are good, replace the front wiper motor.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-102
Correct
Reading
Continuity
NOTE: Make sure the rear wiper and washer switch (107) is in the OFF position.
Between terminals for wires 68C-A
and 68L-A
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19K-C to ground
24 volts
NOTE: Put the rear wiper and washer switch (107) in the ON position.
Terminal for wire 68C-A to ground
24 volts
0 volt
NOTE: If the readings are good, replace the rear wiper motor.
Correct
Reading
Continuity
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (107) in WASH position.
Terminal for wire 68W-A to ground
24 volts
Bad rear wiper and washer switch (107) Also check wires
68W-A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor.
Correct
Reading
Continuity
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).
Terminal for wire 63W-A to ground
24 volts
Bad front wiper and washer switch (108), also check circuit
63W.
NOTE: If the readings are good, replace the front washer pump motor.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-103
Correct
Reading
None
Bad diode.
None
Bad diode.
None
Bad diode.
None
Bad diode.
None
Bad diode.
Continuity
Bad diode.
Continuity
Bad diode.
Continuity
Bad diode.
Continuity
Bad diode.
Continuity
Bad diode.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-104
SECONDARY STEERING
114 116
118
115 117
BS06H241 / BS06H242
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-105
Check Points
None
Bad diode.
None
Bad diode.
Continuity
Bad diode.
Continuity
Bad diode.
Correct
Reading
36 to 42 ohms
Continuity
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
ground
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-106
Correct
Reading
NOTE: Disconnect the wiring harness connector SSM from the secondary steering module.
Continuity
Continuity
Continuity
Open Circuit
Continuity
Continuity
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector SSM to ground
24 volts
24 volts
24 volts
Continuity
11 volts
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
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-107
Correct
Reading
Continuity
Continuity
10 to 45 ohms
24 volts
NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DO
NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then
immediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem is
associated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnect
wire 51-B from secondary steering motor relay.
24 volts
Correct
Reading
NOTE: Disconnect wiring harness connector PSS from secondary steering pressure switch.
Pressure switch pin B to pin C
Continuity
Open Circuit
Open Circuit
Continuity
Open Circuit
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-108
CAN COMMUNICATION
119
BS06H241 / BS06H242
119.DIAGNOSTIC CONNECTOR
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-109
Correct
Reading
Continuity
24 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-110
122 123
124
120
121
BS06H241 / BS06H242
123.RADIO
124.RIGHT SPEAKER
125.LEFT SPEAKER
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-111
Correct
Reading
Continuity
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Accessory or the ON
position.
Terminal for wire PRM-E BUSS to
ground
24 volts
24 volts
Correct
Reading
Continuity
24 volts
12 volts
Correct
Reading
Continuity
12 volts
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-112
Correct
Reading
Continuity
12 volts
Check fuse ECD-F6, also check circuit 12V. Also check the
remote radio power converter (121).
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
RSPK to ground
Voltage
Continuity
Bad circuit between the right speaker and the radio or a bad
radio (123).
Bad circuit between the right speaker and the radio (123).
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
LSPK to ground
Voltage
Continuity
Bad circuit between the left speaker and the radio or a bad
radio (123).
Bad circuit between the left speaker and the radio (123).
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-113
126
129
127
128
BS06H241 / BS06H242
126.AIR SEAT
127.CIGAR LIGHTER
128.AIR CONDITIONING CLUTCH REALY
129.HIGH/LOW SWITCH
130.AIR CONDITIONING COMPRESSOR CLUTCH
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-114
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire 19N at seat switch
24 volts
24 volts
Correct
Reading
24 volts
Continuity
Correct
Reading
Continuity
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (149) to HIGH and
thermostat switch to COLD.
Terminal for wire 61R-B to ground
24 volts
24 volts
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
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-115
Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (149) to HIGH and
the thermostat switch to COLD.
Terminal B for wire 61A to ground
24 volts
NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch.
Between terminals of trinary
pressure switch
Continuity
Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (149) to HIGH and
thermostat switch to COLD.
Terminals for wire 61C-A to ground
Bur 5-2750
24 volts
Issued 8-06
Printed in U.S.A.
4002-116
131
139
132 133 134 138 142
BS06H241 / BS06H242
131.ELECTRONIC PANEL
132.EXTERNAL AIR TEMPERATURE SENSOR
133.INTERNAL AIR TEMPERATURE SENSOR
134.SUN SENSOR
135.BLOWER FAN RESISTOR
136.BLOWER MOTORS
137.THERMOCOUPLE SENSOR
138.MIXED AIR SENSOR
139.COMPRESSOR RELAY
140.RECYCLING MOTOR
141.ELETRONIC WATER VALVE
142.24 TO 12 VOLT CONVERTER
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-117
Correct
Reading
Correct
Reading
Correct
Reading
Correct
Reading
Correct
Reading
Correct
Reading
Correct
Reading
Correct
Reading
Issued 8-06
Printed in U.S.A.
4002-118
Correct
Reading
Correct
Reading
Correct
Reading
Correct
Reading
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-119
BS06H241 / BS06H242
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.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-120
Correct
Reading
Correct
Reading
Correct
Reading
144 Driver
Check Points
NOTE: No information at time of print.
Correct
Reading
NOTE: Disconnect the wiring harness connector DNS RESISTOR from the resistor.
Between terminals 1 and 4 of blower
motor connector
Approximately
x.x ohms
Approximately
x.x ohms
Approximately
x.x ohms
Correct
Reading
Continuity
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (149)
to position 4.
Terminal for wire DNS65 to ground
24 volts
NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the blower
switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the blower
motor resistor (146).
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-121
148 Thermostat
Check Points
Correct
Reading
Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Terminal for wire DNS74 to ground
24 volts
24 volts
24 volts
24 volts
24 volts
Correct
Reading
Correct
Reading
Correct
Reading
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-122
Correct
Reading
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-123
157
156
154
155
BS06H241 / BS06H242
154.HOOD UP RELAY
155.HOOD DOWN RELAY
156.HOOD SWITCH
157.HOOD MOTOR
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a Multimeter for the following tests.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-124
Correct
Reading
Continuity
24 volts
24 volts
24 volts
Correct
Reading
Continuity
24 volts
24 volts
24 volts
Correct
Reading
24 volts
Continuity
Continuity
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-125
Correct
Reading
NOTE: Turn the master disconnect switch ON and disconnect connector HDM. Hold the hood switch (156) in the
raise position.
Terminal for wire 60U-A
24 volts
Bad hood up relay (154), bad hood switch (156), and check
fuse ECC-F7.
24 volts
Bad hood down relay (155), bad hood switch (156), and check
fuse ECC-F7.
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-126
CONNECTORS
CONNECTOR 108F - DIAGNOSTIC CONNECTOR
291663A1
CAV
WIRE IDENT
CIRCUIT
225350C1
CAV
WIRE IDENT
CIRCUIT
19A-W
19A-C
37D-A
Diagnostic Signal
26F-B
0-DAV
26N-B
37E
26R-B
Not Used
32J-E
Not Used
25Y-B
225351C1
245488C1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
19A-B
CIRCUIT
FNR Switched Fused Power
63H-C
26F-A
63L-C
26N-A
0-EE
26R-A
58-D
32J-A
25Y-C
21D-B
68L-C
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-127
CONNECTOR 202M - ROLLBACK JUMPER
245482C1
CAV
WIRE IDENT
CIRCUIT
225316C1
58-A
CAV
58-A
19A-U
25Y-C
WIRE IDENT
CIRCUIT
199436A1
245481C1
CAV
A
WIRE IDENT
35A-E
CAV
CIRCUIT
WIRE IDENT
14-A
CIRCUIT
Alternator D+
199436A1
245480C1
CAV
A
WIRE IDENT
35A-D
Bur 5-2750
CIRCUIT
CAV
1
WIRE IDENT
19R-D
CIRCUIT
Alternator Resistor Fused Pwr
Issued 8-06
Printed in U.S.A.
4002-128
CONNECTOR 64F - FLASHER CONNECTOR
245481C1
CAV
1
WIRE IDENT
45N-A
CIRCUIT
Flasher Optional Side Control
87419488
CAV
245480C1
CAV
1
WIRE IDENT
45N-B
CIRCUIT
Flasher Optional Side Control
WIRE IDENT
13V
36F-A
CAN-HG
CAN High
CAN-LG
CAN Low
36A
0-DX
43-A
36B
36H-A
10
Not Used
11
36C-A
12
0-DW
13
35B
14
52C
15
44A-B
16
51S
17
51CS
18
8602417
CAV
1
WIRE IDENT
61C-A
CIRCUIT
AC relay out
Not Used
19
28J
20
53C-A
21
51C
22
23
Not Used
52
24
Bur 5-2750
CIRCUIT
25
17P-A
26
56
Issued 8-06
Printed in U.S.A.
4002-129
CONNECTOR AIC2 - ADV INSTRUMENT
CLUSTER 2
222136A1
87410948
CAV
WIRE IDENT
1
2
CIRCUIT
Not Used
43S-C
33R
33P-A
33U
52M
52AU
45L-E
10
45R-C
11
35X
WIRE IDENT
CIRCUIT
35B
0-B27
Buzzer Ground
Not Used
12
Not Used
13
Not Used
14
19S-D
15
0-DB
16
57-C
17
21K-A
18
31L
19
Not Used
20
19S-C
21
19E-A
22
0-DA
23
Not Used
24
Not Used
25
Not Used
26
CAV
31D-A
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-130
CONNECTOR CAB-E - CAB TO ENGINE
CAV
WIRE IDENT
CIRCUIT
37
59D
38
60U
39
59U
40
35A-F
225415C1
CAV
WIRE IDENT
CIRCUIT
21C-C
61C
AC Relay Out
21G
21H
18F-A
Not Used
35A-C
44A-C
18G-F
10
45L-B
11
21F
12
45R-B
13
18R-A
14
18J-G
15
21D-C
16
28H
17
0-DX
18
18J
19
0-DW
20
0-DB
21
13C-B
22
52A-A
23
56
24
68W
25
63W
26
14-A
Alternator D+
27
21E
28
31F-A
29
61R-B
AC Relay Control
30
61A-B
31
20G-B
32
36A
33
36F-A
34
36C-A
35
19Y-C
36
60D
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-131
CONNECTOR CAB-F - CAB FRONT CHASSIS
388710A1
CAV
43-A
42R-C
42C-A
19U-D
WIRE IDENT
45L-C
CIRCUIT
291661A1
CAV
WIRE IDENT
CIRCUIT
51B-C
45R-D
46-C
Not Used
0-DR
0-DS
19K-C
4
5
18G-G
18F-E
18B-A
68C
36B
68L-B
O-DY
0-EM
Radio Ground
Not Used
12V-B
10
11
54B-A
Height-RTT Signal
43S-A
12
53B-B
RTD Signal
19U-G
13
64A
Horn Power
14
18D-A
15
18E-A
16
18C-A
17
Not Used
18
Not Used
19
53P-F
20
57-A
21
58-C
22
1-DR
23
44-A
24
52P-A
25
Not Used
26
33P-A
27
19A-T
28
25G-A
29
Not Used
30
Not Used
31
Not Used
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-132
CONNECTOR CAB-T - CAB TO TRANMISSION
380839A1
CAV
WIRE IDENT
CIRCUIT
33R
31D-A
19M
19R-E
CAN-HA
CAN High
36T-A
CAN-LA
CAN Low
35X
25A-A
25C-A
25B-A
10
25D-A
11
0-DM
12
36R-E
13
36G-A
14
CAV
WIRE IDENT
CIRCUIT
Not Used
15
Not Used
16
25K-A
17
25L-A
18
25M-A
19
25N-A
20
25P-A
21
25J-A
22
25S-A
23
31H-A
24
Not Used
25
Not Used
26
87315266
19S1
27
87315267
CAV
WIRE IDENT
CIRCUIT
CAN-H
CAN High
CAN-HJ
CAN-L
CAN Low
CAN-LM
28
0-DN
29
19A-M
30
36H-A
31
32F-A
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-133
CONNECTOR CL - CIGAR LIGHTER
245485C1
CAV
3227856R1
CAV
WIRE IDENT
CIRCUIT
19W
0-DV
WIRE IDENT
CIRCUIT
42C-D
41T-C
49
194788A1
CAV
A
WIRE IDENT
31D
0-HV
CIRCUIT
310057A1
CAV
0-DH
Ground
18K-A
CAN-HB
CAN-LB
20G-B
WIRE IDENT
CIRCUIT
225351C1
CAV
1
WIRE IDENT
CIRCUIT
19L-A
19L-B
0-EJ
CAV
Not Used
13C
13M
4
5
12V-C
0-ER
Bur 5-2750
245482C1
WIRE IDENT
CIRCUIT
Issued 8-06
Printed in U.S.A.
4002-134
CONNECTOR DM - DIODE OR
CAV
WIRE IDENT
21
DNS7
23
DNS12
26
DNS19
CIRCUIT
CONNECTOR DNS-COMPRESSOR-RELAY
245485C1
CAV
A
WIRE IDENT
19RR
B
C
CIRCUIT
Sec. Steering Ignition Fused Pwr
Not Used
19R
CAV
WIRE IDENT
85
DNS19
86
DNS20
30
DNS16
87
DNS14
CIRCUIT
CONNECTOR DNS-AC-SWITCH
CONNECTOR DNS-EXTERNAL-AIR-TEMP-SNS
CAV
1
WIRE IDENT
CIRCUIT
CAV
DNS72
DNS68
DNS71
DNS2
DNS1
WIRE IDENT
DNS48
DNS49
CIRCUIT
CONNECTOR DNS-HVAC-CAN1
CONNECTOR DNS-ACTUATOR
CAV
WIRE IDENT
CIRCUIT
CAV
CAV
WIRE IDENT
DNS8
DNS10
DNS11
DNS2
DNS4
DNS3
10
DNS6
14
DNS9
15
DNS31
16
DBS13
17
DNS18
Bur 5-2750
CIRCUIT
WIRE IDENT
DNS9
DNS8
CIRCUIT
Issued 8-06
Printed in U.S.A.
4002-135
CONNECTOR DNS-NOT-USED
CONNECTOR DNS-HVAC1
225326C1
225294C1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
DNS12
DNS14
DNS10
DNS15
DNS11
DNS13
CONNECTOR DNS-HVAC2
CAV
225315C1
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
DNS25
DNS24
DNS47
DNS43
DNS44
DNS21
DNS36
10
DNS23
DNS35
14
DNS28
15
DNS26
16
DNS22
17
DNS27
18
DNS29
21
DNS22
23
DNS45
24
DNS46
CONNECTOR DNS-INTERNAL-AIR-TEMP-SNS
CAV
WIRE IDENT
DNS4
DNS3
DNS17
DNS5
Bur 5-2750
CIRCUIT
CIRCUIT
CIRCUIT
Issued 8-06
Printed in U.S.A.
4002-136
CONNECTOR DNS-PWM-BLOWER-PIN4
CONNECTOR DNS-VOLTAGE-CONVERTER
CAV
WIRE IDENT
DNS34
DNS33
DNS32
DNS31
CIRCUIT
CONNECTOR DNS-ELECT-WATER-VALVE
HIRSCHMANN 772717-001
CAV
WIRE IDENT
CIRCUIT
DNS38
CAV
DNS47
DNS30
DNS37
DNS29
DNS28
DNS27
DNS26
CONNECTOR DNS-PWM-BLOWER-PIN2
CAV
WIRE IDENT
DNS41
DNS42
CAV
CAV
WIRE IDENT
DNS41
DNS42
CIRCUIT
CIRCUIT
CONNECTOR DNS-RECYCLING-MOTOR
CIRCUIT
CONNECTOR DNS-PWM-BLOWER
WIRE IDENT
WIRE IDENT
DNS21
DNS22
DNS23
DNS24
DNS25
CIRCUIT
CONNECTOR DNS-SPEED-SELECTOR
CONNECTOR DNS-THERMOCOUPLE-SENSO
CAV
CAV
1
WIRE IDENT
CIRCUIT
DNS46
DNS40
WIRE IDENT
DNS74
DNS61
DNS62
DNS63
DNS73
CIRCUIT
CONNECTOR DNS-MIXED-AIR-SENSOR
CAV
WIRE IDENT
DNS39
DNS45
Bur 5-2750
CIRCUIT
Issued 8-06
Printed in U.S.A.
4002-137
CONNECTOR DNS-CTRL-PANEL-LIGHT
CAV
WIRE IDENT
CIRCUIT
CONNECTOR DNS-RESISTOR
CAV
WIRE IDENT
DNS69
DNS61
DNS70
DNS62
DNS63
DNS64
CIRCUIT
CONNECTOR DNS-WATER-VALVE-POT
CONNECTOR DNS-ELECT-WATER-VALVE-S
CAV
WIRE IDENT
DNS55
DNS54
CIRCUIT
CAV
CONNECTOR DNS-RECIRCULATING-SWITCH
CAV
WIRE IDENT
DNS51
DNS53
WIRE IDENT
DNS60
DNS56
DNS57
DNS58
DNS59
CIRCUIT
CIRCUIT
CONNECTOR DNS-DRIVER
CONNECTOR DNS-THERMOSTAT-1
CAV
1
WIRE IDENT
CIRCUIT
DNS67
CAV
CONNECTOR DNS-THERMOSTAT-2
CAV
1
WIRE IDENT
CIRCUIT
DNS68
CONNECTOR DNS-ELECTRIC-FAN
CAV
WIRE IDENT
DNS65
DNS66
Bur 5-2750
411311A1
CIRCUIT
WIRE IDENT
DNS50
DNS52
DNS49
DNS48
DNS55
DNS57
DNS58
DNS59
11
DNS51
12
DNS53
13
DNS54
14
DNS56
CIRCUIT
Issued 8-06
Printed in U.S.A.
4002-138
CONNECTOR DNS-HVAC1-S
245482C1
225294C1
CAV
A
WIRE IDENT
CAV
CIRCUIT
DNS67
DNS76
DNS69
WIRE IDENT
CIRCUIT
19U-F
43S-B
245485C1
CAV
225315C1
CAV
WIRE IDENT
DNS74
DNS75
Bur 5-2750
CIRCUIT
WIRE IDENT
CIRCUIT
18G-D
35A-G
0-BAG
Issued 8-06
Printed in U.S.A.
4002-139
CONNECTOR ECA - ELECTRICAL CENTER A
87315248
CAV
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
L1
J6
J7
A1
19A-N
L1
A2
18L-A
L1
J8
A3
19E-A
L1
J9
A4
19RR
L2
J11
L2
J12
A5
19C-A
L2
J13
A6
19D-A
L2
J14
A7
19P
L2
J15
Backup AC
A8
19B
L2
J16
AC Seat Compressor
A9
13C-B
C1
18N
L2
J18
C2
19J
C3
19K
C4
19H
C5
18M
C6
19N
C7
19M
L1
J1
L1
J2
L1
J3
L1
J4
L1
J5
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-140
CONNECTOR ECB - ELECTRICAL CENTER B
87312843
CAV
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
B3
21K-B
A1
42FS
B4
0-DE
A2
42RS
B5
21F
0-DF
A3
41H-B
B6
A4
41H-C
B7
19P-E
A5
41L-C
B8
52
A6
41L-B
B9
19D-C
52C
A7
41T-B
B10
A8
41T-A
D1
13K-C
A9
21H
D2
13V
A10
21C-B
D3
25T
Neutral Signal
21C
AA1
42C-C
D4
AA2
42R-C
D5
21C-A
AA3
18B-A
D6
21E
AA4
18C-A
D7
19P-D
52A-A
AA5
18E-A
D8
AA6
18D-A
D9
19D-B
AA7
18F-C
D10
52P-B
AA8
18G
AA9
21D-A
AA10
21G
B1
18R-A
B2
0-DD
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-141
CONNECTOR ECC - WORK LIGHTS
87315249
CAV
WIRE IDENT
CIRCUIT
A1
19U-B
A2
42
A3
19Z
A4
1-DV
A5
1DM
A6
19U
A7
19Y
A8
19W
A9
18K-A
B1
60U
CAV
D4
WIRE IDENT
19Y-B
CIRCUIT
Hood Down Relay Fused Power
D5
44-A
D6
44A-A
D7
19U-E
D8
64-A
Horn Power
D9
18L-B
D10
51B-B
L1-1
ECC-L1
L1-1
J2-ECC
L1-2
J2-ECC
L1-2
J3-ECC
B2
0-B25
B3
60D
L1-3
J3-ECC
B4
0-B16
L1-3
J4-ECC
B5
1-DW
L1-4
J4-ECC
J5-ECC
B6
0-EF
L1-4
B7
19U-A
L1-5
J5-ECC
B8
64C
L1-5
J6-ECC
B9
18L-C
L1-6
J6-ECC
J7-ECC
B10
51C
L1-6
C2
0-B22
L1-7
J7-ECC
C4
0-B12
L1-7
J8-ECC
D1
59U
L1-8
J8-ECC
J9-ECC
Diagnostic Power
J9-ECC
Diagnostic Power
D2
19Y-A
L1-8
D3
59D
L1-9
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-142
CONNECTOR ECD - ELECTRICAL CENTER D
87312843
CAV
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
B5
19C-B
53C-A
A1
13H-C
B6
A2
13H-D
B7
58T
A3
13H-B
B8
58L
A4
12V-D
B9
18M
0-DJ
A5
12V-E
B10
A6
12V-F
C2
63C2
A7
12V-G
C4
63C
A9
35C
D1
19J-D
A10
19H
AA1
19T-A
D2
63H-B
AA2
18J-K
D3
19J-F
AA3
19S-B
D4
63C2
AA4
12V
D5
19C-C
AA5
12V-A
D6
53P-C
AA6
12V-B
D7
58H-A
AA9
35A-A
D8
58-E
19A-P
D9
61R-B
AC Relay Control
D10
61C
AC Relay Out
AA10
B1
19J-E
B2
63HC-B
B3
63C3
B4
63LC
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-143
CONNECTOR EDC7 - ENGINE CONTROLLER
CAV
WIRE IDENT
CIRCUIT
42
35W
48
24L
75
0-BV
77
24S
Throttle Supply
78
24R
Throttle Ground
79
24B
Throttle Signal
89
20G-A
225351C1
CAV
BOSCH-89-POLE
CAV
WIRE IDENT
CIRCUIT
55A-A
54A
53A
53B-B
54B-B
55B
CIRCUIT
18J-C
18J-B
0-BE
EDC7 Ground
0-BF
EDC7 Ground
18J-D
18J-E
10
0-BD
EDC7 Ground
11
0-BC
EDC7 Ground
12
28G
13
0-BN
17
21H-A
29
21F-B
32
21E-A
34
CAN-L
CAN Low
35
CAN-H
CAN High
36
28F
37
21GA
40
13M-A
Bur 5-2750
WIRE IDENT
Issued 8-06
Printed in U.S.A.
4002-144
CONNECTOR ENG - ENGINE TO CAB
CAV
225414C1
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
30
61A
31
20G-A
32
36A-A
33
36F
34
36C
35
19Y-D
36
60D-A
37
59D-A
21C-D
38
60U-A
61C-A
AC Relay Out
39
59U-A
61C-B
AC Relay Out
40
35A-G
40
35A-GN
21GA
21H-A
18F-AN
18F-B
Not Used
35A-R
35A-J
Reverse Light
44A-D
44A-DN
18G-H
18G-HN
10
45L-A
10
45L-AN
11
21F-A
12
45R-A
12
45R-AN
13
18R
14
18J-F
15
21D
16
28E
17
0-BJ
18
18J-A
19
0-BG
20
0-BH
21
13C-A
22
52A-B
23
56-A
24
68W-A
25
63W-A
26
14
Alternator D+
27
21E-A
28
31F
29
61R
AC Relay Control
Bur 5-2750
245483C1
CAV
WIRE IDENT
CIRCUIT
13C-A
13M-A
13M-B
Issued 8-06
Printed in U.S.A.
4002-145
CONNECTOR ENG-H - ENGINE TO HOOD
291718A1
CAV
225320C1
CAV
WIRE IDENT
CIRCUIT
0-BAG-N
44A-DN
45L-AN
45R-AN
18G-HN
18F-AN
35A-GN
35A-R
WIRE IDENT
CIRCUIT
25A
0-HF
CAV
WIRE IDENT
CIRCUIT
1-GB
0-BX
225326C1
CAV
WIRE IDENT
CIRCUIT
0-BZ
0-BK
31D-C
Bur 5-2750
Not Used
Issued 8-06
Printed in U.S.A.
4002-146
CONNECTOR FLSHR - FLASHER MODULE
225389C1
CAV
WIRE IDENT
CIRCUIT
373358A1
1-DU
45N-A
0-EH
0-EG
Not Used
6
7
45R-E
45L-D
45A-A
10
45B-A
11
45H
12
45N-B
371614A1
1
2
WIRE IDENT
32F
36R-B
Bur 5-2750
WIRE IDENT
CIRCUIT
Trans Filter Maint Sw
Trans FM Switch Return
CIRCUIT
45L
51B-D
45R
Not Used
CAV
CAV
Not Used
18G-A
18F
18B
36B-A
0-AR
10
Not Used
11
54B
12
53B
13
64
Horn Power
14
18D
15
18E
16
18C
17
Not Used
18
Not Used
19
53P-G
20
57
21
58-B
21
58S-E
22
1-AA
23
44
24
52P
25
26
33P
27
19A-A
28
25G
29
Not Used
30
Not Used
31
Not Used
Issued 8-06
Printed in U.S.A.
4002-147
CONNECTOR FWM - FRONT WIPER MOTOR
245715C1
CAV
WIRE IDENT
CIRCUIT
3227856R1
CAV
WIRE IDENT
CIRCUIT
63H-A
63W-A
63L-A
0-B
19J-A
63C
3227856R1
CAV
245480C1
CAV
1
WIRE IDENT
0-B8
Bur 5-2750
CIRCUIT
WIRE IDENT
CIRCUIT
28G
0-BV
Issued 8-06
Printed in U.S.A.
4002-148
CONNECTOR GND-CAB-SPL - CAB GROUND
SPLICE
CAV
WIRE IDENT
CIRCUIT
0-DD
0-DF
0-DE
0-EQ
Not Used
0-EH
0-EG
0-EF
CAV
WIRE IDENT
CIRCUIT
0-EE
0-EM
Radio Ground
0-EP
Not Used
Not Used
0-DG
0-DT
0-DL
CAV
59D-A
245485C1
WIRE IDENT
CIRCUIT
0-DK
0-DJ
19Y-D
0-DU
59U-A
0-DH
245484C1
CAV
87324393
CAV
WIRE IDENT
CIRCUIT
18G-E
35A-H
0-JA
CIRCUIT
0-DC
0-EA
0-EB
0-EC
Bur 5-2750
WIRE IDENT
Issued 8-06
Printed in U.S.A.
4002-149
CONNECTOR HD-N - HOOD TO ENGINE
194788A1
CAV
225319C1
CAV
WIRE IDENT
WIRE IDENT
36H
0-HW
CIRCUIT
Hydraulic Oil Temp Signal
Hydraulic Oil Temp Ground
CIRCUIT
0-JA-N
44A-EN
45L-BN
45R-BN
18G-JN
18F-BN
35A-HN
225295C1
WIRE IDENT
CIRCUIT
61A-B
18N-A
49A
225316C1
CAV
WIRE IDENT
CIRCUIT
60U-A
60D-A
87552622
CAV
Bur 5-2750
WIRE IDENT
CIRCUIT
0-ED
HVAC Grounds
18N-B
Issued 8-06
Printed in U.S.A.
4002-150
CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC
245731C1
CAV
87315267
CAV
WIRE IDENT
CIRCUIT
CAN-HK
CAN High
CAN-LL
CAN Low
WIRE IDENT
CIRCUIT
30
63L-B
85
63HC-A
86
19J-G
87
87A
Not Used
63C3
291718A1
CAV
WIRE IDENT
CIRCUIT
25B
0-HG
Bur 5-2750
291730A1
CAV
WIRE IDENT
CIRCUIT
46-E
0-MD
Issued 8-06
Printed in U.S.A.
4002-151
CONNECTOR LLF - LH FRONT LIGHTS
225351C1
CAV
WIRE IDENT
225351C1
CIRCUIT
0-AJ
Lights Ground LH
CAV
WIRE IDENT
CIRCUIT
18D
Low Beam LH
44A-E
45L-A
18B
High Beam LH
18F
18F-B
45L
35A-L
Reverse Lamp
Not Used
0-BT
LH Ground (EURO)
Not Used
245483C1
CAV
WIRE IDENT
CIRCUIT
42C-H
0-MU
245715C1
CAV
Bur 5-2750
WIRE IDENT
CIRCUIT
44A-FN
18F-BN
45L-BN
0-BR-N
Issued 8-06
Printed in U.S.A.
4002-152
CONNECTOR LLRW- LH REAR WORK LAMP
245483C1
CAV
WIRE IDENT
CIRCUIT
42R-H
0-ME
225351C1
CAV
WIRE IDENT
CIRCUIT
0-AH
18E
18C
18G-A
45R
Not Used
245482C1
CAV
WIRE IDENT
CIRCUIT
18G-E
18G-EN
0-JC
CAV
Bur 5-2750
WIRE IDENT
CIRCUIT
42C-G
0-MJ
Issued 8-06
Printed in U.S.A.
4002-153
CONNECTOR LRR-E - RH REAR COMBINATION
LAMP
245483C1
CAV
225351C1
CAV
WIRE IDENT
CIRCUIT
44A-F
45R-A
18G-J
35A-K
Reverse Lamp
0-BR
WIRE IDENT
CIRCUIT
42R-G
0-MF
Ground (EURO)
Not Used
CAV
WIRE IDENT
CIRCUIT
65L
0-PA
245715C1
CAV
WIRE IDENT
CIRCUIT
44A-GN
18G-CN
45R-BN
0-BT-N
CAV
1
Bur 5-2750
WIRE IDENT
0-HE
CIRCUIT
Output Speed Ground
25D
19A
Issued 8-06
Printed in U.S.A.
4002-154
CONNECTOR PAF - AIR FILTER RESTRICTION
SWITCH
222136A1
291718A1
CAV
WIRE IDENT
CAV
CIRCUIT
31F
0-BY
WIRE IDENT
CIRCUIT
1-AA
44
225316C1
245482C1
CAV
WIRE IDENT
CIRCUIT
19A-A
25G
Bur 5-2750
CAV
WIRE IDENT
CIRCUIT
33P
0-AL
Issued 8-06
Printed in U.S.A.
4002-155
CONNECTOR PO1 - POWER OUTLET
182068A1
CAV
WIRE IDENT
CIRCUIT
12176446
CAV
A
WIRE IDENT
12V
B
C
CIRCUIT
12V Pwr to Outlet 1
61-A
61R
AC Relay Control
Not Used
0-EK
245483C1
CAV
WIRE IDENT
CIRCUIT
33R-C
0-HM
Ground
12176446
CAV
A
WIRE IDENT
12V
B
C
CIRCUIT
0-EK
245483C1
CAV
Bur 5-2750
WIRE IDENT
CIRCUIT
33R-B
0-HL
Ground
Issued 8-06
Printed in U.S.A.
4002-156
CONNECTOR PRBF - ROLLBACK PRESSURE
SWITCH
245483C1
CAV
WIRE IDENT
CIRCUIT
256340A1
58
CAV
58-B
13D
0-EA
WIRE IDENT
CIRCUIT
409084A1
256340A1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
18R
13K-B
28P
0-EB
1-GA
409084A1
CAV
WIRE IDENT
A
C
CIRCUIT
Not Used
13H
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-157
CONNECTOR PRM-C2 - PRM SIGNAL
409084A1
CAV
256340A1
CAV
WIRE IDENT
A
C
CIRCUIT
28E
28F
0-BAM
0-BN
WIRE IDENT
CIRCUIT
Not Used
19L
256340A1
CAV
WIRE IDENT
CIRCUIT
12ACC-C
0-DL
256340A1
CAV
WIRE IDENT
CIRCUIT
12ACC-B
0-EC
245485C1
CAV
Bur 5-2750
WIRE IDENT
CIRCUIT
51P-A
0-CC
35X-A
Issued 8-06
Printed in U.S.A.
4002-158
CONNECTOR PXF - RTD
245485C1
CAV
WIRE IDENT
CIRCUIT
245485C1
CAV
WIRE IDENT
CIRCUIT
53B
RTD Signal
53B-A
0-AC
0-AM
RTD Ground
53P-H
53P-I
245485C1
CAV
WIRE IDENT
CIRCUIT
54B
RTT Signal
0-AA
CAV
53P-J
Not Used
Not Used
Not Used
292495A1
WIRE IDENT
12V-HB
CIRCUIT
Not Used
12V-HA
0-EN
Radio Ground
245485C1
CAV
A
WIRE IDENT
53B-A
CIRCUIT
RTD Control Signal
0-AM
RTD Ground
53P-I
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-159
CONNECTOR RAD-J1 - RADIO POWER
411311A1
CAV
292497A1
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
RAD10
RAD8
Not Used
RAD4
RAD6
Not Used
RAD1
Not Used
Not Used
Not Used
RAD3
RAD11
Right Speaker
Not Used
RAD9
Not Used
Not Used
10
RAD5
Left Speaker
RAD3
Radio Ground
Not Used
RAD2
11
RAD7
Not Used
RAD1
Radio Ground
12
RAD2
13
Not Used
14
Not Used
194788A1
292501A1
CAV
WIRE IDENT
CIRCUIT
RAD11
Right Speaker
RAD10
RAD9
Not Used
RAD8
Not Used
RAD7
Not Used
RAD6
Not Used
RAD5
Left Speaker
RAD4
Bur 5-2750
CAV
WIRE IDENT
CIRCUIT
36C
0-BAE
Issued 8-06
Printed in U.S.A.
4002-160
CONNECTOR ROOF - ROOF TO CAB
CONNECTION
388708A1
CAV
WIRE IDENT
CIRCUIT
225351C1
43-B
CAV
42R-F
WIRE IDENT
21F-C
CIRCUIT
EDC7 DIGITAL Ground
42C-F
Not Used
19U-C
24B
Throttle Signal
46-D
24B-A
Throttle Signal
0-MN
Roof Grounds
24R
24R-A
0-MK
Roof Grounds
19K-D
24S
Throttle Supply
68C-A
24S-A
Throttle Supply
68L-A
24L
0-EN
Radio Ground
12V-H
43S-B
19U-F
245715C1
CAV
195552A1
CAV
WIRE IDENT
WIRE IDENT
CIRCUIT
Not Used
CIRCUIT
68L-A
65R
19K-D
0-PB
68C-A
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-161
CONNECTOR RWMG - REAR WIPER MOTOR
GROUND
245480C1
CAV
1
WIRE IDENT
0-MA
225253C1
CIRCUIT
Rear Wiper Motor Ground
CAV
WIRE IDENT
CIRCUIT
1A
21K
13K
12ACC
Not Used
Not Used
3227856R1
CAV
WIRE IDENT
CIRCUIT
68W-A
0-BL
382391A1
CAV
WIRE IDENT
Not Used
19U-H
46-C
Not Used
Not Used
Bur 5-2750
CIRCUIT
Not Used
0-B15
49-B
Not Used
10
Not Used
Issued 8-06
Printed in U.S.A.
4002-162
CONNECTOR SBU - BACKUP ALARM DISABLE
SWITCH
382391A1
382391A1
CAV
WIRE IDENT
CIRCUIT
35R-C
35A-B
CAV
WIRE IDENT
CIRCUIT
51S
18L-D
51CS
Not Used
Not Used
Not Used
51B-A
Not Used
Not Used
Not Used
0-B9
0-B21
49-U
49-L
Not Used
Not Used
10
Not Used
10
Not Used
245482C1
CAV
WIRE IDENT
CIRCUIT
19N
0-DK
382391A1
CAV
WIRE IDENT
25G-B
19A-R
Not Used
Not Used
Not Used
Bur 5-2750
CIRCUIT
Not Used
0-B18
49-R
Not Used
10
Not Used
Issued 8-06
Printed in U.S.A.
4002-163
CONNECTOR SDR - DRIVING LIGHTS SWITCH
382391A1
382391A1
CAV
WIRE IDENT
CAV
CIRCUIT
Not Used
WIRE IDENT
CIRCUIT
Not Used
19Z-A
52J
41T
52-AU
Not Used
52J
19P-C
19Z-B
52M
41J
0-B7
0-B19
49-Q
49-P
Not Used
Not Used
10
Not Used
10
Not Used
382391A1
382391A1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
Not Used
55A-B
28J
53P-B
28H
55A-C
Not Used
0-29
RTT/Float Ground
Not Used
55B
Not Used
54B-C
0-B30
0-B2
49U
49-K
Not Used
Not Used
10
Not Used
10
Not Used
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-164
CONNECTOR SFNR - FNR SWITCH
382391A1
CAV
WIRE IDENT
CIRCUIT
382391A1
CAV
WIRE IDENT
CIRCUIT
26R-A
26J
26N-A
Not Used
26J
Not Used
19A-V
Not Used
26F-A
54A
32J-A
0-B3
19A-G
49-M
Not Used
Not Used
10
Not Used
10
Not Used
Not Used
53P-D
382391A1
87345132
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
Not Used
0-DT
1-KA
63LC
45H
Not Used
Not Used
Not Used
Not Used
4
5
19J-B
Not Used
63W
49-T
63HC
10
Bur 5-2750
Not Used
0-b24
49-D
Not Used
10
Not Used
Not Used
Issued 8-06
Printed in U.S.A.
4002-165
CONNECTOR SPB - PARKING BRAKE SWITCH
382391A1
CAV
WIRE IDENT
CIRCUIT
Not Used
382391A1
CAV
WIRE IDENT
CIRCUIT
57-B
19A-L
19P-A
33U
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
0-B29
RTT/Float Ground
49-v
Not Used
10
Not Used
0-B5
10
49-F
382391A1
CAV
WIRE IDENT
CIRCUIT
292494A1
Not Used
CAV
WIRE IDENT
CIRCUIT
19A-j
65R
Right Speaker
31L
0-PB
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
0-B1
49-N
65L
Left Speaker
Not Used
0-PA
10
Not Used
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-166
CONNECTOR SPL-BCK-LGT - SPLICE BACK
LIGHT POWER
CAV
WIRE IDENT
49-M
49-K
49-F
49-Q
49-T
J
K
Not Used
49-G
L
M
87324393
CAV
A
WIRE IDENT
49
CIRCUIT
49-S
CIRCUIT
Back Light Power
Not Used
49-C
49-H
49-L
49A
49-P
49-R
49S
49-E
49-B
49-A
87324393
CAV
WIRE IDENT
CIRCUIT
0-B13
0-B14
0-B15
0-B17
0-B18
0-B19
0-B8
0-B21
0-DAP
0-B23
Not Used
Not Used
87324393
CAV
A
WIRE IDENT
49-E
B
C
CIRCUIT
Back Light Power
Not Used
49-J
Bur 5-2750
Printed in U.S.A.
4002-167
CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK
LIGHT GROUND
CAV
WIRE IDENT
CIRCUIT
0-BS
0-B
0-BL
87324393
CAV
WIRE IDENT
CIRCUIT
Not Used
0-B2
0-B3
0-B4
0-B5
87324391
CAV
0-B6
CAB2 Ground
0-B26
H
J
Not Used
0-B20
0-29
RTT/Float Ground
0-B11
0-B7
WIRE IDENT
CIRCUIT
0-B12
0-B16
0-B22
0-B25
0-B10
Hood Ground
Not Used
87324391
CAV
WIRE IDENT
CIRCUIT
0-BM
0-BY
Bur 5-2750
Not Used
Issued 8-06
Printed in U.S.A.
4002-168
CONNECTOR SPL-PED-BL - SPL BACK LIGHT
POWER 6 PACK
87324391
CAV
WIRE IDENT
CIRCUIT
87324391
CAV
WIRE IDENT
CIRCUIT
49-U
19P-A
49-N
19P
19P-C
49-D
49U
49-V
19P-D
49-S
19P-E
Not Used
87324391
CAV
WIRE IDENT
CIRCUIT
0-B9
0-B1
0-B24
0-B30
0-B29
RTT/Float Ground
0-B11
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-169
CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY
87324462
CAV
WIRE IDENT
CIRCUIT
87324462
CAV
WIRE IDENT
CIRCUIT
42C-A
41T-B
42C-E
41T-E
42C-D
41T
42C-C
41T-A
13K
19Z-A
13K-B
19Z-B
13K-A
19Z
13K-C
19Z-C
35A-D
41H-C
35A-B
41H-B
35A-A
41H-A
35A-C
41H-D
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-170
CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY
CAV
WIRE IDENT
CIRCUIT
0-MF
0-MA
Not Used
Not Used
0-MJ
0-MN
Roof Grounds
0-MK
Roof Grounds
CAV
WIRE IDENT
CIRCUIT
45L-E
45L-D
45L-C
45L-B
45R-C
45R-E
45R-D
45R-B
19J-B
19J
CAV
19J-C
19J-A
87324391
WIRE IDENT
CIRCUIT
0-CB
0-CA
0-CC
0-CF
E
F
Not Used
0-CD
87324393
CAV
WIRE IDENT
CIRCUIT
0-MC
0-MB
0-MU
0-ME
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-171
CONNECTOR SPL-TRN-GRD - SPLICE
TRANSMISSION GROUND
CAV
WIRE IDENT
CIRCUIT
19A-M
19A-S
19A-H
87324391
CAV
A
WIRE IDENT
0-HC
CIRCUIT
Transmission Splice Grounds
Not Used
382391A1
0-HW
HOT Ground
0-HV
0-HL
0-HM
CAV
WIRE IDENT
CIRCUIT
Not Used
19C-D
58C
58T
58C
58-F
0-B20
49-G
Not Used
10
Not Used
87324393
CAV
WIRE IDENT
CIRCUIT
19A-N
19A-F
19A-Q
225316C1
19A-T
CAV
19A-W
21D
19A-C
0-GB
19A-P
19A-R
19A-K
Bur 5-2750
WIRE IDENT
CIRCUIT
Issued 8-06
Printed in U.S.A.
4002-172
CONNECTOR SRHSTLK - RH STALK SWITCH
382391A1
CAV
WIRE IDENT
CIRCUIT
68C
68L
19K-A
87318288
CAV
WIRE IDENT
CIRCUIT
31b
64C
49a
19B
56a
41H-A
56b
41L-A
56d
19Z-C
31
0-EP
56
41J
45A-A
45B-A
Not Used
19K-B
68W
0-B23
49-C
Not Used
10
Not Used
245489C1
CAV
382391A1
CAV
WIRE IDENT
CIRCUIT
Not Used
53P-E
53A
Not Used
Not Used
Not Used
0-B4
49-J
Not Used
10
Not Used
Bur 5-2750
WIRE IDENT
CIRCUIT
19M-C
19R-C
35X-C
0-CD
19S1-X
Not Used
Issued 8-06
Printed in U.S.A.
4002-173
CONNECTOR SSM - SECONDARY STEERING
MODULE
CAV
WIRE IDENT
CIRCUIT
0-B17
49S
Not Used
10
Not Used
225389C1
CAV
WIRE IDENT
CIRCUIT
19R-C
51-A
19S1-X
0-CE
Not Used
382391A1
Not Used
CAV
19M-C
35X-D
51P-A
10
Not Used
11
0-CA
12
0-CB
WIRE IDENT
CIRCUIT
Not Used
19A-D
26E
Not Used
Not Used
Not Used
0-DAP
49-H
32J-C
10
19A-E
382391A1
CAV
WIRE IDENT
CIRCUIT
Not Used
19A-Q
25H
Not Used
Not Used
Not Used
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-174
CONNECTOR SWL - WORK LIGHTS SWITCH
CAV
WIRE IDENT
CIRCUIT
CAN-LF
CAN Low
17P-A
10
0-B28
382391A1
CAV
WIRE IDENT
CIRCUIT
Not Used
42-A
42FS
Not Used
42-B
42RS
0-B14
49-A
Not Used
10
Not Used
291718A1
CAV
WIRE IDENT
CIRCUIT
36G
36R-D
225351C1
CAV
87552623
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
13D
1DN
0-DC
41H-D
43S-D
41T-D
13K-A
42C-E
31H-A
31F-A
6
7
Not Used
Not Used
CAN-HF
Bur 5-2750
CAN High
Issued 8-06
Printed in U.S.A.
4002-175
CONNECTOR TECM - TRANSMISSION
ELECTRONIC CONTROL MODULE
411398A1
CAV
WIRE IDENT
CIRCUIT
0-DP
0-DQ
0-DM
0-DN
32J-D
35C
58H-A
25P-A
10
25L-A
12
25S-B
13
25S-C
15
37D-A
Diagnostic Signal
17
32F-A
18
37E
19
25A-A
20
26F-B
Bur 5-2750
CAV
WIRE IDENT
CIRCUIT
21
52P-C
22
25Y-A
23
19T-A
25
CAN-HD
CAN High
26
CAN-LK
CAN Low
27
CAN-LJ
CAN Low
29
25H
30
26R-B
31
26E
32
25M-A
39
36T-A
41
25C-A
42
25B-A
43
25F
Forward Signal
44
26N-B
45
19A-K
46
36R-E
49
36G-A
51
25J-A
55
25N-A
56
25K-A
57
58L
62
25D-A
63
25Z
64
25R-
Reverse Signal
65
25W
66
25G-C
67
25T-C
Neutral Signal
Issued 8-06
Printed in U.S.A.
4002-176
CONNECTOR TR-SS - SEC-STR-MOD-OPT
380838A1
CAV
245488C1
CAV
WIRE IDENT
CIRCUIT
19M-A
19R-A
35X-B
0-HP
19S1-E
Not Used
239451A1
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
33R-A
31D-B
31D
19M-A
19R-A
36T
35X-B
25A
25C
25B
10
25D
11
0-HD
12
36R-A
13
36G
14
Not Used
15
Not Used
16
25K
16
25K-9
17
25L-9
17
25L
18
25M
19
25N
0-HP
20
25P
0-HC
21
25J
31D-B
22
25S
23
31H
Not Used
24
Not Used
25
Not Used
26
19S1-E
27
Bur 5-2750
28
0-HE
29
19A
30
36H
31
32F
Issued 8-06
Printed in U.S.A.
4002-177
CONNECTOR TRC - TRANSMISSION CONTROL
245486C1
371566A1
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
19A-H
25K
25F
Forward Signal
25L-9
25R
Reverse Signal
25K-9
25T-B
Neutral Signal
25L
25M
25N
25P
25J
25S
36T
36R-C
10
Not Used
11
Not Used
12
Not Used
13
Not Used
14
Not Used
15
Not Used
16
Not Used
Bur 5-2750
245487C1
CAV
WIRE IDENT
CIRCUIT
Not Used
25W
25Z
25Y
Issued 8-06
Printed in U.S.A.
4002-178
CONNECTOR TSS - TURBINE SPEED SENSOR
245482C1
291718A1
CAV
WIRE IDENT
CIRCUIT
25C
0-HH
CAV
WIRE IDENT
CIRCUIT
51B-D
0-AQ
8602416
CAV
WIRE IDENT
CIRCUIT
256340A1
35W
Water Indicator
CAV
0-BP
Sensor Ground
56-A
18J-H
0-BQ
WIRE IDENT
CIRCUIT
225316C1
CAV
182069A1
CAV
WIRE IDENT
CIRCUIT
0-BW
1-GC
Bur 5-2750
WIRE IDENT
CIRCUIT
52A-B
0-BB
Issued 8-06
Printed in U.S.A.
4002-179
CONNECTOR YPB - PARKING BRAKE SOLENOID
291718A1
CAV
WIRE IDENT
CIRCUIT
291718A1
CAV
WIRE IDENT
CIRCUIT
52P
58
0-AN
58S-E
0-AD
245482C1
CAV
WIRE IDENT
CIRCUIT
57
0-AE
225316C1
CAV
WIRE IDENT
CIRCUIT
51-C
0-CF
245482C1
CAV
WIRE IDENT
CIRCUIT
5P-A
0-DU
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-180
NOTES
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4002-181
Symbols
12 Volt Radio .......................................................112
A
A/C High/Low Pressure Switch ............................115
Air Filter Restriction Switch ....................................67
Air Seat Compressor and Switch .........................114
Alarm
Back-up (Europe Only) ......................................96
Back-up (North America Only) ..........................96
Back-up, Disable Switch ...................................76
Back-up, Relay ..................................................76
Alternator ...............................................................40
B
Back-up Alarm (Europe Only) ................................96
Back-up Alarm (North America Only) ....................96
Back-up Alarm Disable Switch ..............................76
Back-up Alarm Relay .............................................76
Batteries ................................................................41
Beacon Switch .......................................................79
Beacon, Rotating (Option) .....................................78
Brake Lamp Pressure Switch ................................83
Brake Lamps Relay ...............................................83
Brake Warning Pressure Switch ............................68
Buzzer ...................................................................66
C
CAN Communication Diagnostics Connector ......109
Cigar Lighter ........................................................114
Circuit Breaker Cab B+ ..........................................47
Climate Control, Automatic
24 to 12 Volt Converter ...................................118
Blower Motor Resistor .....................................117
Blower Motors .................................................117
Compressor Relay ..........................................118
Electronic Panel ..............................................117
Electronic Water Valve ....................................118
External Air Temperature Sensor ....................117
Internal Air Temperature Sensor .....................117
Mixed Air Sensor .............................................117
Recycling Motor ..............................................118
Sun Sensor .....................................................117
Thermocouple Sensor .....................................117
Climate Control, Standard
Air Conditioning Switch ...................................121
Air Recirculation Motor ....................................120
Air Recirculation Switch ..................................122
Blower Motor ...................................................120
Blower Motor Speed Resistors with Thermal Fuse
120
Blower Switch ..................................................121
Control Panel Lights ........................................121
Driver ...............................................................120
Electronic Water Valve ....................................120
Thermostat ......................................................121
Water Valve Potentiometer .............................121
Bur 5-2750
Printed in U.S.A.
4002-182
Connector DNS-RESISTOR ................................137
Connector DNS-SPEED-SELECTOR .................136
Connector DNS-THERMOCOUPLE-SENSO ......136
Connector DNS-THERMOSTAT-1 ......................137
Connector DNS-THERMOSTAT-2 ......................137
Connector DNS-VOLTAGE-CONVERTER .........136
Connector DNS-WATER-VALVE-POT ................137
Connector DNS-YELLOW ...................................135
Connector DS ......................................................138
Connector E_HD .................................................138
Connector ECA ....................................................139
Connector ECB ....................................................140
Connector ECC ...................................................141
Connector ECD ...................................................142
Connector EDC7 .................................................143
Connector EM ......................................................143
Connector ENG ...................................................144
Connector ENG_D ...............................................144
Connector ENG_H ...............................................145
Connector ENG_T ...............................................145
Connector ESS ....................................................145
Connector FFH ....................................................145
Connector FLSHR ...............................................146
Connector FM ......................................................146
Connector FRONT ...............................................146
Connector FWM ..................................................147
Connector FWMG ................................................147
Connector FWW ..................................................147
Connector GHC ...................................................147
Connector GND_CAB_SPL .................................148
Connector GND_CAB_SPL2 ...............................148
Connector HD ......................................................148
Connector HD_E .................................................148
Connector HD_N .................................................149
Connector HDM ...................................................149
Connector HOT ...................................................149
Connector HVAC_CAN1 .....................................150
Connector HVAC1 ...............................................149
Connector HVAC2 ...............................................149
Connector ISS .....................................................150
Connector K_WCO ..............................................150
Connector LBEE ..................................................150
Connector LLF .....................................................151
Connector LLFW .................................................151
Connector LLR_E ................................................151
Connector LLR_N ................................................151
Connector LLRW .................................................152
Connector LPL .....................................................152
Connector LRF ....................................................152
Connector LRFW .................................................152
Connector LRR_E ...............................................153
Connector LRR_N ...............................................153
Connector LRRW ................................................153
Connector LSPK ..................................................153
Connector OSS ...................................................153
Connector PAF ....................................................154
Connector PBD ....................................................154
Bur 5-2750
Printed in U.S.A.
4002-183
Connector SPL_PED_BL_GD .............................168
Connector SPL_PIN ............................................168
Connector SPL_PK1 ...........................................169
Connector SPL_PK2 ...........................................169
Connector SPL_PK3 ...........................................170
Connector SPL_ROOF ........................................170
Connector SPL_SEC_STR ..................................170
Connector SPL_TRN_GRD .................................171
Connector SPL_TRNS_PWR ..............................171
Connector SRC ...................................................171
Connector SRC_1 ...............................................171
Connector SRHSTLK ..........................................172
Connector SRTD .................................................172
Connector SRWP ................................................172
Connector SS_TR ...............................................172
Connector SSM ...................................................173
Connector STA ....................................................173
Connector STE ....................................................173
Connector SW_PD ..............................................174
Connector SWL ...................................................174
Connector TCOT .................................................174
Connector TDM ...................................................174
Connector TECM .................................................175
Connector TR_SS ...............................................176
Connector TRAN_E .............................................176
Connector TRANS ...............................................176
Connector TRC ....................................................177
Connector TS1 ....................................................177
Connector TS2 ....................................................177
Connector TSS ....................................................178
Connector WF .....................................................178
Connector WSH ...................................................178
Connector YCS ....................................................178
Connector YFN ....................................................178
Connector YFR ....................................................178
Connector YPB ....................................................179
Connector YPE ....................................................179
Connector YPP ....................................................179
Connector YRC ...................................................179
Connector YSS ....................................................179
Connector, Diagnostic ...........................................63
Coolant Level Sender ............................................74
Crank Control Relay ..............................................41
Crank Request Relay ............................................41
D
Declutch Brake Switch ...........................................63
Declutch Switch .....................................................63
Diagnostic Connector ............................................63
Diodes
Lights .................................................................81
Secondary Steering .........................................105
Wipers .............................................................103
Dome Lamp ...........................................................79
Door Switch ...........................................................78
Driving Lamp Switch ..............................................86
Bur 5-2750
E
Electrical Wire Identification ....................................8
Electromagnetic Detents .......................................54
Electronic Diesel Control .......................................51
Engine Speed Sensor ...........................................63
F
Fan PWM Solenoid ...............................................61
Fan Reverse Relay ................................................59
Fan Reversing Solenoid ........................................61
Fan Reversing Switch ...........................................59
Filter Maintenance Switch .....................................63
Flasher Module ......................................................84
FNR Switch for Joystick Controls ..........................63
FNR Switch for Single Axis Controls .....................63
Front
Left Hand Work Lamp .......................................79
Right Hand Work Lamp .....................................80
Front Left Hand Combination Lamp ......................88
Front Right Hand Combination Lamp ....................89
Front Washer Pump Motor ..................................102
Front Wiper and Washer Switch ..........................100
Front Wiper Cut Out Relay ....................................98
Front Wiper High Speed Relay ..............................98
Front Wiper Low Speed Relay ..............................99
Front Wiper Motor ...............................................101
Fuel Filter Heater ...................................................48
Fuel Filter Heater Relay ........................................46
Fuel Level Sender .................................................67
G
Grid Heater ............................................................47
Grid Heater Relay ..................................................47
H
Hazard Switch .......................................................85
Heater
Fuel Filter ..........................................................48
Grid ...................................................................47
Water Separator ................................................47
Height Control Switch ............................................53
Height Control/Return-To-Travel Proximity Switch 55
High-Low Beam Switch .........................................85
Hood
Down Relay .....................................................124
Motor ...............................................................125
Switch .............................................................124
Up Relay .........................................................124
Horn .......................................................................90
Horn Relay ............................................................90
Horn Switch ...........................................................85
Hydraulic Filter Restriction Switch .........................72
Hydraulic Oil Temperature Sender ........................72
I
Ignition Switch .......................................................43
Instrument Cluster Connector 1 ............................65
Issued 8-06
Printed in U.S.A.
4002-184
Instrument Cluster Connector 2 .............................71
Intermediate Speed Sensor ...................................63
L
Lamp
Dome .................................................................79
High Beam ..................................................88, 89
Left Hand Front Combination ............................88
Left Hand Front Work ........................................79
Left Hand Rear Combination (Europe Only) .....95
Left Hand Rear Combination (North America Only)
............................................................94
Left Hand Rear Work ........................................80
License Plate (Europe Only) .............................96
License Plate (North America Only) ..................95
Low Beam ...................................................88, 89
Position .......................................................88, 89
Right Hand Front Combination ..........................89
Right Hand Front Work .....................................80
Right Hand Rear Combination (Europe Only) ...93
Right Hand Rear Combination (North America
Only) ...................................................92
Right Hand Rear Work ......................................80
Switch, Driving ..................................................86
Turn .............................................................88, 89
Left Hand Front Combination Lamp ......................88
Left Hand Front Work Lamp ..................................79
Left Hand Rear Combination Lamp (Europe Only) 95
Left Hand Rear Combination Lamp (North America
Only) .........................................................94
Left Hand Rear Work Lamp ...................................80
Left Speaker ........................................................112
License Plate Lamp .........................................95, 96
License Plate Lamp (Europe Only) ........................96
License Plate Lamp (North America Only) ............95
Lights Diodes .........................................................81
Locating Components on the Schematic Posters ..38
M
Magnetic Detents ...................................................54
Master Disconnect Switch .....................................42
Module
Flasher ..............................................................84
Secondary Steering .........................................106
Time Delay ........................................................42
Transmission Electronic Control .......................63
Motor
Hood ................................................................125
Starter ...............................................................43
N
Neutral Start Relay ................................................44
O
Outlet, Power .......................................................111
Output Speed Sensor ............................................63
Bur 5-2750
P
Parking Brake Relay .............................................. 66
Parking Brake Solenoid ......................................... 67
Parking Brake Switch ............................................ 73
Pilot Control Relay ................................................. 55
Pilot Control Switch ............................................... 60
Pilot Pressure Solenoid ......................................... 56
Pin Engage Solenoid ............................................. 56
Pin Engage Switch ................................................ 56
Potentiometer
Throttle .............................................................. 50
Power Converter (24 volts to 12 volts) ................111
Power Outlet ........................................................111
Power Relay Module
A Ignition Power ................................................ 46
B Ignition Power ................................................ 46
C Fuel Filter Heater ........................................... 46
D Accessory Power ........................................... 48
E Power Converter 24V to 12V .......................111
Proximity Switch
Height Control/Return-To-Travel .......................55
Return-To-Dig ................................................... 54
R
Radiator Coolant Temperature Sender ................. 68
Radio
12 Volt .............................................................112
Rear
Left Hand Combination Lamp (Europe Only) .... 95
Left Hand Combination Lamp (North America
Only) .................................................. 94
Left Hand Work Lamp ....................................... 80
Right Hand Combination Lamp (Europe Only) . 93
Right Hand Combination Lamp (North America
Only) .................................................. 92
Right Hand Work Lamp ..................................... 80
Rear Washer Pump Motor ...................................102
Rear Wiper and Washer Switch ............................ 99
Rear Wiper Motor ................................................102
Redundant Brake Pressure Switch 1 .................... 73
Redundant Brake Pressure Switch 2 .................... 73
Relay
Backup Alarm ....................................................76
Brake Lamps ..................................................... 83
Compressor Clutch .........................................114
Crank Control ....................................................41
Crank Request .................................................. 41
Fan Reverse ..................................................... 59
Front Wiper Cut Out .......................................... 98
Front Wiper High Speed ................................... 98
Front Wiper Low Speed .................................... 99
Fuel Filter Heater .............................................. 46
Grid Heater ....................................................... 47
Hood Down .....................................................124
Hood Up ..........................................................124
Horn .................................................................. 90
Neutral Start ...................................................... 44
Issued 8-06
Printed in U.S.A.
4002-185
Parking Brake ....................................................66
Pilot Control .......................................................55
Power Relay Module A Ignition Power ..............46
Power Relay Module B Ignition Power ..............46
Power Relay Module C Water Separator Htr ....46
Power Relay Module D Accessory Power .........48
Power Relay Module E Power Converter ........111
Ride Control ......................................................58
Starting ..............................................................40
Voltmeter ...........................................................44
Resistor
Alternator ...........................................................40
Return to Dig Switch Switch ..................................55
Return-To-Dig Proximity Switch ............................54
Return-To-Travel/Float Switch ...............................53
Ride Control Relay ................................................58
Ride Control Solenoid ............................................60
Ride Control Switch ...............................................58
Right Hand Front Combination Lamp ....................89
Right Hand Front Work Lamp ................................80
Right Hand Rear Combination Lamp (Europe Only) .
93
Right Hand Rear Combination Lamp (North America
Only) .........................................................92
Right Hand Rear Work Lamp ................................80
Right Speaker ......................................................112
Rollback Jumper ....................................................61
Rollback Pressure Switch ......................................60
Rotating Beacon (Option) ......................................78
S
Seat Compressor and Switch ..............................114
Secondary Steering
Module ............................................................106
Motor ...............................................................107
Pressure Switch ..............................................107
Solenoid ..........................................................105
Secondary Steering Diodes .................................105
Sender
Coolant Level ....................................................74
Fuel Level ..........................................................67
Hydraulic Oil Temperature ................................72
Radiator Coolant Temperature ..........................68
Torque Converter Output Temperature .............63
Sensor
Engine Speed ....................................................63
Intermediate Speed ...........................................63
Output Speed ....................................................63
Transmission Solenoid Valve and Temperature ...
63
Turbine Speed ...................................................63
Water In Fuel .....................................................50
Shifter, Transmission .............................................63
Solenoid
Fan PWM ..........................................................61
Fan Reversing ...................................................61
Parking Brake ....................................................67
Bur 5-2750
Printed in U.S.A.
4002-186
Transmission Auto ............................................63
Transmission Enable .........................................63
Transmission Kick-down ...................................63
Turn Signal ........................................................85
Work Lamps ......................................................78
Switch Pad .............................................................70
T
Thermal Fuse
Blower Motor ...................................................120
Throttle Potentiometer ...........................................50
Time Delay Module ................................................42
Torque Converter Output Temperature Sender ....63
Transmission Auto Switch .....................................63
Transmission Electronic Control Module ...............63
Transmission Enable Switch .................................63
Transmission Kick-down Switch ............................63
Transmission Shifter ..............................................63
Transmission Solenoid Valve and Temperature Sensors ...........................................................63
Turbine Speed Sensor ...........................................63
Turn Signal Switch .................................................85
U
Understanding the Troubleshooting Tables ...........38
V
Voltmeter Relay .....................................................44
W
Warning Buzzer .....................................................66
Water In Fuel Sensor .............................................50
Water Separator
Heater ...............................................................47
Heater Relay .....................................................46
Wiper
Front Cut Out Relay ..........................................98
Front Motor ......................................................101
Front Switch ....................................................100
Front Washer Pump Motor ..............................102
Front Washer Switch .......................................100
Front Wiper High Speed Relay .........................98
Front Wiper Low Speed Relay ..........................99
Rear Motor ......................................................102
Rear Switch .......................................................99
Rear Washer Pump Motor ..............................102
Rear Washer Switch .........................................99
Wiper Diodes .......................................................103
Wire Identification ....................................................8
Work Lamp Switch .................................................78
Bur 5-2750
Issued 8-06
Printed in U.S.A.
4003
Section
4003
BATTERIES
Bur 6-42330
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42330
Issued 4-03
3
3
4
4
4
5
5
5
6
7
7
8
8
Printed in U.S.A.
4003-3
SAFETY RULES
WARNING: Never try to charge the battery if
the electrolyte in the battery is frozen.
47-83A
WARNING: Some
batteries
have
a
ventilation tube. If there is battery acid in the
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
Bur 6-42330
Issued 4-03
Printed in U.S.A.
4003-4
MAINTENANCE
Electrolyte Level
Bur 6-42330
Issued 4-03
Printed in U.S.A.
4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the
battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 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.
B790863
1. TEMPERATURE IN F
2. TEMPERATURE IN C
Bur 6-42330
Issued 4-03
Printed in U.S.A.
4003-6
B790499
Bur 6-42330
Issued 4-03
Printed in U.S.A.
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.
47-83
Slow Charge
Fast Charge
10 Hours at 5 Amperes
5 Hours at 10 Amperes
15 Hours at 5 Amperes
7.5 Hours at 10 Amperes
20 Hours at 5 Amperes
10 Hours at 10 Amperes
5 Hours at 20 Amperes
2 Hours at 50 Amperes
30 Hours at 5 Amperes
15 Hours at 10 Amperes
80 Minutes or Less
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
Bur 6-42330
Issued 4-03
Printed in U.S.A.
4003-8
Slow Charge
Fast Charge
10 Hours at 5 Amperes
5 Hours at 10 Amperes
15 Hours at 5 Amperes
7.5 Hours at 10 Amperes
20 Hours at 5 Amperes
10 Hours at 10 Amperes
5 Hours at 20 Amperes
2 Hours at 50 Amperes
30 Hours at 5 Amperes
15 Hours at 10 Amperes
24 Hours at 10 Amperes
6 Hours at 40 Amperes
4 Hours at 60 Amperes
80 Minutes or Less
Bur 6-42330
Issued 4-03
Printed in U.S.A.
Section
4005
4005
INSTRUMENT CLUSTER
Bur 5-2760
4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2760
Issued 8-06
3
4
4
5
6
9
10
10
10
10
11
13
13
13
13
13
14
14
14
15
17
27
32
Printed in U.S.A.
4005-3
INSTRUMENT CLUSTER
10
11
15
14
12
13
BD06H039
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
The instrument cluster monitors a number of functions and can be tailored to fit the operators 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:
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-4
Self-Test
1. Turn the ignition (key) switch to the ON position.
2. The instrument cluster will automatically check
each monitored system.
3. All LEDs (Light Emitting Diodes) will illuminate
for 2 - 3 seconds.
4. Four gauges will energize for 2 - 3 seconds.
5. The warning alarm will sound for 2 - 3 seconds.
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-5
1
3
A - Automatic
M - Manual operation.
C - Substitute Clutch.
L - Limp Home.
S - Transmission Shutdown.
U - TCU Shutdown.
7
BD06F185
between
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-6
D
BD06F186
BD06F188
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-7
BD06F169
BD06F027
BD06F170
BD06F184
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-8
BD06F172
BD06F170
BD06F187
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-9
BD06H038 / BD06F188
Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to
scroll through the menus.
Items and selections in this menu are:
1. Power Mode Menu
Month
Year
Part Number
Serial Number
ID
Version
2. Preferences Menu
6. Cluster H/W
Part Number
Loader Version
Clock - 24 or 12 hour
ID
Version
3. Options Menu
7. Cluster S/W
Change Model *
Show RPM
Show MPH/KPH
4. Display Menu
8. Config Menu
Day Display
Day LED
Night Display
Night LED
Special
5. Clock Menu
Hour
Minute
Day
Bur 5-2760
- Reset Error
- Factory Set
Issued 8-06
Printed in U.S.A.
4005-10
* The tests in the configuration menu should be
performed only by a qualified operator or technician,
as some tests require the engine to be running at
high RPMs.
Software Screen
Select Screen
The select screen will allow you to make time
s e t t i n g s a s w e l l a s g i ve a c c e s s t o m a c h i n e
information. Navigate this screen also by highlighting
your selection and pressing confirm. This will allow
you to change clock settings or view the hardware
and software screens. No operator changes can be
made to the hardware or software screens.
BD06H028
Hardware Screen
Scroll to the hardware selection and press confirm to
display machine information.
BD106F193
Bur 5-2760
BD06H038
Issued 8-06
Printed in U.S.A.
4005-11
Preferences
BD06F178
BD06F179
BD06F176
S h o u l d a n e r r o r m e s s a g e d i s p l ay, p r e s s t h e
confirmation button to acknowledge and begin again.
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-12
Clutch Calibration
After warming the oil temperature:
1. Park the machine on a firm level surface.
2. Place the
NEUTRAL.
Transmission
Control
Lever
in
BD06F196
BD06F202
Not in neutral
Machine moving
Adjust K1
Adjust K2
Adjust K3
Adjust K4
Adjust KV
Adjust KR
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-13
Auto Idle
Idling can be changed from automatic to a fixed rate.
The fixed idle rate is defined as Standard Idle at 900
RPM. Highlight the auto idle selection by using the
arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.
Display Menu
BD06F174
Options Menu
Use the arrow keys to choose the options menu.
Press the confirm key, and the options sub-menu will
appear. The options menu will allow the operator to
choose options for the fan, idle.
Fan Auto
The fan can be set to run at automatic or the fan will
run at maximum speed. Automatic is the more
common or preferred setting. It will switch between
high speed, low speed, or reverse as conditions
require depending on actual temperature of the
coolant, turbocharger air, transmission oil, and
hydraulic oil.
RPM
Engine speed in RPM will show on the display if the
engine speed is running up to 550 RPMs, and will
disappear if the engine speed is lower than 300
RPM.
MPH/KPH
Vehicle speed will show on the display if it is up to 1.0
MPH / 1.5 KPH and will disappear if the vehicle
speed is less than 0.6 MPH / 1.0 KPH.
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-14
D
BD06F186
A. Escape key
B. enter key
C. up key
D. down key
2. Yellow Faults, buzzer will beep once every 2
seconds:
A. Operator can acknowledge it by pressing the
enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
D. Yellow lamp will stay ON.
E. Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer
alternating sounds:
will
be
continuous,
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-15
DEFINITION
1310
Change filter
1311
Change filter
1312
1313
1314
1315
1.
2.
3.
4.
1.
2.
3.
4.
1317
1.
2.
3.
4.
1318
1319
1.
2.
3.
4.
1320
1321
1322
1323
1324
1325
1326
1327
1328
1331
1332
1333
Engine overspeed
1334
1316
1335
Bur 5-2760
1.
2.
3.
4.
Issued 8-06
Printed in U.S.A.
4005-16
CODE
1336
DEFINITION
Transmission oil filter blocked
NOTE: The following fault codes are for optional climate controlled heating and air conditioning system.
CODE
1909
1910
1919
1920
1921
Bur 5-2760
DEFINITION
Open circuit evaporator temperature sensor
Issued 8-06
Printed in U.S.A.
4005-17
DEFINITION
3001
3002
3003
3004
3006
3007
3008
3009
3015
3016
3019
3021
3022
3023
3024
3025
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-18
CODE
DEFINITION
3028
3029
3030
3031
3033
3034
3035
3036
3037
3043
3046
3051
3032
3052
3060
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-19
DESCRIPTION AND POSSIBLE
STEPS FOR REPAIR
CODE
DEFINITION
3061
3062
3063
3064
3065
3066
3067
3068
3069
3070
3071
3072
3073
3074
3075
3076
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-20
DESCRIPTION AND POSSIBLE
STEPS FOR REPAIR
CODE
DEFINITION
3077
3078
3079
3080
3081
3082
3083
3088
3089
3090
3091
3093
3095
3102
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-21
CODE
DEFINITION
3105
3106
3107
3110
3111
3104
3112
3113
3114
3118
3119
3131
3137
3138
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-22
CODE
DEFINITION
3141
3147
3154
3155
3156
3161
3172
3173
3174
3171
3175
3176
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-23
CODE
DEFINITION
3178
3179
3180
3188
3192
3196
3200
3204
3208
3210
3211
3212
Bank 1 no signal
3213
3218
3219
3220
Bank 2 no signal
3221
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-24
CODE
DEFINITION
3227
3228
3230
3231
3232
3233
3234
3238
3242
3243
3244
3229
Defective ECU.
Replace ECU if problem reoccurs
3245
3246
3247
3248
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-25
CODE
DEFINITION
3253
3254
3255
3256
3258
3259
3260
3261
3262
3265
3266
3278
3279
3280
Bur 5-2760
Buffer overrun
No additional information available at time of print
Issued 8-06
Printed in U.S.A.
4005-26
CODE
DEFINITION
3286
3290
3281
3283
3284
3285
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-27
DEFINITION
4114
4116
4117
4119
4120
4121
4133
4134
4135
4136
4137
4145
4146
4113
4147
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-28
CODE
DEFINITION
4148
4149
4150
4151
4152
4153
4154
4155
4156
4158
4160
4180
4185
4186
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-29
CODE
DEFINITION
4209
4210
4211
4212
4213
4214
4215
4216
4217
4225
4226
4227
4228
4229
4230
4231
4232
4233
4241
4242
4243
4273
4274
4275
Bur 5-2760
Slippage at clutch K1
1.
2.
3.
4.
5.
Slippage at clutch K2
1.
2.
3.
4.
5.
Slippage at clutch K3
1.
2.
3.
4.
5.
Issued 8-06
Printed in U.S.A.
4005-30
CODE
DEFINITION
Slippage at clutch K4
1.
2.
3.
4.
5.
Slippage at clutch KV
1.
2.
3.
4.
5.
Slippage at clutch KR
1.
2.
3.
4.
5.
4279
4281
4276
4277
4278
4282
4284
Overspeed output
4288
4289
4290
4291
4292
Bur 5-2760
Issued 8-06
Printed in U.S.A.
4005-31
CODE
DEFINITION
4294
4305
4306
4307
4308
4309
4310
4325
4326
4337
4338
Configuration error
4339
4341
4342
4293
Bur 5-2760
1. Check batteries.
2. Check B+ wires from batteries to TCU.
3. Check voltage at TCU connector pin 45.
1.
2.
3.
4.
Issued 8-06
Printed in U.S.A.
4005-32
DEFINITION
9128
9129
9130
Bur 5-2760
Issued 8-06
Printed in U.S.A.
5001
Section
5001
REMOVAL AND INSTALLATION OF STEERING
COMPONENTS
Bur 5-2780
5001-2
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2780
Issued 8-06
3
3
5
8
8
8
10
10
10
12
12
12
14
14
14
16
16
16
Printed in U.S.A.
5001-3
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
Tag hoses connected to steering control valve.
STEP 5
STEP 8
BD06G262
BD06G246
STEP 9
STEP 6
BD06G247
BD06G244
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-4
STEP 10
STEP 13
BD06G248
BD06G258
STEP 11
STEP 14
BD06G249
BD06G259
Pull floor mat away from the column and remove the
lower trim from the column.
STEP 12
STEP 15
BD06G257
Bur 5-2780
BD06G260
Issued 8-06
Printed in U.S.A.
5001-5
Installation
STEP 16
STEP 18
BD06G261
STEP 17
BD06G264
STEP 19
Have an assistant push the valve into place while
turning the steering shaft, this will engage the
splines.
STEP 20
BD06G263
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-6
STEP 21
STEP 24
BD06G261
BD06G257
STEP 25
STEP 22
BD06G249
BD06G260
STEP 26
STEP 23
BD06G248
BD06G258
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-7
STEP 27
STEP 30
BD06G247
BD06G262
STEP 28
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
STEP 34
STEP 29
BD06G244
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-8
Installation
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-9
1
2
3
6
10
4
9
8
BC05M084
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-10
Installation
1. Install bolts with washers (8) through priority
valve. Install new O-ring on top of priority valve
(not shown). Install priority valve (7) onto low
pressure pump, tighten bolts to37 to 48 Nm
(27 to 35.5 pound feet).
2. Install new O-rings (6) onto high pressure pump
discharge tube (5).
3. Place tube into position and intsall four split
flanges (3) and eight bolts (4) with washers,
tighten bolts.
6. Disconnect
reservoir.
vacuum
pump
from
hydraulic
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-11
3
6
BC05M087
1.
2.
3.
4.
5.
6.
7.
8.
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-12
Installation
1. Position auxiliary steering pump and motor (7) on
its mounting plate while connecting and hand
tightening pressure tube (5) to auxiliary steering
priority valve (6). See illustration on page 13.
Issued 8-06
Printed in U.S.A.
5001-13
2
1
3
8
7
4
5
BC05M085
1. GROUND CABLE
2. POSITIVE CABLE
3. NUT (4)
4. SUCTION HOSE
7. AUXILIARY STEERING PUMP AND MOTOR
5. PRESSURE TUBE
8. WIRING HARNESS
6. AUXILIARY STEERING PRIORITY VALVE
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-14
STEERING CYLINDER
Removal
1. Loosen the fill cap for the hydraulic reservoir to
release pressure in the reservoir, then tighten the
fill cap.
2. Disconnect grease hoses (1 and 16) from
steering cylinders (11). See illustration on page
15.
3. Disconnect hydraulic hoses (2, 3, 9, and 10) from
steering cylinders (11).
4. Install a plug in each hose (2, 3, 9, and 10) to
prevent entry of foreign matter.
5. Remove locknut (15).
6. Remove cap screw (13).
7. Remove pin (12).
8. Remove washers (14).
9. Remove cap screw (8), washer (7), and spacer
(6) securing pivot pin (5) at rear of steering
cylinders (11).
10. Use a suitable driver and drive pivot pin (5) out of
steering cylinder (11).
11. Remove washer(s) (4) from between steering
cylinders (11) and rear frame of machine.
12. Remove steering cylinders (11).
Installation
1. Put steering cylinders (11) in position in machine.
Make sure that washers (4) are installed
between steering cylinder (11) and rear frame.
See illustration on page 15.
NOTE: Install a washer (4) on top and bottom of
steering cylinders (11) if possible. If only one washer
(4) can be installed, place washer (4) at bottom of
steering cylinders (11).
2. Make sure washers (14) are installed between
steer ing cylinders (11) and front frame of
machine.
3. Install the pivot pin (5) to secure rear of steering
cylinders (11) to machine frame. Install spacer
(6), washer (7), and cap screw (8) to secure pivot
pin (5).
4. Tighten cap screw (8).
5. Install pin (12) in front of steering cylinders (11).
Make sure that washers (14) are installed in
correct position.
6. Install cap screw (13) and new locknut (15) in
steering cylinders (11) rod end and pin (12).
Tighten locknut (15).
NOTE: Cap screw (13) should turn freely in hole
after tightening.
7. Connect hose assemblies (2, 3, 9, and 10) to
steering cylinders (11).
8. Connect grease hoses (1 and 16) to steering
cylinders (11).
9. Tighten hydraulic reservoir fill cap.
10. Start engine.
11. Turn steering wheel all the way to right and then
to the left several times.
12. Stop the engine. Check fluid level in hydraulic
reservoir. Add oil as required. See Section 1002
for specifications.
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-15
10
8
7
6
5
4
3
11
2
12
13
14
15
11
16
BS03B141
1.
2.
3.
4.
GREASE HOSE
HOSE ASSEMBLY
HOSE ASSEMBLY
WASHER
5.
6.
7.
8.
PIVOT PIN
SPACER
WASHER
CAP SCREW
9.
10.
11.
12.
HOSE ASSEMBLY
HOSE ASSEMBLY
STEERING CYLINDER
PIN
13.
14.
15.
16.
CAP SCREW
WASHER
LOCKNUT
GREASE HOSE
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-16
Installation
1. Install the valve, bolts, spacers and nuts onto the
machine, tighten the bolts.
2. Install new O-rings onto the fittings of the hoses,
install and tighten the hoses.
3. Stop the vacuum pump, install and tighten the
reservoir filler cap.
4. Start and run the machine at low idle, turn the
steering wheel from full left lock to full right lock
holding the steering over relief.
5. Stop the machine and check for leaks.
6. Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-17
BS06G529
1.
2.
3.
4.
5. RELIEF VALVE
6. RETURN HOSE TO FILTERS
7. RETURN MANIFOLD
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5001-18
NOTES
Bur 5-2780
Issued 8-06
Printed in U.S.A.
5002
Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS,
AND TROUBLESHOOTING
Bur 5-2790
5002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding The Results Of The Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2790
Issued 8-06
3
3
4
4
4
5
5
5
5
6
6
7
8
9
10
Printed in U.S.A.
5002-3
SPECIAL TOOLS
B785789
B009638
B797157
Bur 5-2790
Issued 8-06
Printed in U.S.A.
5002-4
Test Procedure
1. Install articulation lock.
BB830300
1. AMMETER CLAMP
1
BD03A040
1. ARTICULATION LOCK
the
oil
is
at
operating
Bur 5-2790
Issued 8-06
Printed in U.S.A.
5002-5
Test Procedure
1. Remove the connector that is between the
ter minals on the magnetic switch and the
auxiliary steering motor.
2. Remove the auxiliary steering motor from the
auxiliary steering pump.
3. Remove the drive coupling from the auxiliary
steering motor (3).
4. Connect the auxiliary steering motor (3), remote
starter switch (1) and tester (2) to the 24 volt
battery system (5) as illustrated.
B795328
6. AMMETER
7. VOLTMETER
8. LOAD CONTROL
B790852
1.
2.
3.
4.
5.
Bur 5-2790
Issued 8-06
Printed in U.S.A.
5002-6
1
BD03A040
1. ARTICULATION LOCK
2
1
BD06F148
1. G1 TEST PORT
2. G2 TEST PORT
Bur 5-2790
Issued 8-06
Printed in U.S.A.
5002-7
Bur 5-2790
Issued 8-06
Printed in U.S.A.
5002-8
Bur 5-2790
Issued 8-06
Printed in U.S.A.
5002-9
BS06G529
1.
2.
3.
4.
Bur 5-2790
5. RELIEF VALVE
6. RETURN HOSE TO FILTERS
7. RETURN MANIFOLD
Issued 8-06
Printed in U.S.A.
5002-10
Pressure Test
1. Disconnect the return hose (2) from the
connector (4).
2. Install a T fitting and connect a pressure gauge
capable of reading 35 bar (500 psi).
3. Start and run the machine at high idle.
Bur 5-2790
Issued 8-06
Printed in U.S.A.
Section
5005
5005
STEERING CYLINDERS
Bur 5-3160
5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3160
Issued 8-06
3
3
3
3
5
Printed in U.S.A.
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
1. Fasten tube (18) in a vise. Be careful not to
damage the tube. See illustration on page 4.
2. Remove gland (1) from tube (18).
3. Pull piston rod (14) and piston (9) straight out of
tube (18).
4. Fasten piston rod (14) yoke in vise and put a
support below piston rod near piston (9). Put a
shop cloth between support and piston rod to
prevent damage to piston rod.
5. Loosen and remove bolt and washer (8) that hold
piston (9).
6. Remove piston (9) from piston rod (14).
Inspection
1. Clean all parts in cleaning solvent.
2. Check to be sure that piston rod (14) is straight. If
piston rod is bent, install a new piston rod.
3. Inspect inside of tube (18) for deep grooves and
other damage. If there is any damage to tube, a
new tube must be used.
4. Remove small scratches on piston rod (14) or
inside tube (18) with emery cloth of medium grit.
Use emery cloth with a rotary motion.
5. Inspect bushing (17). If bushing requires
replacement, remove grease fitting (15) and
retaining rings (16) then press bushing from tube
end.
Bur 5-3160
Issued 8-06
Printed in U.S.A.
5005-4
15
16
17
16
18
8
9
19
13
12
11
10
14
BC05M089
1.
2.
3.
4.
5.
GLAND
ROD WIPER
ROD SEAL
BUFFER SEAL
BEARING
6.
7.
8.
9.
10.
BACKUP RING
O-RING
BOLT AND WASHER
PISTON
RING CAST IRON
11.
12.
13.
14.
WEAR RING
RING LOADER
SEAL
PISTON ROD
15.
16.
17.
18.
GREASE FITTING
RETAINING RING
BUSHING
TUBE
Bur 5-3160
Issued 8-06
Printed in U.S.A.
5005-5
Assembly
1. Install bearing (5) in gland (1).
2. Install buffer seal (4) in gland (1) so that lips of
seal are toward small end of gland.
3. Install rod seal (3) in gland (1). Rod seal must be
installed so that lips of seal are toward small end
of gland. Seal can be difficult to install. Use tools
that will not damage seal. See illustration on
page 4.
4. Install rod wiper (2) in gland (1) with wiper lips
toward large end of gland.
5.
6. Install O-ring (7) on gland (1).
7. Install backup ring (6) on gland (1). The backup
ring must be toward large end of gland. If backup
ring is not flat on both sides, the side that is not
flat must be toward O-ring (7).
8. Fasten piston rod (14) yoke in vise.
10. Push gland (1) onto piston rod (14) large end
first. If necessary, use a soft hammer to drive the
gland onto piston rod.
Bur 5-3160
Issued 8-06
Printed in U.S.A.
5005-6
NOTES
Bur 5-3160
Issued 8-06
Printed in U.S.A.
Section
5006
5006
CENTER PIVOT
Bur 5-3170
5006-2
TABLE OF CONTENTS
SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3170
Issued 8-06
3
3
4
4
6
9
Printed in U.S.A.
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
Bur 5-3170
Issued 8-06
Printed in U.S.A.
5006-4
CENTER PIVOT
Disassembly
23. Remove the pivot pin from the rear frame and the
steering cylinder rod eye.
28. Install blocks between the rear axle and the rear
frame on both sides of the machine to prevent
the rear frame from tipping.
29. Put a jack in contact with both sides of the rear
frame near the center pivot area. Use another
jack at the rear of the machine to prevent the rear
frame from tipping.
30. Loosen and remove the bolt (1), washer (2), and
spacer (3) that fasten the upper pivot pin (4) to
the rear chassis (5).
32. Loosen and remove the bolts (1) and washers (2)
that fasten the lower pin plate (15) to the lower
pivot pin (10).
33. Loosen and remove the bolts (1) and washers (2)
that fasten the lower pin plate (15) to the bottom
of the rear chassis (5).
34. Use the ram and hand pump to remove the lower
pivot pin (10).
Bur 5-3170
Issued 8-06
Printed in U.S.A.
5006-5
2
3
7
5
8
10
6
9
5
12
16
11
6
8
13
6
2
14
1
5
8
15
BS03B152
1.
2.
3.
4.
BOLT
WASHER
SPACER
UPPER PIVOT PIN
5.
6.
7.
8.
REAR CHASSIS
SEAL
BEARING RETAINER
SHIM
9.
10.
11.
12.
13.
14.
15.
16.
BEARING RETAINER
BOTTOM SPACER
LOWER PIN PLATE
FRONT CHASSIS
Bur 5-3170
Issued 8-06
Printed in U.S.A.
5006-6
36. Remove the bottom spacer (14).
37. Release the parking brake.
38. Use prybars to turn the left rear wheel backwards
and the right rear wheel forward to move the front
of the rear frame to the left for access to the
bearings. Install blocks under the wheels to
prevent the rear frame from moving.
Assembly
1. Pack the bearing cones with grease. Be careful
not to mix the bearing cones.
2. Lubricate the bore in the top pivot with grease.
3. Install a bearing cup (20) in the top pivot (22).
4. Install the bearing driver (17) and plate (21).
17 18
19
20
43. Loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (7) and shims (8)
to the top of the top pivot.
44. Remove the bearing retainer (7) and shims (8).
45. Use the puller to remove the seal (6) from the top
of the bottom pivot.
46. Use the puller to remove the seal (6) from the
bottom of the top pivot.
47. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the upper pivot
bearing (9) from the top pivot. See Special Tools
in this section.
NOTE: The spacers are matched to the bearing
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.
48. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the lower pivot bearing
(12) from the bottom pivot. See Special Tools in
this section.
NOTE: The spacers are matched to the bearing
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.
21
22
BC06A118
17
23
18
19
26
24
25
21
22
BC06A119
Bur 5-3170
Issued 8-06
Printed in U.S.A.
5006-7
9. Put the bearing retainer (7) in place on the upper
pivot bearing assembly (9).
10. Install the bearing driver (17) and plate (21).
11. Tighten a nut (18) on the screw (19) until the
bearing retainer (7) is tight against the upper
pivot bearing assembly (9).
17
18
19
27
BC06A125.
21
22
21. Install the upper pivot pin (4) in the top pivot.
22. Lubricate the top pivot until grease is forced out
of the seal (6).
23. Rotate the upper pivot pin (4) to check the
bearing assembly. The upper pivot pin (4) must
rotate smoothly, but not easily. Leave the upper
pivot pin (4) in place to keep dirt out of the upper
pivot bearing (9).
24. Lubricate the bore for the bottom pivot with
grease. Install a bearing cup in the bottom pivot.
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
the bearing retainer (7).
19
21
18
28
29
17
BC06A123
BC06A121
17. Fill the other seal (6) for the top pivot with grease.
Bur 5-3170
Issued 8-06
Printed in U.S.A.
5006-8
21
18
25
19
24
29
23
26
17
BC06A124
BC06A126
41. Install the other seal (6) in the bottom pivot. The
top of the seal (6) must be even with the top of
the bottom pivot.
21
18
19
29
30
12
BC06A121
17
13
BC06A125
Bur 5-3170
Issued 8-06
Printed in U.S.A.
5006-9
26. Align the hole in the pivot pin with the holes in the
steering cylinder rod eye, and install the pivot pin.
27. Install the bolt and self-locking nut that hold the
pivot pin.
28. Repeat steps 25, 26 and 27 for the other steering
cylinder.
11. Install the lower pin plate (15), three inner bolts
(1), and washers (2) that fasten the lower pin
plate (15) to the lower pivot pin (10).
45. Bleed air from the front axle bleed screws. Refer
to Section 7002 for complete brake bleeding
instructions.
Issued 8-06
Printed in U.S.A.
5006-10
NOTES
Bur 5-3170
Issued 8-06
Printed in U.S.A.
Section
5008
5008
Bur 6-42430
5008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42430
Issued 4-03
3
4
4
4
4
Printed in U.S.A.
5008-3
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Motor ...........................................................................................................................................................24 volts
Auxiliary steering pump
Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)
Bur 6-42430
Issued 4-03
Printed in U.S.A.
5008-4
Assembly
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup ring
(5) from the plate (17).
NOTE: The only serviceable items on the pump
assembly are the seals (6), backup rings (5), O-rings
(7), seal (4), retaining ring (3) and gasket (13). If any
of the other items are damaged, replace the pump
assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.
Bur 6-42430
Issued 4-03
Printed in U.S.A.
5008-5
10
11
16
12
1
13
3
17
14
15
5
6
23
19
7
22
18
22
7
20
23
6
5
21
2
BS01C121
1.
2.
3.
4.
5.
6.
MOTOR
BOLT
RETAINING RING
SEAL
BACKUP RING
SEAL
7.
8.
9.
10.
11.
12.
O-RING
SWITCH
CABLE
SCREW
LOCK WASHER
WASHER
13.
14.
15.
16.
17.
18.
GASKET
LOCK WASHER
SCREW
WIRE
PLATE
BODY
19.
20.
21.
22.
23.
DRIVEN GEAR
DRIVE GEAR
END PLATE
PINS
WEAR PLATE
Bur 6-42430
Issued 4-03
Printed in U.S.A.
5008-6
NOTES
Bur 6-42430
Issued 4-03
Printed in U.S.A.
SECTION INDEX
POWER TRAIN
Section Title
Section Number
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A.
Bur 5-3180
6001
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN
COMPONENTS
Bur 5-4010
6001-2
TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-4010
Issued 8-06
3
3
7
8
13
13
15
16
18
18
20
21
Printed in U.S.A.
6001-3
TRANSMISSION
Removal
STEP 7
STEP 1
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 2
Place the master disconnect switch in the OFF
position.
STEP 3
Refer to Section 9007 and remove ROPS cab or
ROPS canopy.
STEP 4
Refer to Section 8001 and remove the hydraulic
pump.
BD01D315
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
STEP 9
BD01D306
BD01D310
Issued 8-06
Printed in U.S.A.
6001-4
STEP 10
STEP 13
BD01D312
BD01F281
STEP 14
STEP 11
BD03A165
BD01D316
STEP 12
BD01D314
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-5
STEP 15
STEP 18
BD03A161
BD01D339
STEP 19
STEP 16
BD01D340
BD03A160
Remove two bolts. Remove fill tube, with cap and oil
gauge assembled, two seals, and metal strainer.
Discard seals.
STEP 20
STEP 17
BD01D343
BD01D318
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-6
STEP 21
STEP 23
BD01D342
BD03A164
STEP 24
STEP 22
BD01D345
BD03A163
STEP 25
BD01D361
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-7
Transmission Mounting
4
2
1
C
B
1
3
2
2
5
7
1
5
2
A
BS03B153
1.
2.
3.
4.
5.
Bur 5-4010
ISOLATOR BOLT
WASHER
BOLT
BOLT
BOLT
6.
7.
A.
B.
C.
MOUNTING BRACKET
TOP MOUNTING BRACKET
REAR CHASSIS TRUNNION
BRACKET (6 OR 7)
SMALLER PIECE ON TOP
Issued 8-06
Printed in U.S.A.
6001-8
Installation
STEP 29
STEP 26
Check isolators for deterioration, tears, deformation,
or other damage. Replace as necessary: refer to
Page 7.
STEP 27
BD03A164
STEP 30
BD01D361
STEP 28
BD03A163
BD01D345
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-9
STEP 31
STEP 33
BD01D343
STEP 34
STEP 32
BD01D340
STEP 35
BD03A163
BD01D318
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-10
STEP 36
STEP 39
BD03A160
BD01F281
STEP 40
STEP 37
BD01D314
BD03A161
STEP 41
STEP 38
BD01D316
BD03A165
Issued 8-06
Printed in U.S.A.
6001-11
STEP 42
STEP 45
BD01D312
BD01D315
STEP 46
STEP 43
BD01D306
BD01D310
STEP 44
STEP 47
BD01D317
Bur 5-4010
BD03A177
Issued 8-06
Printed in U.S.A.
6001-12
STEP 48
STEP 50
STEP 49
STEP 51
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-13
FRONT AXLE
Removal
STEP 4
STEP 1
BD03A167
BD03A040
STEP 5
STEP 2
BD03A166
BD03A092
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.
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-14
STEP 6
STEP 9
BD03A168
BD01F297
STEP 10
STEP 7
BD01F295
BD01F298
STEP 11
BD01D392
BD01F296
STEP 8
STEP 12
Carefully lower front axle and remove from under
machine.
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-15
3
4
BS03B151
1. BOLT
2. WASHER
3. WASHER
Bur 5-4010
4. NUT
5. FRONT AXLE
Issued 8-06
Printed in U.S.A.
6001-16
Installation
STEP 15
STEP 13
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 14
BD01F295
BD01F296
BS06G052
STEP 16
BD01F297
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-17
STEP 17
STEP 20
BD01F298
BD03A166
STEP 21
BD01D392
STEP 18
Repeat Step 78 to remove other jack stand from
under machine.
STEP 19
BD03A167
STEP 22
If necessary, fill axle with gear lubricant specified in
Section 1002.
STEP 23
Refer to Section 7002 and bleed brakes.
BD03A168
STEP 24
Star t engine and raise bucket. Have assistant
remove safety link. Lower bucket to ground and stop
engine.
STEP 25
Put articulation lock in OPERATING position.
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-18
REAR AXLE
Removal
STEP 5
STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and for th at least 30 times to release any
pressure from hydraulic circuit.
STEP 2
BD03A169
STEP 6
BD03A040
STEP 3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.
BD01F299
STEP 4
STEP 7
BD03A162
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-19
STEP 8
STEP 10
Carefully lower rear axle and remove through side of
machine.
STEP 11
Remove and discard two seals from rear axle pivot
point.
BD01F295
STEP 9
BD03A170
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-20
6
5
1
4
3
2
6
5
7
10
6
3
11
5
12
BS01D132
1.
2.
3.
4.
Bur 5-4010
TRUNNION
O-RING
SEAL
FRONT CAP
5.
6.
7.
8.
WASHER
BOLT
WASHER
BOLT
9.
10.
11.
12.
REAR AXLE
PIVOT PIN
SHIM(S)
REAR CAP
Issued 8-06
Printed in U.S.A.
6001-21
Installation
STEP 13
STEP 12
6
10
12
BD01D482A
A
B
BS01E091A
SHIM(S) REQUIRED
(mm)
0.07 to 0.55
None
0.56 to 1.09
0.50
1.10 to 1.59
1.0
1.60 to 2.09
1.50
2.10 to 2.59
2.60 to 3.02
BD01D499
Clean front (A) and rear (B) pivot area of rear axle
where seals (3) will be installed.
STEP 14
A
3
4
12
2
BS01E092
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.
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-22
STEP 16
11
12
STEP 17
4
10
1
BS01E091
BD01F295
BS06G052
STEP 18
Remove hydraulic jack supporting rear axle and jack
stands supporting loader.
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-23
STEP 19
STEP 21
If necessary, fill axle with gear lubricant specified in
Section 1002.
STEP 22
Refer to Section 7002 and bleed brakes.
STEP 23
Put articulation lock in OPERATING position.
BD03A169
STEP 20
BD03A162
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6001-24
NOTES
Bur 5-4010
Issued 8-06
Printed in U.S.A.
6002
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE
CHECKS, AND TROUBLESHOOTING
Bur 5-2840
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2840
Issued 8-06
3
3
9
9
9
9
9
10
10
10
10
10
11
11
11
11
11
11
12
12
12
12
12
12
13
15
16
16
16
16
16
17
17
17
17
17
17
17
17
17
17
18
19
19
19
Printed in U.S.A.
6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit.
Includes: CAS-2324 special 90 degree adapter and
CAS-2325 plug and cap set.
CAS-1804 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi)
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm)
Transmission oil operating temperature..........................................................................80 to 120 C (176 to 248 F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K2 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K3 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K4 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-4
1
3
12
9
6
8
11
14
7
13
10
BS01A190
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-5
12
11
1
2
10
3
9
4
15
14
8
13
BS03A262
1.
2.
3.
4.
5.
6.
7.
8.
CLUTCH SHAFT KR
POWER TAKE OFF
CLUTCH SHAFT KV
CLUTCH SHAFT K2
CLUTCH SHAFT K3
OUTPUT FLANGE REAR
OUTPUT FLANGE CONVERTER SIDE
OUTPUT SHAFT
9.
10.
11.
12.
13.
14.
15.
TRANSMISSION PUMP
INPUT FLANGE
CONVERTER
INDUCTIVE TRANSMITTER FOR ENGINE SPEED
CLUTCH SHAFT K4
CONVERTER RELIEF VALVE
CLUTCH SHAFT K1
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-6
BS01A191
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-7
5
9
10
8
BS01A192
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-8
BS01B048
1.
2.
3.
4.
LIFTING LUGS
POWER TAKE OFF
TRANSMISSION CONTROL VALVE
TRANSMISSION SUSPENSION BORES
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-9
TRANSMISSION OPERATION
General
Transmission ECM
Modulation and shifting are controlled by the
Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e
(Transmission ECM). This module replaces the oil
and springs that are found in hydraulically modulated
transmissions.
T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h
e n g a 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
enhanced clutch life, whether the transmission is set
to the automatic or manual shift mode.
The Transmission ECM also informs the Information
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.
calibrate
the
oil
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-10
Limp-Home Mode
In this mode, the transmission will go into second
gear, forward or reverse, no matter what gear is
selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
g e a r s u n t i l a n o p e r a b l e g e a r i s fo u n d . T h e
transmission will go into the Limp Home Mode if
there is a fault on one clutch, a fault on one clutch
valve, or a fault on more than one speed sensor.
Transmission/Transmission ECM
Shutdown Mode
In this mode, the Transmission ECM has detected a
s 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
Mode if there is a fault on more than one clutch, a
fault on the solenoid power supply, or invalid voltage.
In this mode, the Transmission ECM will shut off all
solenoid valves and the power supply and the
transmission shifts into and stays in neutral.
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.
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-11
Gear Selections
Automatic/Manual Modes
Issued 8-06
Printed in U.S.A.
6002-12
Manual Mode
Downshift Button
The downshift button is located on front of the
joystick control lever in machines with a single lever
configuration, and on top of the control tower in
machines with a three lever configuration.
Automatic Mode
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-13
IDENTIFICATION/LOCATION
CONNECTION
DESIGNATION ON
VALVE BLOCK
H
M10x1
52
M14x1.5
53
KV M10x1
55
KR M10x1
56
K1 M10x1
57
K2 M10x1
58
K3 M10x1
60
K4 M10x1
63
M14x1/5
65
M10x1
1 5/16 - 12 UNF-2B
16
1 5/16 - 12 UNF-2B
34
M18x1.5
47
M18x1.5
48
M18x1.5
Connections
49
68
System Pressure
M16x1.5
69
Pilot Pressure
M16x1.5
NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-14
BC01B047
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-15
Date:
TEST POINTS
Shift
Speed
P
65
V
53
R
55
1
56
2
57
3
58
4
60
5
51
6
52
LP
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
P= MAIN PRESSURE
V= FORWARD CLUTCH
5= CONVERTER IN
R= REVERSE CLUTCH
6= CONVERTER OUT
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-16
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-17
Test Procedure
1. Block the machine tires.
Test Procedure
FLOWMETER TEST
Test Equipment Required
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter.
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-18
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56C (100F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operators gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-19
ERROR CODES
In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with
a recorded error number. See section 4005 for error code retrieval procedures and definitions.
Shifter
Shifter Wire
Color
Shifter Tower
Connector
Shifter Shroud
Connector
Harness
Wire #
Harness
ped/cab #
Trans. ECM #
power
B+
black/red
19A_H
43
45
forward
yellow
25F
44
43
reverse
pink
25R
45
64
neutral
gray
25T_B
46
67
gear2(3-4)
B2
green
25W
48
65
gear1(1-2)
B1
blue
25Z
49
63
downshift
DS
purple
25Y
50
22
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the
shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In
neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low
and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is
engaged.
Transmission
ECM Pin #
Transmission
Valve
Clutch #
Transmission
Valve Pin #
Wire #
Trans/Cab
Pin #
A1P1
56
Y1
K4
25K
16
A1P2
10
Y2
KR
25L
17
A1P3
32
Y3
K1
25M
18
A1P4
55
Y4
K3
25N
19
A1P5
Y5
KV
25P
20
A1P6
51
Y6
K2
25J
21
VPSI
12,13
all Y
all K
25S
22
TEMP
39
TEMP
none
36T
TEMP
46
TEMP
none
36R
12
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6002-20
NOTES
Bur 5-2840
Issued 8-06
Printed in U.S.A.
6003
Section
6003
TRANSMISSION
Bur 5-2850
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2850
Issued 8-06
3
3
4
4
5
16
Printed in U.S.A.
6003-3
SPECIAL TOOLS
CAS2869 TRANSMISSION
OUTPUT SHAFT SEAL
INSTALLATION TOOL
(521 AND 621
MODELS ONLY)
CAS2803 TRANSMISSION
TORQUE CONVERTER SEAL
INSTALLATION TOOL
CAS2802 ALIGNMENT
DOWEL SET
CAS2796 NESTING
PLATE
CAS2798 GEAR
PULLER COLLET SET
CAS2800 CLUTCH
ASSEMBLY HOLDING
KNOB SET
CAS2797 LIFTING
EYEBOLT SET
SPECIAL TORQUES
Oil pipes
Studs ............................................................................................................................... 9 Nm (80 pound inches)
Socket head screw ...................................................................................................... 23 Nm (204 pound inches)
Screw plug.......................................................................................................................... 51 Nm (38 pound feet)
Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches)
Plugs................................................................................................................................. 25 Nm (221 pound inches)
Output shaft
Output shaft screws (apply Loctite 243 to threads) ..................................................... 23 Nm (204 pound inches)
Housing cover screws (apply Loctite 574 to threads).................................................. 46 Nm (407 pound inches)
Output flange screws................................................................................................... 34 Nm (301 pound inches)
Oil feed housing and transmission pump
Transmission pump screws ......................................................................................... 46 Nm (407 pound inches)
Oil feed housing screws .............................................................................................. 25 Nm (221 pound inches)
Engine connection and converter
Input shaft screws ............................................................................................................ 115 Nm (85 pound feet)
Converter housing screws.................................................................................................. 68 Nm (50 pound feet)
Cover............................................................................................................................ 23 Nm (204 pound inches)
Converter cover........................................................................................................... 46 Nm (407 pound inches)
Input flange .................................................................................................................. 34 Nm (301 pound inches)
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-4
SPECIFICATIONS
Clutch KV and KR plate clearance ......................................................................... 2.7 to 2.9 mm (0.106 to 0.114 in)
Clutch K1plate clearance........................................................................................ 2.4 to 2.6 mm (0.094 to 0.102 in)
Clutch K2 and K3 plate clearance .......................................................................... 1.8 to 2.0 mm (0.071 to 0.079 in)
Clutch K4 plate clearance....................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-5
DISASSEMBLY
STEP 1
STEP 4
GD98M833
GD98M837
STEP 2
STEP 5
GD98M835
STEP 3
GD98M838
STEP 6
GD98M836
GD98M839
Issued 8-06
Printed in U.S.A.
6003-6
STEP 7
STEP 10
GD98M844
GD98M847
STEP 11
STEP 8
GD98M845
GD98M848
STEP 12
STEP 9
GD98M849
GD98M846
C o n n e c t s u i t a bl e l i f t i n g e q u i p m e n t t o s h a f t .
R e m o v e c o v e r, s h a f t , a n d c o n v e r t e r f r o m
transmission and place in hydraulic press.
Bur 5-2850
R e m o ve fo u r h ex h e a d s c r e w s a n d r e m o ve
diaphragm and input shaft.
Issued 8-06
Printed in U.S.A.
6003-7
STEP 13
STEP 16
GD98M850
GD98M853
STEP 17
STEP 14
GD98M854
GD98M851
STEP 15
STEP 18
GD98M852
Issued 8-06
Printed in U.S.A.
6003-8
STEP 19
STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 24
GD98M856
STEP 20
GD98M862
STEP 25
GD98M860
STEP 21
GD98M863
STEP 26
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 22
Pry the shaft seal out of the housing bore.
GD98M864
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-9
STEP 27
STEP 30
Remove CAS2800 clutch assembly holding knob
set and lift cover free.
STEP 31
BK00D029
GD98M867
STEP 28
STEP 32
BK00D028
GD98M872
STEP 29
STEP 33
BK00D026
Bur 5-2850
GD98M873
Issued 8-06
Printed in U.S.A.
6003-10
STEP 34
STEP 37
GD98M877
GD98M874
STEP 35
STEP 38
GD98M875
GD98M878
STEP 36
STEP 39
GD98M876
Issued 8-06
Printed in U.S.A.
6003-11
STEP 40
STEP 43
GD98M881
BK00D020
STEP 41
STEP 44
GD98M882
BK00D019
STEP 45
STEP 42
GD98M885
BK00D018
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-12
STEP 46
STEP 48
GD98M886
GD98M889
STEP 47
STEP 49
GD98M887
GD98M890
STEP 50
GD98M888
GD98M892
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-13
STEP 51
STEP 54
GD98M893
BK00D018
STEP 52
STEP 55
GD98M894
BKOOD020
STEP 53
STEP 56
GD98M895
Bur 5-2850
BK00D019
Issued 8-06
Printed in U.S.A.
6003-14
STEP 57
STEP 59
BS00G001
GD98M800
STEP 58
STEP 60
GD98M801
BK00D022
STEP 61
BK00D018
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-15
STEP 62
STEP 64
BK00D020
STEP 63
GD98M803
STEP 65
Remove bearings from input shaft using a bearing
puller.
BK00D019
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-16
ASSEMBLY
NOTE: The following steps are for the reassembly of
the oil pipes.
STEP 69
STEP 66
2
3
GD98M607
STEP 70
GD98M603
STEP 67
Secure suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 pound inches)
STEP 68
GD98M608
STEP 71
GD98M605
GD98M609
Install both oil pipes into the housing cover. Tilt the
cover 180 degrees and install pipes into the housing
bores using a rolling tool.
NOTE: The pipe end must be slightly below the
housing plane face.
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-17
STEP 72
STEP 75
GD98M610
BK00D019
STEP 73
BK00D018
STEP 76
GD98M612
STEP 74
BK00D020
Issued 8-06
Printed in U.S.A.
6003-18
STEP 77
STEP 79
A
GD98M617
225B
1.
2.
3.
4.
5.
6.
7.
A
PLATE CARRIER
PISTON
OUTER PLATE - ONE-SIDED COATED
INNER PLATES
OUTER PLATES - COATED ON BOTH SIDES
SNAP RING
END SHIM
RUNNING CLEARANCE 2.7 TO 2.9 MM (0.106 TO 0.114
IN)
STEP 80
STEP 78
GD98M618
GD98M616
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-19
STEP 81
STEP 84
GD98M619
GD98M621
STEP 85
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
Dimension B . . . . . . . . . . . . . . . . . 4.45 mm (0.18 in)
Difference = Running. . . . . . . . . . . 2.80 mm (0.11 in)
Clearance
Required running clearance is 2.7 to 2.9 mm (0.106
to 0.114 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
STEP 82
GD98M622
STEP 83
STEP 86
GD98M623
GD98M620
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-20
STEP 87
STEP 90
GD98M624
BP00G020
STEP 91
STEP 88
BK00D024
GD98M625
Heat bearing.
STEP 92
STEP 89
BK00D023
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-21
STEP 93
STEP 96
STEP 94
GD98M632
STEP 97
STEP 95
GD98M633
STEP 98
GD98M631
GD98M634
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-22
STEP 99
STEP 101
A
BK00D019
232A
1.
2.
3.
4.
5.
6.
7.
A.
BK00D018
STEP 100
PLATE CARRIER
PISTON
OUTER PLATE - ONE-SIDED COATED
INNER PLATES
OUTER PLATES - COATED ON BOTH SIDES
SNAP RING
END SHIM
CLUTCH K1 RUNNING CLEARANCE 2.4 TO 2.6 MM
(0.094 TO 0.102 IN); CLUTCHES K2 AND K3 RUNNING
CLEARANCE 1.8 TO 2.0 MM (0.071 TO 0.079 IN)
STEP 102
BK00D020
Bur 5-2850
GD98M636
Issued 8-06
Printed in U.S.A.
6003-23
STEP 103
STEP 105
GD98M637
GD98M639
STEP 104
Example
Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in)
Difference = Running Clearance . . .2.1 mm (0.08 in)
GD98M638
STEP 106
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as
determined in Step 105.
STEP 107
Example
Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)
3
2
1
GD98M640
Issued 8-06
Printed in U.S.A.
6003-24
STEP 108
STEP 111
GD98M641
BK00D024
Heat bearing.
STEP 109
STEP 112
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
GD98M642
STEP 110
BK00D025
STEP 113
GD98M643
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-25
NOTE: The following steps are for assembly of
clutch K4.
STEP 116
STEP 114
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
GD98M649
STEP 117
GD98M647
STEP 115
GD98M650
STEP 118
GD98M648
GD98M651
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-26
STEP 119
STEP 121
A
BK00D019
BS02C131
1.
2.
3.
4.
5.
6.
7.
A.
PLATE CARRIER
PISTON
OUTER PLATE - ONE-SIDED COATED
INNER PLATES
OUTER PLATES - COATED ON BOTH SIDES
SNAP RING
END SHIM
RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055
IN)
STEP 122
STEP 120
GD98M653
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-27
STEP 123
STEP 125
GD98M654
GD98M656
STEP 124
Example
Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in)
Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in)
Clearance
Required running clearance is 1.2 to 1.4 mm (0.047
to 0.055 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
GD98M655
STEP 126
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as
determined in Step 125.
STEP 127
Example
Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-28
STEP 128
STEP 131
1
2
3
GD98M658
GD98M661
STEP 132
STEP 129
GD98M662
GD98M659
STEP 130
STEP 133
GD98M660
GD98M663
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-29
STEP 134
STEP 138
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
BK00D024
Heat bearing.
STEP 135
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
GD98M666
SM121A
STEP 139
BK00D025
STEP 136
Repeat Steps 134 and 135 to install bearing on
opposite end of shaft.
GD98M667
STEP 140
STEP 137
Check operation of the clutch using compressed air.
NOTE: The following steps are for the reassembly of
the input shaft.
GD98M668
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-30
STEP 141
STEP 144
GD98M669
GD98M672
Install the turbine shaft until the snap ring snaps into
the recess of the input shaft.
STEP 142
STEP 145
SM121A
K1
AB
K3
K4
AN
KR
K2
KV
GD98M673
BK00D024
STEP 146
STEP 143
BK00F003
GD98M671
Issued 8-06
Printed in U.S.A.
6003-31
STEP 147
STEP 150
BK00D029
GD98M681
STEP 151
STEP 148
KR
KV
K4
K2
K3
K1
GD98M692
GD98M679
STEP 152
STEP 149
AN
KV
K2
KR
K4
K1
K3
AB
GD98M866
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-32
STEP 153
STEP 156
BK00D028
GD98M686
STEP 154
STEP 157
STEP 155
GD98M688
STEP 158
GD98M689
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-33
STEP 159
STEP 162
GD98M690
GD98M697
STEP 160
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
NOTE: The following steps are for the assembly of
the oil feed housing and transmission pump.
STEP 164
GD98M691
STEP 161
GD98M702
GD98M696
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-34
STEP 165
STEP 168
GD98M703
GD98M706
STEP 169
STEP 166
GD98M707
GD98M704
STEP 170
STEP 167
GD98M708
GD98M705
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-35
STEP 171
STEP 173
GD98M709
GD98M712
Install the oil feed housing with the hex head screws
and flat washers. Tighten the screws to a torque of
25 Nm (221 pound inches).
STEP 172
STEP 174
GD98M711
GD98M713
P u t in p u t s h a f t in a v i s e a s s h ow n . Po s i t io n
diaphragm on input shaft and secure using 12 hex
head screws. Tighten screws to a torque of 115 Nm
(85 pound feet).
STEP 175
GD98M714
Issued 8-06
Printed in U.S.A.
6003-36
STEP 176
STEP 178
GD98M715
GD98M718
STEP 179
GD98M716
STEP 177
GD98M719
GD98M717
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-37
STEP 180
STEP 183
GD98M720
STEP 181
258
STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 pound inches).
STEP 185
GD98M724
STEP 182
GD98M727
Bur 5-2850
Issued 8-06
Printed in U.S.A.
6003-38
STEP 186
STEP 189
GD98M729
GD98M735
STEP 190
STEP 187
GD98M736
STEP 188
STEP 191
GD98M730
STEP 192
GD98M733
Bur 5-2850
GD98M737
Printed in U.S.A.
6004
Section
6004
FRONT AXLE
Bur 5-3190
6004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL END AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY OF THE BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY OF DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determine Shim Thickness for a Perfect Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Rolling Moment of Drive Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3190
Issued 8-06
3
4
6
6
7
7
13
23
23
23
24
27
28
29
30
32
32
33
34
36
40
Printed in U.S.A.
6004-3
SPECIAL TOOLS
Planetary bearing puller collet set ............................................................................................................... CAS2881
Brake housing seal installer......................................................................................................................... CAS2880
Differential bearing cone puller collet set..................................................................................................... CAS2871
Differential bearing preload wrench ............................................................................................................. CAS2851
Brake housing inner bearing cup installer ................................................................................................... CAS2877
Brake housing outer bearing cup installer ................................................................................................... CAS2878
Brake housing inner bearing cup installer ................................................................................................... CAS2879
Wear ring installer adapter .......................................................................................................................... CAS2874
Wear ring installer adapter ......................................................................................................................... CAS2875
Pinion depth gauge set................................................................................................................................ CAS2872
Pinion depth gauge block ............................................................................................................................ CAS2873
Puller body and screw ................................................................................................................................. CAS2882
Support bracket ........................................................................................................................................... CAS2883
Slide hammer puller adapter ..................................................................................................................... CAS10846
Slide hammer ..............................................................................................................................................OEM4252
Replacer ...................................................................................................................................................... CAS2297
Magnetic base with indicator ................................................................................................................... CAS10066A
Heat gun .................................................................................................................................................... CAS10810
Lifting sling...................................................................................................................................................OEM4106
Engine stand................................................................................................................................................OEM4135
Snap ring pliers............................................................................................................................................OEM6484
Snap ring pliers............................................................................................................................................OEM6177
Snap ring pliers............................................................................................................................................OEM6492
Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288
Step plate ............................................................................................................................................................8061
Step plate ............................................................................................................................................................8067
Step plate ............................................................................................................................................................8073
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-4
BS01D011
BS01D009
BS01D013
BS01D012
BS01D014
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-5
BS01D016
BS01D010
BS01D015
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-6
LUBRICATION
4
4
4
3
2
2
2
BS00M069
BS00M070
5. BLEEDER
BS00M071
BD00M234
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a
changed braking behavior.
A wear measurement has to be made on both wheel ends.
Remove screw plug, actuate brake and determine dimension X using a feeler gauge.
If dimension X is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.
Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-7
STEP 3
STEP 1
BD00M238
STEP 4
STEP 2
BD03B008
BD00M236
STEP 5
BD00M237
BD03B009
Loosen the screw plugs and drain the oil from the
axle casting.
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-8
STEP 6
STEP 9
BD00M241
BD00M244
STEP 10
STEP 7
BD00M245
BD03B010
STEP 11
STEP 8
BD03B011
BD00M243
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-9
STEP 12
STEP 15
BD03B012
BD03B015
STEP 13
STEP 16
BD03B013
BD03B016
STEP 14
STEP 17
BD03B014
Bur 5-3190
BD03B017
Issued 8-06
Printed in U.S.A.
6004-10
STEP 18
STEP 21
BD03B021
STEP 19
STEP 22
BD00M253
BD03B019
STEP 20
STEP 23
BD00M257
BD03B020
Bur 5-3190
BD03B022
Issued 8-06
Printed in U.S.A.
6004-11
STEP 24
STEP 27
BD00M259
BD00M262
STEP 28
STEP 25
BD00M263
BD00M260
Pull the pin out of the support shim and remove the
released cup springs.
STEP 26
STEP 29
BD00M261
Bur 5-3190
BD03B023
Issued 8-06
Printed in U.S.A.
6004-12
STEP 30
STEP 32
BD03B024
STEP 31
STEP 33
BD00M267
STEP 34
BD00M266
BD00M269
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-13
Assembly
STEP 35
SM121A
STEP 38
BD00M271
STEP 36
BD00M273
STEP 39
BD01F107
STEP 37
BD03B026
STEP 40
Freeze the bearing outer ring. Press the bearing
outer ring into the brake housing using CAS2853.
BD01F105
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-14
STEP 41
STEP 42
BD03B024
BD03B027
STEP 43
BS00M073
SHAFT SEAL
1. BRAKE HOUSING
2. SHAFT SEAL
* GREASE FILLING
Bur 5-3190
BD00M277
Issued 8-06
Printed in U.S.A.
6004-15
STEP 44
STEP 45
BD00M263
BD00M279
STEP 46
BS00M072
1.
2.
3.
4.
BRAKE HOUSING
GUIDE RING
SUPPORT RING
U-RING
5. U-RING
6. SUPPORT RING
7. WHEEL END SHAFT
Bur 5-3190
BD00M280
Issued 8-06
Printed in U.S.A.
6004-16
STEP 47
BD00M281
STEP 48
BS00M074
1. PIN
2. GRIPPING RINGS
3. CUP SPRINGS
4. SUPPORT SHIM
5. RETAINING RING
X. 10.5 MM +0.3 (0.41 IN +0.02)
STEP 50
BD00M282
1. GRIPPING RINGS
BD00M284
STEP 49
STEP 51
BD00M283
BD00M285
Printed in U.S.A.
6004-17
STEP 52
STEP 54
1
BD00M286
BD00M288
1. SPLINE
Drive the stop bolt into the planet carrier. Then coat
the spline with anti-corrosive antiseize.
STEP 53
STEP 55
BD03B028
BD00M289
BD03B034
1. BRAKE HOUSING
2. CIRCLIP
3. SLOTTED PIN
4. SUPPORT SHIM
5. PISTON
X INSTALLATION DIMENSION
5.0 MM 0.5 MM
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-18
STEP 56
STEP 58
2
BD03B016
STEP 59
3
4
BS06A166
1. BRAKE PISTON
2. BRAKE DISC
3. PLATE 4 MM
4. PLATE 2 MM
BD03B030
STEP 60
STEP 57
BD03B029
Bur 5-3190
BD01C009
Issued 8-06
Printed in U.S.A.
6004-19
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
STEP 61
SM121A
STEP 63
BD00M292
BD00M294
STEP 62
STEP 64
BD00M293
Bur 5-3190
BD03B031
Issued 8-06
Printed in U.S.A.
6004-20
STEP 67
STEP 65
BD00M298
Insert the sun gear shaft onto the stub shaft until
contact.
BD00M296
STEP 68
STEP 66
BD00M299
BD00M297
Insert the stub shaft into the spline of the axle bevel
gear until contact.
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-21
STEP 69
STEP 72
BD00M245
BD00M300
STEP 70
STEP 73
BD00M244
STEP 71
BD03B033
STEP 74
BD03B032
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-22
STEP 75
STEP 76
1
BD00M303
1. O-RING
BD00M304
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-23
STEP 77
BD00M305
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-24
STEP 3
BD00M235
BD00M241
STEP 2
STEP 4
BD00M236
BD03B032
STEP 5
BD00M237
Loosen the screw plugs and drain the oil from the
axle casing.
BD00M243
Pull the stub shaft out of the sun gear shaft. Repeat
steps 3 through 5 for the other wheel end.
NOTE: Pay attention to the released shim(s).
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-25
STEP 6
STEP 9
BD00M395
BD00M398
STEP 10
STEP 7
BD01F072
BD03B035
STEP 11
STEP 8
BD00M400
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-26
STEP 12
STEP 13
BD00M401
BD00M402
STEP 14
BD00M403
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-27
STEP 17
BD00M406
BD01F089
STEP 18
STEP 16
BD00M407
STEP 19
BD00M408
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-28
STEP 23
BD00M409
BD00M412
STEP 24
Use a rubber hammer to remove the drive pinion out
of the differential carrier.
STEP 21
STEP 25
Take off the spacer ring and pull the bearing inner
ring from the drive pinion shaft.
STEP 26
BD01F091
STEP 22
BD00M414
BD00M411
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-29
STEP 30
BD00M334
BD00M337
Remove the screw plug with the vent valve from the
axle casing.
STEP 28
STEP 31
BD00M335
BD00M338
STEP 32
STEP 29
BD00M339
BD00M336
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-30
STEP 36
2
3
4
1
BD00M340
1. VENT
VALVE
BD00M343
1. O-RING
STEP 37
STEP 34
2
1
BD00M344
BD00M341
1. BRAKE TUBE
2. UNION SCREW
STEP 35
BD00M342
Issued 8-06
Printed in U.S.A.
6004-31
STEP 38
STEP 41
BD00M345
MD00M348
STEP 39
BD00M346
STEP 40
1
2
3
BD00M347
1. O-RING
2. SCREW PLUG
3. VENT VALVE
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-32
STEP 44
STEP 42
Install the CAS2873 pinion depth gauge block and
CAS2289-1 gauge tube on the differential carrier.
STEP 45
STEP 43
BD00M351
1. 168.0 +0.05
BD01F106
204.25 mm
------(8.041 inch)
+1.00 mm
------(0.039 inch)
s = 205.25 mm
-----(8.08 inch)
Bur 5-3190
36.00 mm
------(1.417 inch)
+168.05 mm
------(6.616 inch)
s = 204.05 mm
-----(8.04 inch)
Issued 8-06
Printed in U.S.A.
6004-33
STEP 49
STEP 46
BD01F065
BD00M352
STEP 47
BD01F063
STEP 48
BD01F087
Issued 8-06
Printed in U.S.A.
6004-34
STEP 52
STEP 50
BD01F101
STEP 53
STEP 51
BD00M359
STEP 54
BD00M357
BD00M360
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-35
STEP 55
STEP 58
BD01F091
BD01F098
STEP 56
STEP 59
BD00M362
BD01F091
Put the input yoke in place and install the washer and
locknut. Using CAS1579A yoke holding wrench
tighten the locknut.
Tighten torque . . . . . . . . . 700 Nm (516 pound-feet)
ATTENTION: Apply Loctite, Type No. 262, onto the
thread of the locknut.
STEP 57
Remove the locknut again and pull off the input yoke
from the drive pinion shaft.
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-36
STEP 63
BD00M427
BD00M430
Insert the axle bevel gear and slide the splined shaft
into the clutch discs.
STEP 61
STEP 64
BD00M428
BD00M431
STEP 65
STEP 62
BD00M432
Issued 8-06
Printed in U.S.A.
6004-37
STEP 66
BD00M433
BD00M435
STEP 67
STEP 69
BD00M434
BD00M436
Dimension I
-------(1.50 inch)
+ 37.75mm
Dimension II
Difference = Disc clearance
-------(1.49 inch)
= 0.30 mm
------(0.01 inch)
Issued 8-06
Printed in U.S.A.
6004-38
STEP 70
STEP 73
BD00M437
BD00M440
STEP 71
STEP 74
BD00M438
BD00M441
STEP 75
STEP 72
BD00M442
BD00M439
Issued 8-06
Printed in U.S.A.
6004-39
STEP 76
STEP 79
BC00M443
BD00M446
STEP 77
BD00M444
STEP 78
BD00M445
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-40
STEP 82
STEP 80
STEP 83
To adjust the bearing preload, note the position of the
adjusting nut. Now tighten the nut two additional
notches.
STEP 84
BD00M447
STEP 85
STEP 81
BD00M449
BD01F072
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004-41
STEP 86
1.
BD00M450
BD00M453
Insert the stub shaft into the spline of the axle bevel
gear.
STEP 87
STEP 89
BD03B035
BD00M454
STEP 88
BD00M452
Issued 8-06
Printed in U.S.A.
6004-42
STEP 90
STEP 91
BD03B032
BD00M456
Bur 5-3190
Issued 8-06
Printed in U.S.A.
6004
Section
6004
REAR AXLE
Bur 5-3200
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACE HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3200
Issued 8-06
3
3
3
4
6
6
7
7
13
13
24
24
24
25
25
26
28
28
28
31
34
35
36
38
39
40
Printed in U.S.A.
6004-3
SPECIFICATIONS
Lubricant Capacity............................................................................................................ 26.5 liters (28 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ......................................10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim .........................................................................4.0 to 4.5 mm (0.15 to 0.18 inch)
Sun Gear Shaft End Play.............................................................................................................1.00 mm (0.04 inch)
Drive Pinion Rolling Torque ................................................................................. 1.5 to 3.0 Nm (13.2 to 26.5 lb-inch)
Differential Carrier Disc Clearance ..............................................................................................0.40 mm (0.02 inch)
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing......................................................................... 440 Nm (325 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads).................................................. 700 Nm (516 pound feet)
Bolts Securing Differential Ring Gear .................................................................................. 390 Nm (288 pound feet)
Bolts Securing Axle Housing to Center Section .................................................................. 290 Nm (215 pound feet)
Locknut Securing Planetary Carrier................................................................................... 1000 Nm (737 pound feet)
SPECIAL TOOLS
Slide hammer puller adapter . . . . . . . . . CAS10846-3
Slide hammer . . . . . . . . . . . . . . . . . . . . . . OEM4252
Pressure Ring Installer . . . . . . . . . . . . . . . CAS2860
Planetary Bearing Puller . . . . . . . . . . . . . . CAS2881
Planetary Bearing Puller . . . . . . . . . . . . . . CAS2849
Bearing Cone Puller . . . . . . . . . . . . . . . . . CAS2843
Bearing Cone Puller Body . . . . . . . . . . . . . CAS2844
Pinion Shaft Seal Installer . . . . . . . . . . . . . CAS2841
Seal Driver. . . . . . . . . . . . . . . . . . . . . . . . . CAS2859
Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . CAS2510
Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . OEM4106
Wheel Nut Socket . . . . . . . . . . . . . . . . . . 380100000
Bearing Cup Installer . . . . . . . . . . . . . . . . 380100001
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-4
BS01D011
BS01D009
BS01D013
BS01D012
BS01D014
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-5
BS01D016
BS01D010
BS01D015
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-6
LUBRICATION
4
5
2
1
2
BC06G003
5. BREATHER
6. BRAKE INLET
NOTE: Refer to section 1002 of this service manual for proper lubricant.
BS00M071
BD00M234
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement
should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking
function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 50 Nm (40 pound feet).
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-7
STEP 3
STEP 1
BD06G004
STEP 4
BD06G001
STEP 5
STEP 2
BD06G005
BD06G002
BD06G003
Issued 8-06
Printed in U.S.A.
6004-8
STEP 6
STEP 9
BD06G006
BD06G009
STEP 7
STEP 10
BD06G007
BD06G012
STEP 11
STEP 8
BD06G013
BD06G008
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-9
STEP 12
STEP 15
BD06G014
STEP 13
Repeat Steps 10, 11, and 12 to remove the
remaining three retaining rings, planetary gears, and
six bearings.
BD00M250
STEP 16
STEP 14
BD00M251
BD06G015
STEP 17
BD06G017
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-10
STEP 18
STEP 21
BD06G020
BD06G018
STEP 22
STEP 19
BD06G022
BD06G047
STEP 23
STEP 20
BD06G023
BD06G019
W E A R FAC E P R OT E C T I O N W H E N U S I N G
COMPRESSED AIR. Apply compressed air to brake
housing por t to push brake piston from brake
housing.
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-11
STEP 24
STEP 27
BD00M263
BD00M260
STEP 25
BD06G024
STEP 26
BS00M072
1.
2.
3.
4.
BRAKE HOUSING
GUIDE RING
SUPPORT RING
GROOVED RING
5. GROOVED RING
6. SUPPORT RING
7. WHEEL END SHAFT
BD00M262
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-12
STEP 28
STEP 31
BD06G028
BD01F102A
STEP 32
STEP 29
BD06G029
BD06G026
STEP 33
STEP 30
BD06G027
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-13
Assembly
STEP 39
STEP 34
Clean all parts except friction plates in brake disc
p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FAC E
PROTECTION WHEN USING COMPRESSED AIR.
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 35
I n s p e c t b e a r i n g r o l l e r s fo r p i t t i n g , s c o r i n g ,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
da ma ge. Che ck asso ciat ed b e ar ing cup s for
scratches, grooves, or cracks. Check bearings for
rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth,
replace the bearing.
BD06G033
STEP 36
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
SM121A
STEP 40
STEP 37
Check planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of
these conditions are seen. Check planetary carrier
shaft splines for bro ken, cracke d, or twisted
condition. Replace if necessary.
BD06G034
STEP 38
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-14
STEP 41
STEP 43
BD06G035
BD06G037
STEP 42
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
STEP 44
Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
against the shoulder in the brake housing.
SM121A
BD06G036
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-15
STEP 45
STEP 47
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
BD06G032
A
A
A
1
BD06G039
BS00M073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
STEP 46
BD06G038
Issued 8-06
Printed in U.S.A.
6004-16
STEP 48
STEP 49
A
BD00M278
BD00M279
STEP 50
BC06G002
4. SUPPORT RING
5. GUIDE RING
A. BRAKE HOUSING
Bur 5-3200
BD00M280
Issued 8-06
Printed in U.S.A.
6004-17
STEP 51
STEP 53
BD00M282
1. GRIPPING RINGS
BD00M284
STEP 54
STEP 52
BD00M283
BD00M285
STEP 55
3
A
2
1
BS00M074
1. PIN
4. SUPPORT SHIM
2. GRIPPING RINGS
5. RETAINING RING
3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43
INCH)
Bur 5-3200
BD00M286
Issued 8-06
Printed in U.S.A.
6004-18
STEP 56
STEP 58
BD00M287
BD06G051
STEP 59
BS00M075
1. BRAKE HOUSING
2. SNAP RING
3. PIN
4. SUPPORT SHIM
5. PISTON
A. 4.0 TO 4.5 MM
(0.15 TO 0.18 INCH)
BD00M251
Install the six pins (3) in the support shim (4) to lock
the snap ring (2). Dimension (A) between top of pins
(3) and top of support shim (4) must be 4.5 to 5.0 mm
(0.18 to 0.20 inch).
STEP 60
STEP 57
BD06G052
BD06G049
Printed in U.S.A.
6004-19
STEP 61
STEP 64
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
BD06G053
STEP 62
BD06G055
STEP 65
BD06G054
BD06G056
STEP 63
Install the planetary gears on the bearings.
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-20
STEP 66
STEP 69
BD06G057
BD06G060
STEP 67
STEP 70
BD06G058
BD06G061
STEP 68
STEP 71
BD06G059
Bur 5-3200
BD06G062
Issued 8-06
Printed in U.S.A.
6004-21
STEP 72
STEP 74
BD06G063
Install a new slotted pin into the wheel end lock nut.
BD06G065
STEP 73
BD06G064
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-22
STEP 79
STEP 75
BD06G068
BD06G066
STEP 76
Take a measurement from the straight edge to the
face of the planetar y gear ring, the difference
between this measurement and the measurement in
the next step will be dimension A.
STEP 77
STEP 80
Subtract dimension A from dimension B. Then
subtract 1.30 mm (0.05 inch) from the difference. The
difference is the required shim size.
Example:
Dimension B
Dimension A
Difference
Required end play
Difference = shim
size
STEP 81
BD06G067
STEP 78
Install the stub shaft in the spline of the axle bevel
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear.
Bur 5-3200
BD06G069
Issued 8-06
Printed in U.S.A.
6004-23
STEP 82
STEP 84
BD06G072
BD06G070.
STEP 83
STEP 85
BD06G071
Bur 5-3200
BD00M300
Issued 8-06
Printed in U.S.A.
6004-24
STEP 86
BD00M305
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-25
STEP 92
STEP 89
BD06G077
BD06G074
STEP 93
STEP 90
BD06G078
STEP 91
STEP 94
BD06G075
BD06G076
Use a slide puller and remove the slotted pin from the
lock nut.
Bur 5-3200
BD06G079
Use a pry bar and remove the seal form the brake
housing.
Issued 8-06
Printed in U.S.A.
6004-26
STEP 95
STEP 98
BD06G080
BD06G082
Installation
STEP 99
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
STEP 96
SM121A
BC06G005
BD06G083
STEP 97
BD06G081
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-27
STEP 100
STEP 103
BD06G084
BD06G087
STEP 104
STEP 101
BD06G088
BD06G085
Install a new slotted pin into the wheel end lock nut.
NOTE: If the slot is not aligned tighten the nut to
align the slot, never loosen the nut to align the slot.
STEP 102
STEP 105
BD06G086
Bur 5-3200
BD00M304
Printed in U.S.A.
6004-28
DIFFERENTIAL
Removal
STEP 108
STEP 106
BD06G127
BD06G002
Disassembly
STEP 109
BD06G003
STEP 107
BD01F059
BD06G126
Issued 8-06
Printed in U.S.A.
6004-29
STEP 110
STEP 113
BD01F075
BD06G129
STEP 114
STEP 111
BD00M326
BD00M323
STEP 115
STEP 112
BD06G131
BD00M324
Bur 5-3200
Pull the outer bearing ring and shims from both axle
housings.
NOTE: Make sure to identify the shims into which
axle housing they were removed.
Issued 8-06
Printed in U.S.A.
6004-30
7
6
5
4
3
2
1
9
10
12
3
6
8
4
11
7
BC06G001
1.
2.
3.
4.
Bur 5-3200
BEARING
HOUSING
WASHER, THRUST
SHIM
5.
6.
7.
8.
OUTER CLUTCH
PLATE
DIVIDER
GEAR, BEVEL
9.
10.
11.
12.
PINION, BEVEL
SHAFT
COVER
BOLT, M15 X 45
Issued 8-06
Printed in U.S.A.
6004-31
Assembly
STEP 118
STEP 116
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
BD06G151
STEP 119
BD06G149
STEP 117
BD06G152
STEP 120
BD06G150
Bur 5-3200
BD06G153
Install the axle bevel gear. Make sure axle bevel gear
splines mate with splines of all inner clutch plates.
Issued 8-06
Printed in U.S.A.
6004-32
STEP 121
STEP 124
BD06G154
BD06G157
STEP 122
BD06G155
STEP 123
BD06G158
BD06G156
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-33
STEP 126
STEP 128
BD06G159
BD06G161
STEP 129
STEP 127
BD06G162
BD06G160
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-34
STEP 134
STEP 130
Heat lock nut securing flange with a hot air blower to
loosen Loctite, approximately 120 C (248 F).
STEP 131
BD06G134
STEP 135
BD06G132
STEP 132
Remove the input flange from the drive pinion.
STEP 133
BD06G135
STEP 136
BD06G133
BD06G136
STEP 137
Drive out both bearing cups from the differential
carrier.
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-35
STEP 140
STEP 138
3
2
BD06G139
BD06G137
STEP 139
STEP 141
Calculation example A:
Dimension I
Dimension II
Results in dimension Y
BD06G138
Bur 5-3200
36.13 mm
-------(1.422 inch)
+167.95 mm
-------(6.612 inch)
= 204.08 mm
------(8.034 inch)
Calculation example B:
Dimension X
Dimension Y
Difference = shim
thickness
205.30 mm
-------(8.080 inch)
204.08 mm
-------(8.034 inch)
= 1.22 mm
------(0.046 inch)
Issued 8-06
Printed in U.S.A.
6004-36
STEP 142
STEP 145
BD06G140
STEP 143
BD06G143
BD06G141
STEP 144
BD06G144
BD06G142
Issued 8-06
Printed in U.S.A.
6004-37
STEP 147
STEP 149
BD06G147
STEP 150
BD06G145
STEP 148
STEP 151
Install holding wrench, CAS1579A, on input flange.
Hold flange using holding tool and tighten nut to a
torque of 700 Nm (515 pound feet). Remove holding
wrench.
NOTE: When tightening rotate the pinion shaft in
both directions several times.
STEP 152
BD06G146
BD06G148
STEP 153
Remove the nut and input yoke from the drive pinion
shaft.
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-38
-20
-10
+10
+20
Shim A
1.20
1.10
1.00
0.90
0.80
Shim B
0.80
0.90
1.00
1.10
1.20
STEP 154
STEP 155
2
BD06G163
4
BC06G004
1.
2.
3.
4.
DIFFERENTIAL
DRIVE HOUSING
AXLE HOUSING
INPUT PINION
5. AXLE HOUSING
A. RING GEAR SIDE
B. CARRIER SIDE
STEP 156
BD06G164
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-39
STEP 157
STEP 160
BD06G165
BD06G168
STEP 161
BD06G166
STEP 159
BD06G169
BD06G167
Bur 5-3200
Issued 8-06
Printed in U.S.A.
6004-40
Installation
STEP 164
STEP 162
BD06G172
BD06G170
Install the shaft seal with the sealing lip towards oil
sump using pinion shaft seal install CAS2841.
NOTE: Wet the outer diameter of the seal with a
solution of 50% water and 50% mineral spirits. Fill
the space between the sealing and dust lip with
grease.
STEP 163
STEP 165
BD06G171
BD06G173
Bur 5-3200
Issued 8-06
Printed in U.S.A.
Bur 5-3210
6005
Section
6005
6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3210
Issued 8-06
3
3
3
4
4
5
5
6
6
7
7
7
8
8
8
9
9
9
10
10
10
Printed in U.S.A.
6005-3
SPECIAL TORQUES
Coupler to Flywheel Bolts...................................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler Bolts ...................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Transmission Bolts.............................................................. 75 to 81 Nm (55 to 60 pound feet)
Center, Rear and Front Drive Shaft Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet)
Carrier Bearing Bolts ........................................................................................... 99 to 128 Nm (73 to 94 pound feet)
Lock Nut for Yoke on Front Drive Shaft.......................................................... 339 to 375 Nm (250 to 275 pound feet)
STEP 4
STEP 1
STEP 5
Loosen the set screws that secure the center bearing
to the front drive shaft.
STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD03A166
STEP 2
BD03A167
STEP 8
BD03A183
Remove the lock nut that fastens the yoke to the front
drive shaft.
STEP 3
Issued 8-06
Printed in U.S.A.
6005-4
STEP 14
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11
BD03A183
STEP 15
Tighten the set screws that secure the center bearing
to the front drive shaft alternately until they stop
turning and the hex head socket wrench starts to
spring.
BD03A167
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
75 to 81 Nm (55 to 60 pound feet).
STEP 16
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed,
make sure the yoke being installed is 90 to the yoke
on the other end of the front drive shaft.
Bur 5-3210
BD03A166
Install the bolts and straps that fasten the front drive
shaft to the center drive shaft. Tighten the bolts to a
torque of 75 to 81 Nm (55 to 60 pound feet).
Issued 8-06
Printed in U.S.A.
6005-5
CENTER BEARING
Removal
STEP 20
STEP 17
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD03A166
STEP 23
STEP 18
STEP 24
BD03A183
BD03A183
STEP 19
STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD03A183
Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
Bur 5-3210
Issued 8-06
Printed in U.S.A.
6005-6
CENTER BEARING
Installation
STEP 30
STEP 31
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 27
Install the bearing housing so that the lubrication
fitting is at the top.
STEP 28
BD03A183
Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
of 339 to 375 Nm (250 to 275 pound feet).
STEP 32
BD03A183
STEP 29
BD03A166
STEP 33
Install the lubrication hose into the fitting on the
bearing housing.
BC05M214
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
procedure with the other set screw.
Bur 5-3210
STEP 34
Lubr icate the center bear ing with the grease
specified in Section 1002.
Issued 8-06
Printed in U.S.A.
6005-7
Installation
STEP 35
STEP 39
BD03A166
BD03A165
STEP 36
Use a prybar to disengage the center drive shaft from
the yoke of the front drive shaft.
STEP 40
STEP 37
BD03A166
BD03A165
STEP 38
Hold the center drive shaft and remove from the
machine.
Bur 5-3210
Issued 8-06
Printed in U.S.A.
6005-8
Installation
STEP 41
STEP 45
BD01D323
BD01F304
STEP 42
Hold the rear drive shaft into position and install the
bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 75 to 81 Nm
(55 to 60 pound feet).
STEP 46
STEP 43
BD01D323
BD01F304
Install the bolts and straps that fasten the rear drive
shaft to the transmission. Tighten the bolts to a
torque of 75 to 81 Nm (55 to 60 pound feet).
STEP 44
Hold the rear drive shaft and remove from the
machine.
Bur 5-3210
Issued 8-06
Printed in U.S.A.
6005-9
Installation
STEP 47
STEP 50
BD01D342
BD01D342
STEP 51
STEP 48
BD03A172
BD03A172
STEP 49
Remove the engine drive shaft from the machine.
Bur 5-3210
Issued 8-06
Printed in U.S.A.
6005-10
UNIVERSAL JOINTS
Removal
Installation
NOTE: The bearing race and journal that make up
the universal joint are not serviced separately. If the
bearing race or journal is worn or damaged, a new
universal joint must be used.
STEP 52
Remove the drive shaft from the machine.
STEP 53
STEP 55
2
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.
Bur 5-3210
Issued 8-06
Printed in U.S.A.
Section
6006
6006
Bur 5-3220
6006-2
TABLE OF CONTENTS
WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3220
Issued 8-06
3
3
3
3
3
3
4
Printed in U.S.A.
6006-3
Torque Specification
TIRE PRESSURES
23.5 x 25 L3.......................................................................................................................................2.75 bar (40 psi)
23.5R25 Dirt/Traction.........................................................................................................................2.75 bar (40 psi)
23.5R25 Rock ....................................................................................................................................2.75 bar (40 psi)
CHANGING TIRES
The split rim wheels used on this machine
can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and
stand at the front or rear of the tire.
When inflating a tire off the machine, put
the wheel in a tire inflation cage. The
retaining ring and rim can come off with
enough force to result in death to a person
in front of the rim.
48-44
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and
axle flange are clean and free of dirt and grease.
2. Install the wheel, hardened washers and wheel
bolts.
Bur 5-3220
Issued 8-06
Printed in U.S.A.
6006-4
BS06G052
Bur 5-3220
Issued 8-06
Printed in U.S.A.
Section
6007
6007
Bur 6-81450
6007-2
TABLE OF CONTENTS
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-81450
Issued 3-06
3
3
5
5
Printed in U.S.A.
6007-3
CONTROL VALVE
Disassembly
STEP 4
STEP 1
BD06A010
BD06A007
STEP 5
STEP 2
BD06A011
STEP 6
STEP 3
BD06A012
BD06A009
Issued 3-06
Printed in U.S.A.
6007-4
STEP 7
STEP 9
BD06A013
BD06A015
STEP 10
STEP 8
BD06A016
BD06A014
Bur 6-81450
Issued 3-06
Printed in U.S.A.
6007-5
Inspection
1. Clean all metal parts in cleaning solvent.
2. Immerse end housings, valve housing, valve
plate, and distribution plate in cleaning solvent
and agitate cleaning solvent. WEAR EYE
PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign
matter from interior of housings and plates and to
ensure that all bores are clear of foreign matter.
Assembly
NOTE: Apply clean engine oil (15W-40) to pistons
and springs, orifices, new O-rings, and filter screens
before assembly.
STEP 11
BD06A017
STEP 12
3
1
1
2
2
BD06A018
1. VIBRATION DAMPER
2. PISTONS
3. PRESSURE REDUCING
VALVE
STEP 13
BD06A019
Issued 3-06
Printed in U.S.A.
6007-6
STEP 14
STEP 17
BD06A020
BD06A023
STEP 15
STEP 18
BD06A021
BD06A024
STEP 16
STEP 19
BD06A022
1
2
2
BD06A025
1. VIBRATION DAMPER
2. PISTONS
Issued 3-06
Printed in U.S.A.
6007-7
STEP 20
STEP 23
BD06A026
BD06A028
STEP 24
STEP 21
BD06A029
STEP 22
STEP 25
BD06A023
BD06A027
BD06A030
Issued 3-06
Printed in U.S.A.
6007-8
STEP 26
STEP 28
BD06A031
BD06A033
STEP 27
STEP 29
BD06A032
Bur 6-81450
BD06A034
Issued 3-06
Printed in U.S.A.
SECTION INDEX
BRAKES
Section Title
Section Number
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A.
Bur 5-3230
7001
Section
7001
REMOVAL AND INSTALLATION OF BRAKE
COMPONENTS
Bur 5-3240
7001-2
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3240
Issued 8-06
4
4
4
6
6
6
8
8
8
Printed in U.S.A.
7001-3
3
1
4
5
6
8
BC05M136
1.
2.
3.
4.
FRONT AXLE
REAR AXLE
BRAKE VALVE
PARKING BRAKE ACCUMULATOR
5.
6.
7.
8.
FRONT ACCUMULATOR
REAR ACCUMULATOR
BRAKE PUMP
CONNECTOR TO FAN VALVE
Bur 5-3240
Issued 8-06
Printed in U.S.A.
7001-4
BRAKE VALVE
Removal
Installation
Bur 5-3240
Issued 8-06
Printed in U.S.A.
7001-5
1
6
2
3
9
10
BC05M137
1.
2.
3.
4.
5.
BRAKE VALVE
REAR ACCUMULATOR LINE
PARKING BRAKE LINE
BRAKE PUMP INPUT
BRAKE VALVE DISCHARGE
6.
7.
8.
9.
10.
Bur 5-3240
Issued 8-06
Printed in U.S.A.
7001-6
Installation
to
the
parking
brake
tubes
from
both
brake
(1)
from
the
hose
from
parking
brake
Bur 5-3240
Issued 8-06
Printed in U.S.A.
7001-7
5
6
4
8
8
7
1
1
BC05M138
1.
2.
3.
4.
BRAKE ACCUMULATORS
PARKING BRAKE ACCUMULATOR
MOUNTING NUT
HOSE PARKING BRAKE ACCUMULATOR
5.
6.
7.
8.
Bur 5-3240
Issued 8-06
Printed in U.S.A.
7001-8
BRAKE PUMP
Removal
Installation
that
are
Bur 5-3240
Issued 8-06
Printed in U.S.A.
7001-9
9
6
3
2
4
BC05M139
1. BRAKE PUMP
2. MOUNTING BOLT (2)
3. WASHER (2)
4. SUCTION HOSE
5. PRESSURE HOSE
6. DRIVE GEAR
7. WASHER
8. SLOTTED NUT
9. COTTER PIN
Bur 5-3240
Issued 8-06
Printed in U.S.A.
7001-10
NOTES
Bur 5-3240
Issued 8-06
Printed in U.S.A.
7002
Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING
Bur 5-3250
7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Valve Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3250
Issued 8-06
3
3
4
5
5
6
7
7
8
9
10
11
Printed in U.S.A.
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
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-4
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-5
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-6
BD03A092
1. SAFETY LINK
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-7
4
BD06F145
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-8
BD00N121
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-9
4
BD06F145
6. Start the engine and let idle until both the front
and rear accumulators 3 and 4 are fully charged.
The accumulators are fully charged at 190 to 196
bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal 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
BD00M030
1. ARTICULATION LOCK
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-10
5
NOTE
4
3
2
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
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-11
NOTES
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-12
1
2
3
1
4
30
31
32
14
33
34
21
30
7
35
29
36
8
9
15
27
28
10
15
26
11
16
24
14
12
25
14
17
5
23
22
21
15
19
18
13
5
20
BC05G011
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7002-13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Bur 5-3250
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
CHECK VALVE
CARTRIDGE
PLUG (T 60 NM (44 LB-FT))
JET
WVI UNIT
PLUG (T 60 NM (44 LB-FT))
PLUG (T 100 NM (74 LB-FT))
RV UNIT
SPRING RETAINER
SLEEVE
THRUST RING
SLEEVE LVV
Issued 8-06
Printed in U.S.A.
7002-14
NOTES
Bur 5-3250
Issued 8-06
Printed in U.S.A.
7003
Section
7003
BRAKE PUMP
Bur 5-2920
7003-2
TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2920
Issued 8-06
4
4
4
4
Printed in U.S.A.
7003-3
14
17
15
16
10
18
10
19
7
13
8
9
11
12
7
10
11
5
4
2
1
BC06F594
1.
2.
3.
4.
5.
6.
7.
RETAINING RING
SEAL RETAINER
0-RING
OUTER LIP SEAL
INNER LIP SEAL
SHAFT END COVER HOUSING
QUAD RING
8.
9.
10.
11.
12.
13.
BACKUP SEAL
CHANNEL SEAL
DOWEL PIN
THRUST PLATE
GEAR HOUSING
PORT END COVER HOUSING
14.
15.
16.
17.
18.
19.
WASHER
BOLT
DRIVEN GEAR
DRIVE GEAR
DRIVE SCREW
NAME PLATE
PUMP ILLUSTRATION
Bur 5-2920
Issued 8-06
Printed in U.S.A.
7003-4
BRAKE PUMP
Disassembly
1. Secure the pump by the port end cover (13) in a
soft jawed vise.
2. Draw a line the length of the pump to assist
during assemble.
3. Loosen and remove bolts (15).
4. Tap the shaft end cover housing (6) with soft
hammer to loosen it, remove the shaft end cover
housing (6).
5. Remove the backup seal (8), channel seal (9),
and thrust plate (11).
6. Remove the drive gear (17) from the gear
housing (12).
7. Remove the driven gear (16) from the gear
housing (12).
8. Tap the gear housing (12) with a soft hammer to
loosen it, remove the gear housing (12).
9. Remove the backup seal (8), channel seal (9),
and thrust plate (11).
10. Remove the retaining ring (1) form the shaft end
cover housing (6).
11. Remove the seal retainer (2), O-ring (3), and
outer lip seal (4) from the shaft end cover
housing (6).
12. Remove the inner lip seal (5) from the shaft end
cover housing (6).
Inspection
1. Discard all seals and quad rings. Clean all parts
in cleaning solvent. Check all machined surfaces
for damage or wear.
2. Hold a straightedge across each gear housing
and use a feeler gauge to measure the amount
of wear caused by the gear teeth in the gear
pocket. If the wear in any gear pocket is more
than 0.18 MM. (0.007 inch), use a new gear
housing.
3. Inspect the thrust plates for scoring, pitting, or
other damage.
4. Inspect the gears for wear and damage. There
must be no scoring on the gear hubs or on the
outside edges of the gear teeth. There must be
no more than 0.05 MM. (0.002 inch) wear in the
seal area of the drive shaft. If any gear must be
discarded, you must use a new hydraulic pump.
Assembly
1. Install a new lip seal (3) into the seal retainer (2)
so the lip of the seal will be facing away from the
gears when the seal retainer (2) is installed into
the shaft end cover housing (6).
2. Install a new lip seal (4) into the shaft end cover
housing (6) with the lip of the seal facing towards
the gears.
3. Install a new O-ring (3) onto the seal retainer (2),
lubricate the O-ring with hydraulic oil.
4. Press the seal retainer (2) into the shaft end
cover housing (6) and install the retaining ring
(1).
5. Place the shaft end housing (6), facing down,
into a soft jawed vise.
6. Install new backup seals (8) and channel seals
(9) into the thrust plates (11).
7. Place a thrust plate (11) onto the shaft end cover
housing (6).
IMPORTANT: Be sure to place the thrust plate (11)
onto the shaft end cover housing (6) in the position
shown in the illustration on page 3.
8. Lubricate the driven gear (16) with hydraulic oil,
slide the driven gear (16) through the thrust plate
(11) into the shaft end cover housing (6).
9. Lubricate the drive gear (17) with hydraulic oil,
slide the drive gear (17) through the thrust plate
(11) into the shaft end cover housing (6).
10. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
either in the gear housing (12) or the shaft end
cover housing (6).
11. Align the marks made during disassembly,
carefully place the gear housing (12) onto the
gears.
12. Slide the thrust plate (11) onto the shafts of the
gears.
IMPORTANT: Be sure to place the thrust plate (11)
onto the gears in the position shown in the illustration
on page 3.
13. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (10) are in place
either in the gear housing (12) or the port end
cover housing (13).
14. Align the marks made during disassembly, place
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).
Bur 5-2920
Issued 8-06
Printed in U.S.A.
BRAKE ACCUMULATORS
Bur6-47761
7004
Section
7004
7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-47761
Revised 2-04
3
3
3
4
4
Printed in U.S.A.
7004-3
SPECIAL TOOL
E
C
F
G
D
A
94L95
BC04A001
Bur 6-47761
Revised 2-04
Printed in U.S.A.
7004-4
TEMPERATURE
0 C
32 F
5 C
41 F
10 C
50 F
15 C
59 F
20 C
68 F
25 C
77 F
30 C
86 F
35 C
95 F
40 C
104 F
CHARGE PRESSURE
51.2 BAR
743 PSI
52.2 BAR
757 PSI
53.1 BAR
770 PSI
54.1 BAR
784 PSI
55.0 BAR
798 PSI
55.9 BAR
811 PSI
56.9 BAR
825 PSI
57.8 BAR
839 PSI
58.8 BAR
852 PSI
Bur 6-47761
Revised 2-04
Printed in U.S.A.
Section
7008
7008
PARKING BRAKE
Bur 5-2930
7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2930
Issued 8-06
3
3
4
4
5
Printed in U.S.A.
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
STEP 8
BD01F143
STEP 4
Place the master disconnect switch in the OFF
position.
STEP 5
BD03A186
STEP 9
STEP 6
BD03A187
BD03A184
Issued 8-06
Printed in U.S.A.
7008-4
Inspection
STEP 14
Disengage the parking brake.
STEP 10
Clean and inspect all parts for wear and damage.
Inspect the brake disc for wear and damage.
Replace all parts that are worn or damaged.
Assembly
STEP 11
STEP 15
BD03A187
STEP 12
BD0CA185
STEP 16
Install the cover on the parking brake.
STEP 17
BD03A186
STEP 13
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.
Bur 5-2930
STEP 18
Remove the articulation lock.
STEP 19
Place the master disconnect switch to the ON
position.
Issued 8-06
Printed in U.S.A.
7008-5
STEP 25
STEP 21
Start the machine and run the engine at low idle in
third gear neutral.
BD06F142
STEP 22
Place the Transmission-Auto switch to the manual
position.
STEP 26
STEP 23
Place the Parking Brake switch to the ON position.
STEP 24
BD06F143
BD06F141
Bur 5-2930
Issued 8-06
Printed in U.S.A.
7008-6
STEP 27
STEP 33
Verify that the machine does not move.
STEP 34
Reduce the engine speed to low idle and return the
transmission to neutral.
STEP 35
BD06F144
STEP 28
BD06F141
STEP 29
Shift the gear selector into third gear forward and
slowly increase the engine speed to wide open
throttle.
STEP 36
If any machine movement was detected, the parking
brake must be adjusted, see procedures this section.
STEP 30
Verify that the machine does not move.
STEP 31
Reduce the engine speed to low idle and return the
transmission neutral.
STEP 32
Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
throttle.
Bur 5-2930
Issued 8-06
Printed in U.S.A.
SECTION INDEX
HYDRAULICS
Section Title
Section Number
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A.
Bur 5-3260
8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC
COMPONENTS
Bur 5-4050
8001-2
TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XT Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-4050
Issued 8-06
3
3
4
5
6
8
8
9
11
12
12
13
13
14
15
15
17
17
18
20
20
22
24
24
25
26
27
27
28
29
29
30
31
31
32
33
33
34
35
35
35
Printed in U.S.A.
8001-3
STEP 5
STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.
STEP 2
BD06H198
STEP 6
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
BD03A092
Raise the lift arms and install the safety link on the lift
arm cylinder.
STEP 3
STEP 7
Drain the hydraulic reservoir.
STEP 8
STEP 4
Place the master disconnect switch in the OFF
position.
BD03A093
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-4
REAR OF MACHINE
6
7
5
3
2
BC05M094
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-5
1
3
4
BC05M093
1. DUMP LINE
2. ROLLBACK LINE
3. LOWER LINE LEFT
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-6
Installation
STEP 9
Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5,
and 6) from the remote control valve(s) at the loader
control valve. Refer to the illustration on page 4 for
color coding. Install a plug in each hose and a cap on
each fitting.
STEP 16
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
STEP 13
STEP 17
STEP 14
Attach proper lifting equipment to lift loader control
valve.
STEP 18
STEP 15
STEP 19
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
BC05M096
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-7
STEP 23
STEP 27
STEP 28
STEP 24
Tighten the accumulator manual bleeder valve
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 29
Stop the engine and check for leaks.
STEP 25
Place the master disconnect switch in the ON
position.
STEP 30
STEP 26
STEP 31
BD03A092
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-8
STEP 37
STEP 32
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
BD06F208
STEP 33
Place the master disconnect switch in the OFF
position.
STEP 38
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
STEP 39
BD06F207
BD06F210
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.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-9
STEP 41
Installation
STEP 45
STEP 42
Loosen and remove the screws and washers holding
the hydraulic control tower cover. Remove the cover.
STEP 43
Loosen and remove the screws that fasten the
remote control valve to the hydraulic control tower.
STEP 44
Remove the remote control valve from the hydraulic
control tower.
STEP 46
Install the remote control valve and screws in the
hydraulic control tower and tighten the screws.
STEP 47
Install the cover over the remote control valve and
install the screws and washers.
STEP 48
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
STEP 51
Place the master disconnect switch in the ON
position.
STEP 52
Start the engine and run the engine at low idle.
STEP 53
Check to see that the remote control valve works
correctly.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-10
STEP 54
STEP 57
STEP 55
Check the level of hydraulic oil in the reservoir and
add as required.
STEP 56
BD06F208
STEP 58
BD06F209
BD06F207
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-11
8
4
6
7
1
5
5
2
1
8
3
6
4
BC05M092
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-12
4
3
4
6
2
7
7
1
7
1
5
BC05M091
1.
2.
3.
4.
5.
6.
7.
Bur 5-4050
1.
2.
3.
4.
5.
6.
7.
Issued 8-06
Printed in U.S.A.
8001-13
1
5
4
2
1
3
2
3
4
5
BC05M090
1.
2.
3.
4.
5.
6.
Bur 5-4050
1.
2.
3.
4.
5.
6.
Issued 8-06
Printed in U.S.A.
8001-14
HYDRAULIC PUMP
10
15
4
5
6
4
16
5
8
15
6
13
2
3
14
11
9
12
BC05M095
1.
2.
3.
4.
Bur 5-4050
5.
6.
7.
8.
SPLIT FLANGE
9. STEERING HIGH PRESSURE
TUBE
10. CLAMPS
HOSE SUCTION
11. STEERING LOAD SENSE HOSE
HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE
13.
14.
15.
16.
Issued 8-06
Printed in U.S.A.
8001-15
Removal
NOTE: When disconnecting hydraulic fittings, plug
hoses and cap fittings to prevent entry of foreign
matter into hydraulic system.
STEP 59
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 69
Connect lifting equipment to hydraulic pump (1). Take
up all slack in lifting equipment. Remove four
mounting bolts (2) and washers securing pump to
transmission. Pull hydraulic pump from transmission
and remove from loader. Remove and discard O-ring
from pump.
Installation
NOTE: Install new O-rings where required.
STEP 60
Place the master disconnect switch in the OFF
position.
STEP 61
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.
STEP 62
Refer to Section 9007 and remove the ROPS cab or
ROPS canopy.
STEP 63
Remove eight bolts (4) and washers. Remove four
split flanges (5). Disconnect tubes (6) with suction
hoses (7) from hydraulic pump. Remove and discard
O-ring face seals from flange heads of tubes.
STEP 70
Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
four washers and bolts (2) to secure pump (1) to
transmission, tighten the bolts. Disconnect lifting
equipment from pump.
STEP 71
Connect pump pressure hoses (9 and 13) to steering
priority manifold (14).
STEP 72
Connect drain hose (3).
STEP 73
Connect load sense hoses (11 and 12).
STEP 74
STEP 64
STEP 75
STEP 65
Tag and disconnect case drain hoses (8) from fittings
(16); remove hoses (8). Remove and discard O-ring
face seals from fittings.
STEP 66
Tag and disconnect load sense hoses (11 and 12).
Remove and discard O-ring face seals from fittings.
STEP 67
Tag and disconnect drain hose (3). Remove and
discard O-ring face seals from fittings.
STEP 68
Tag and disconnect pump pressure hoses (9 and 13)
from steering priority manifold (14). Remove and
discard O-ring face seals from flange heads of
hoses.
Bur 5-4050
STEP 76
Install four split flanges (5). Install eight bolts (4) and
washers, tighten bolts (4) to 73 to 90 Nm (53.8 to
66.3 pound feet).
STEP 77
Refer to Section 9007 and install the ROPS cab or
ROPS canopy.
STEP 78
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 79
Place the master disconnect switch in the ON
position.
Issued 8-06
Printed in U.S.A.
8001-16
STEP 80
STEP 81
Start the engine and run the engine at low idle for two
minutes.
Bur 5-4050
STEP 82
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
Issued 8-06
Printed in U.S.A.
8001-17
LIFT CYLINDERS
Removal
STEP 87
STEP 83
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
BD01D709
STEP 84
Relieve the pressure in the ride control accumulator
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
STEP 89
BD01D708
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-18
Installation
STEP 90
STEP 93
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 94
BD01D710
STEP 91
BD01D714
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.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-19
STEP 96
STEP 99
BD01D710
Align the pivot pin with the front frame and install the
spacer, washer and bolt. Tighten the bolt.
BD01D712
Install the pivot pin for the yoke. Stop the engine.
STEP 100
STEP 97
BD01D709
BD01D708
Align the pivot pin with the yoke and install the
spacer, washer and bolt. Tighten the bolt.
STEP 101
STEP 98
If the yoke of the lift cylinder is not aligned with the
loader frame, have another person start and run the
engine at low idle and use the loader control lever to
SLOWLY move the yoke into alignment with the
loader frame.
STEP 102
Lubricate the pivot pins with molydisulfide grease.
STEP 103
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the
hydraulic reservoir.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-20
STEP 108
STEP 104
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 105
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 106
BD01D695
STEP 109
BD01D694
STEP 107
BD01D697
BD01D696
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-21
STEP 110
STEP 113
BD01D699
BD01D701
Remove the pivot pin from the rod end of the bucket
cylinder.
STEP 114
STEP 111
BD01D704
BD01D700
STEP 112
Remove the pivot pin from the head end of the bucket
cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
replaced.
STEP 115
BD01D698
Bur 5-4050
BD01D706
Printed in U.S.A.
8001-22
Installation
STEP 120
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
STEP 121
STEP 118
STEP 122
BD01D706
STEP 123
BD01D704
STEP 119
Install the spacer, washer and bolt that fasten the
pivot pin to the front frame. Tighten the bolt.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-23
STEP 124
STEP 127
BD01D697
BD01D694
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
target bar.
STEP 126
STEP 132
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-24
OIL COOLER
Removal
STEP 138
STEP 133
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 134
Place the master disconnect switch in the OFF
position.
STEP 135
Raise the engine hood and remove the shield on the
right side of the machine between the tire and the oil
cooler.
STEP 136
BD03A154
STEP 139
BD03A120
STEP 137
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
BD03A179
STEP 140
BD06H195
Issued 8-06
Printed in U.S.A.
8001-25
Installation
STEP 144
STEP 141
BD03A120
BD06H195
STEP 142
STEP 145
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 146
Place the master disconnect switch in the ON
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
the cooling frame
STEP 149
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
STEP 143
BD03A154
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-26
STEP 153
STEP 150
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
BD06H196
STEP 151
STEP 154
BD06H198
STEP 152
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
Bur 5-4050
BD06H197
STEP 155
Loosen and remove the two bolts that fasten the
accumulator bracket to the front frame. Remove the
ride control accumulator from the machine.
Issued 8-06
Printed in U.S.A.
8001-27
Installation
STEP 159
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
STEP 160
Turn off and disconnect the vacuum pump from the
hydraulic reservoir.
STEP 161
BD06H197
STEP 162
Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.
STEP 163
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
hydraulic reservoir.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-28
STEP 166
STEP 164
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
STEP 167
Place the master disconnect switch in the OFF
position.
STEP 168
Disconnect the electrical connector on top of the ride
control valve.
STEP 169
STEP 165
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
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-29
Installation
STEP 178
STEP 173
STEP 179
STEP 174
STEP 180
STEP 175
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
STEP 184
Refer to Section 8002 and perform the Ride Control
Test Procedure.
STEP 176
Lubricate and install new O-rings.
STEP 177
Connect the hoses to the ride control valve.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-30
STEP 188
STEP 185
Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no 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.
2
1
BD03A174
STEP 186
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
Tag and disconnect the fan forward hose (1) from the
fan reversing valve. Install a plug in the hose and a
cap on the fitting. Tag and disconnect the fan reverse
hose (2) from the fan reversing valve. Install a plug in
the hose and a cap on the fitting.
STEP 187
STEP 189
4
BD03A173
BD03A174
Tag and disconnect the fan valve return hose (3) from
the fan reversing valve. Install a plug in the hose and
a cap on the fitting. 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.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-31
Installation
STEP 198
STEP 193
Place the fan reversing valve into position on the
machine.
STEP 194
Lubricate and install new O-rings in the fittings.
STEP 195
Install the bolts, washers and nuts. Tighten the nuts.
STEP 196
BD03A174
STEP 199
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 200
4
BD03A173
STEP 201
Start the engine and run the engine at low idle for two
minutes.
STEP 197
STEP 202
STEP 203
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
reservoir.
2
1
BD03A174
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8001-32
THERMAL VALVE
Removal
Installation
STEP 204
STEP 208
STEP 205
Loosen the filler cap on the hydraulic reservoir to
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
STEP 209
STEP 210
Install the bolts, washers and nuts. Tighten the nuts.
STEP 211
Connect the hoses to the thermal valve, remove and
discard tags.
STEP 212
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 213
STEP 206
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
STEP 207
Remove the mounting bolts from the thermal valve,
remove the valve from the machine.
Bur 5-4050
Issued 8-06
Printed in U.S.A.
8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,
AND PRESSURE CHECKS
Bur 5-3270
8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE HIGH PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE LOW PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3270
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8002-3
SPECIFICATIONS
Manufacturer........................................................................................................................................ Bosch-Rexroth
High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2500 psi at 2000rpm)
Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2500 psi at 2000rpm)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Circuit relief valve pressure setting
Auxiliary A and B port.................................................................................................................290 bar (4200 psi)
Bucket A port..............................................................................................................................290 bar (4200 psi)
Bucket B port..............................................................................................................................290 bar (4200 psi)
Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Brake accumulator pressure .......................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.
Bur 5-3270
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8002-4
SPECIAL TOOLS
B877168V
633L95
B877895M
632L95
B877558M
B785789M
CAS-10280 FLOWMETER
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8002-5
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and
damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is
the oil level correct?.
No
No
No
Yes
Heat the oil in the hydraulic system to
operating temperature. Operate the
machine to find which circuits have
problems.
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8002-6
No
No
No
No
No
Yes
Check the cylinder piston packing. Is the
packing good?
Yes
See Page 20. Check and adjust the circuit
relief valves. Then check the operation of
the circuit again. Does the circuit work
correctly?
Yes
The problem is repaired.
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Printed in U.S.A.
8002-7
STEP 3
STEP 1
BD06G180
1
BD00M041
1. ARTICULATION LOCK
STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.
BD06F148
STEP 4
Start the engine and run at low idle.
STEP 5
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).
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8002-8
STEP 7
The difference between the two readings should be
24 to 27 bar (350 to 390 psi).
STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump load-sense pressure.
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8002-9
STEP 3
STEP 1
BD06G180
1
2
BD00M041
1. ARTICULATION LOCK
STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.
BD06F148
STEP 4
Start the engine and run at low idle.
STEP 5
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).
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STEP 7
The difference between the two readings should be
25 to 28 bar (360 to 400 psi).
STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump differential pressure.
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8002-11
STEP 3
STEP 1
1
BD00M041
1. ARTICULATION LOCK
STEP 2
STEP 4
STEP 5
Roll the loader bucket back against the stops.
STEP 6
Record the reading on the test gauge.
BD06F148
STEP 7
Reading should be 248 to 255 bar (3600 to 3700 psi).
STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump limit pressure.
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8002-12
STEP 9
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.
NOTE: One turn of the adjustment screw will change
the pressure approximately 35 bar (500 psi).
BD06H193
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8002-13
STEP 3
STEP 1
1
BD00M041
1. ARTICULATION LOCK
STEP 2
STEP 4
STEP 5
Steer hard in either direction over relief pressure.
STEP 6
Record the reading on the test gauge.
BD06F148
STEP 7
Reading should be 239 to 243 bar (3465 to 3525 psi).
STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the steering limit pressure.
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STEP 9
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
Bur 5-3270
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8002-15
STEP 3
STEP 1
1
BD00M041
1. ARTICULATION LOCK
STEP 2
STEP 4
Start the engine and run at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
Record the reading on the test gauge.
BD06F148
STEP 7
Reading should be 198 to 202 bar (2870 to 2930 psi).
Connect two 345 bar (5000 psi) test gauge to the test
port (1) located on the large hydraulic tube on the
bottom of the pump.
Bur 5-3270
STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump cutoff pressure.
Issued 8-06
Printed in U.S.A.
8002-16
BD06G179
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8002-17
Pressure Check
STEP 6
Open the right side compartment to gain access to
the loader control handle.
STEP 7
STEP 1
Make sure that the temperature of the hydraulic oil is
at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.
To measure the
instrument cluster:
oil
temperature
with
the
STEP 8
Start and run the machine at low idle, hold the bucket
control lever in the ROLLBACK position to increase
the system pressure.
STEP 9
A pressure reading of 29.5 to 39.5 bar (425 to 575
psi) should be obtained, if pressure is not as
specified do the following steps.
STEP 2
Raise lift arms to the top and turn off the engine. Turn
the ignition switch to the RUN position.
STEP 3
Repeatedly put the loader control lever into FLOAT
position and back to neutral.
STEP 4
The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
NOTE: If 10 full actuations cannot be made, an
internal hydraulic leak exists, proceed to next step.
STEP 10
Lower the bucket to the ground and turn off the
engine. Tur n the ignition switch to the RUN
position.
STEP 11
Operate the pilot controls several times until the
gauge pressure suddenly drops to zero. The last
pressure reading before the drop to zero is the
nitrogen charge pressure in the accumulator. If the
pressure is below 13 to 15 bar (188 to 218 psi),
replace the accumulator. If accumulator test is good,
go to next step.
STEP 12
Replace the pilot controls, see section 8001, retest
the system, if test fails go to next step.
STEP 13
Replace the loader control valve, see section 8001,
retest the system.
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.
Bur 5-3270
Issued 8-06
Printed in U.S.A.
8002-18
STEP 1
Connect the flow meter (3) by disconnecting the inlet
hose (6) to the valve supply tube (13), installing a cap
(12) on the fitting at the valve supply tube (13). Refer
to illustration on page 19.
STEP 6
Using the temperature gauge on the flow meter,
continue to run the engine at high idle until the
temperature of the hydraulic oil is at least 52C to
60C (125F to 140F).
STEP 7
Run the engine at low idle, fully open the flow meter
valve.
STEP 2
STEP 8
STEP 9
STEP 3
Connect a T fitting (10) into the loader control valve
inlet hose (6) and to the flow meter inlet hose (11).
Close the flow meter valve slowly and read the flow
at 34.5 bar (500 psi) the flow should be 249 to 255
L/min (65.8 to 66.8 gpm).
STEP 4
STEP 10
Close the flow meter valve slowly and read the flow
at 2000 psi @ 2000 rpm. The flow should read 244.5
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
needle valve are in the open position. Start and run
the engine at high idle, slowly close the flow meter
valve until a pressure reading of 103 bar (1500 psi) is
obtained.
STEP 12
Continue slowly closing the flow meter valve until
3500 psi is reached. The flow should read between
120 to 122 L/min (31.6 and 32.1 gpm).
STEP 13
If any of the pump flow readings are not within
specifications, the pump may be out of calibration
a n d Te c h n i c a l S u p p o r t S e r v i c e s s h o u l d b e
contacted.
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Issued 8-06
Printed in U.S.A.
8002-19
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BS06G117
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Printed in U.S.A.
8002-20
STEP 4
STEP 1
STEP 5
4
1
STEP 6
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21C (70F).
STEP 7
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEP 8
Compare the reading to the specifications on Page 3.
STEP 9
1
1
3
Adjustment
BS03B022
1.
2.
3.
4.
5.
6.
STEP 2
Raise the lift arms and install the safety link on the lift
arm cylinder.
STEP 3
STEP 1
Loosen the lock nut. Turn the adjustment screw
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
NOTE: One turn of the adjusting screw will change
the pressure approximately 138 bar (2000 psi).
STEP 2
Check the pressure again. Repeat the adjustment as
necessary.
Bur 5-3270
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Printed in U.S.A.
8002-21
STEP 6
Dump the bucket until it hits the dump stops. Hold the
bucket in the dump position for 5 to 10 seconds.
STEP 2
Install the ar ticulation lock, star t the machine,
activate the parking brake.
STEP 3
With the pilot controller in neutral, set the ride control
rocker switch on the right side console to the Always
On position and observe the switch lamp, the lamp
should illuminate.
STEP 4
Set the ride control rocker switch to the Off position
and observe the switch lamp, the lamp should go out.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not
illuminate see section 4002 and troubleshoot the
electrical system for the ride control.
STEP 5
Raise the lift arms to the top of their travel and dump
the bucket.
STEP 7
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
their stops, place the pilot control lever in the neutral
position.
STEP 8
Set the ride control rocker switch to the Always On
position. The lift arms should rise 15 to 30 cm (6 to
12 inches) with an empty bucket.
NOTE: Test results will be for a machine with a
empty factory bucket and no attachments.
STEP 9
If there is little or no lift arm raise, the test may have
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
NOTE: If test was done to slowly repeat in the
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.
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Printed in U.S.A.
8002-22
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BC00N140
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
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8002-23
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31
29
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34
BC00N140
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.
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Printed in U.S.A.
8002-24
NOTES
Bur 5-3270
Issued 8-06
Printed in U.S.A.
8003
Section
8003
CLEANING THE HYDRAULIC SYSTEM
Bur 7-49641
8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 7-49641
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4
4
5
7
Printed in U.S.A.
8003-3
SPECIAL TOOLS
806128
806127
TR98H032
Bur 7-49641
Revised 8-06
Printed in U.S.A.
8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major
cause of the malfunction of hydraulic components.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in
several ways.
1. When you drain the oil or disconnect any line.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic
and visible.
1. Microscopic contamination occurs when very fine
particles of foreign material are in suspension in
the hydraulic oil.
2. These particles are too small to see or feel.
Microscopic contamination can be found by
identification of the following problems or by
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
problems:
spools
do
not
return
to
Bur 7-49641
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8003-5
Bur 7-49641
in
the
Revised 8-06
Printed in U.S.A.
8003-6
24. Close the valve that is installed in the hole for the
drain plug.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the
reservoir filler neck and replace filler cap.
28. Remove the valve from the hole for the drain
plug.
29. Install the drain plug.
Bur 7-49641
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8003-7
27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
Bur 7-49641
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8003-8
NOTES
Bur 7-49641
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8004
Section
8004
HYDRAULIC PUMP
Bur 5-2970
8004-2
TABLE OF CONTENTS
PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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8004-3
PUMP SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
High pressure pump (steering pump next to transmission) ............. 120 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(31.6 U.S. gpm at 2500 psi at 2000rpm)
Low pressure pump (loader pump farthermost from transmission) ... 86 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(22.5 U.S. gpm at 2500 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts...................................................................................................165 Nm (121.5 pound-feet)
Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet)
Control piston plug ..............................................................................................................90 Nm (66 pound-feet)
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-4
EQUIPMENT PUMP
7
6
4
5
4
3
10
1
11
12
13
21
22
23
24
20
19
18
14
17
15
16
30
29
15
26
27
28
25
BC06F550
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Bur 5-2970
SNAP RING
SEAL
MAIN BODY
O-RING
PLUG
CONTROL VALVE
CAP SCREW
PISTON ROD
CONTROL PISTON
SHAFT
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
TAPERED BEARING
BEARING RACE
SHIM
SPRING
HALF BEARING
SWASH PLATE
PISTONS
RETAINING PLATE
BALL
CYLINDER
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
PRESSURE PINS
BACKUP PLATE
SPRING
SNAP RING
PORT PLATE
SHIM
TAPERED BEARING
BEARING RACE
DOWEL PIN
END COVER
Issued 8-06
Printed in U.S.A.
8004-5
Disassembly
STEP 3
STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.
STEP 2
BC06F552
STEP 4
BC06F551
BC06F553
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-6
STEP 5
STEP 6
BC06F555
BC06F554
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-7
STEP 7
STEP 9
BC06F558
STEP 10
BC06F556
STEP 8
BC06F559
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-8
STEP 11
STEP 14
BC06F560
STEP 12
BC06F563
STEP 15
BC06F561
STEP 13
BC06F564
BC06F562
Bur 5-2970
Issued 8-06
Printed in U.S.A.
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
STEP 20
BC06F565
STEP 18
BC06F568
STEP 21
BC06F566
BC06F569
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-10
STEP 22
STEP 24
BC06F570
STEP 23
BC06F572
STEP 25
BC06F571
Bur 5-2970
BC06F573
Issued 8-06
Printed in U.S.A.
8004-11
Assembly
STEP 27
STEP 26
BC06F575
BC06F574
STEP 28
BC06F576
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-12
STEP 29
STEP 31
BC06F579
STEP 32
BC06F577
STEP 30
BC06F578
BC06F580
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-13
STEP 33
STEP 34
BC06F582
STEP 35
BC06F581
BC06F583
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-14
STEP 36
STEP 39
BC06F584
STEP 37
BC06F585
BC06F587
STEP 38
BC06F586
Bur 5-2970
Issued 8-06
Printed in U.S.A.
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
Bur 5-2970
Issued 8-06
Printed in U.S.A.
8004-16
STEP 42
STEP 43
BC06F591
BC06F590
Bur 5-2970
Issued 8-06
Printed in U.S.A.
Section
8005
8005
Bur 5-2980
8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-2980
Issued 8-06
3
4
5
6
7
8
9
14
14
18
18
Printed in U.S.A.
8005-3
SPECIFICATIONS
Manufacturer................................................................................................................................................... Rexroth
Special Torques
End plate mounting bolts.................................................................................................. 70 Nm (51.5 pound feet)
Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound inches)
Allen head plugs.............................................................................................................. 240 Nm (177 pound feet)
Allen head locking screw................................................................................................ 100 Nm (73.7 pound feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches)
Anticavitation valves ....................................................................................................... 100 Nm (73.7 pound feet)
Combination anticavitation and circuit relief ................................................................. 200 Nm (147.5 pound feet)
Main relief valve pressure settings (XT and Z-Bar) ............................................... 248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A port (XT and Z-Bar) ....................................................................................................152 bar (2205 psi)
Bucket B port (XT and Z-Bar) ....................................................................................................290 bar (4206 psi)
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-4
1
2
4
3
5
22
6
6
21
20
19
8
18
17
16
10
11
6
15
14
8
12
12
13
BS03C033
1. BOLT
2. WASHER
3. LOCKING SCREWS
4. PLATE
5. REGENERATION
RELIEF VALVE
6. O-RINGS
14. PLUG
21. CONE
11. HOUSING
17. SPRING
12. PLUG
2 SPOOL VALVE HOUSING CONFIGURATION
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-5
26
27
25
24
23
28
6
31
29
30
6
6
33
31
34
6
34
24
33 32
24
23
23
35
30
32
29
BC06F593
6.
23.
24.
25.
26.
O-RINGS
SPRING RETAINER
SPRING
SPRING
COVER
27.
28.
29.
30.
31.
BOLT
PISTON
CAP NUT
JAM NUT
PISTON
32.
33.
34.
35.
BOLT
COVER
ADJUSTING ROD
SPOOL
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-6
37
36
37
BS03C036
36. HOUSING
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-7
38
39
BS03C035
38. NUT
39. STUD
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-8
31
29
30
33
6
34
23
24
32
23
35
33
31
23
24
6
34
29
32
30
BS03C037
Bur 5-2980
O-RINGS
SPRING RETAINER
SPRING
CAP NUT
JAM NUT
31.
32.
33.
34.
35.
PISTON
BOLT
COVER
ADJUSTING ROD
SPOOL
Issued 8-06
Printed in U.S.A.
8005-9
DISSASEMBLY
STEP 1
STEP 7
STEP 2
STEP 8
STEP 9
STEP 3
Remove bolts (32), covers (33), spring (24), and
spring retainer (23).
STEP 10
STEP 4
STEP 11
STEP 5
STEP 6
Remove locking screw (22) and cone (21).
STEP 12
STEP 13
STEP 14
Remove pilot pressure reducing valve (9).
STEP 15
Remove bolts (1) and washers (2), remove plate (4)
from housing (11).
NOTE: For 4 spool configuration remove nut (38)
from stud (39), remove housings (36) from housing
(11).
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-10
STEP 16
STEP 18
2
1
2
BS03C025
BS03C027
1. O-RINGS
2. THRUST RINGS
1. O-RINGS
2. THRUST RING
STEP 17
STEP 19
1
2
1
1
BS03C026
1. O-RINGS
2. THRUST RINGS
Bur 5-2980
BS03C028
1. O-RINGS
2. THRUST RING
3. SPOOL SEAL
Issued 8-06
Printed in U.S.A.
8005-11
STEP 20
1
2
1
1
2
2
BS03C029
1. O-RINGS
2. THRUST RINGS
Remove and discard O-rings and thrust rings from pressure relief valve (20).
STEP 21
1
1
2
1
2
1
BS03C030
1. O-RINGS
2. THRUST RINGS
Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-12
STEP 22
1
2
1
BS03C031
1. O-RINGS
2. COIL
Remove and discard O-rings and thrust rings from anticavitation valve (13).
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-13
STEP 23
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).
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-14
INSPECTION
1. Discard all O-rings, thrust rings, and spool seals.
2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for
damage and wear.
ASSEMBLY
STEP 1
4
A
See Note
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.
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-15
STEP 2
1
2
1
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
1
2
1
2
BS03C030
1. O-RINGS
2. THRUST RINGS
Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm
(73.7 pound feet).
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-16
STEP 4
1
2
1
1
2
2
BS03C029
1. O-RINGS
2. THRUST RINGS
Install new O-rings and thrust rings on pressure relief valve (20).
Bur 5-2980
Issued 8-06
Printed in U.S.A.
8005-17
STEP 5
STEP 8
2
1
1
2
BS03C025
BS03C028
STEP 6
STEP 9
1. O-RINGS
2. THRUST RINGS
1. O-RINGS
2. THRUST RING
3. SPOOL SEAL
STEP 10
Install and torque locking screw (14) to 100 Nm
(73.7 pound feet).
2
1
STEP 11
STEP 12
BS03C026
1. O-RINGS
2. THRUST RINGS
STEP 13
STEP 7
STEP 14
1
STEP 15
BS03C027
1. O-RINGS
Bur 5-2980
2. THRUST RING
Issued 8-06
Printed in U.S.A.
8005-18
STEP 16
STEP 1
STEP 17
STEP 18
Install cone (18), spring (17), locking screw (16).
Torque locking screw to 100 Nm (73.7 pound feet).
STEP 19
Install cone (21) and locking screw (22). Torque
locking screw to 40 Nm (30 pound feet).
that
are
STEP 2
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21C (70F).
STEP 3
STEP 20
STEP 4
STEP 21
STEP 5
STEP 22
Install spring retainers (23), spring (24 and 25), cover
(26), and bolts (27). Torque bolts to 6 Nm (53 pound
inches).
NOTE: Prior to installation in the machine, circuit
reliefs can be tested.
STEP 2
STEP 23
Install valve in machine, see section 8001.
STEP 24
Check loader limit pressure, see section 8002.
Bur 5-2980
Issued 8-06
Printed in U.S.A.
Section
8006
8006
CYLINDERS
Bur 5-3280
8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3280
Issued 8-06
3
3
3
4
4
4
6
7
7
7
9
11
11
11
12
12
12
Printed in U.S.A.
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
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-4
LIFT CYLINDER
Disassembly
Inspection
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-5
13
5
6
7
4
8
11
9
10
15
12
17
16
18
14
1
3
2
2
3
BC05J002
1.
2.
3.
4.
5.
TUBE
BUSHING
WIPER
GLAND
WIPER
6.
7.
8.
9.
10.
ROD SEAL
BUFFER SEAL
BUSHING
BACKUP RING
O-RING
11.
12.
13.
14.
15.
O-RING
SCREW
ROD
BOLT
PISTON
16. SEAL
17. RING
18. WEAR RING
LIFT CYLINDER
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-6
Assembly
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).
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-7
BUCKET CYLINDERS
Disassembly
1. Clean the outside of the cylinder. If the hoses
were removed with the cylinder, remove the
hoses from the cylinder.
2. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Do not damage the
tube (1).
3. Loosen and remove the cap screws (2) and
hardened washers (18) from the gland (3) and
the tube (1).
4. Pull the piston rod (4) straight out of the tube (1)
to prevent damage to the tube (1).
5. Fasten the piston rod eye or yoke in a vise and
put a support under the piston rod (4) near the
piston (7). Put a shop cloth between the support
and the piston rod (4) to prevent damage to the
piston rod (4).
6. Remove the retaining ring (10) that fastens the
pin (11) in the piston (7) and piston rod (4).
7. Remove the pin (11) from the piston (7) and the
piston rod (4).
8. Turn the piston (7) off the piston rod (4) and
remove the piston (7).
9. Remove the gland (3) from the piston rod (4).
Inspection
1. Discard the parts that were removed from the
piston and the gland.
2. Clean all parts in cleaning solvent. Use only lint
free cloths for cleaning and drying.
3. Check to be sure that the piston rod is straight. If
the piston rod is not straight, replace it with a
new piston rod.
4. Illuminate the inside of the tube for deep grooves
and other damage. If there is any damage to the
tube, replace it with a new tube.
5. Remove any small scratches on the piston rod or
inside the tube with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
6. Inspect the bushings in the piston rod eye or
yoke and the tube. Replace as required.
7. Inspect the gland for rust and clean and remove
rust as necessary.
8. Inspect the gland end of the tube for sharp edges
that will cut the gland O-ring and remove as
necessary.
9. Inspect the piston for damage and wear. If the
piston is damaged or worn, replace it with a new
piston.
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-8
19
20
19
4
2
18
3
17
15
12
16
11
7
13
14
8
8
6
1
5
10
19
20
19
BC05M026
1.
2.
3.
4.
5.
6.
TUBE
CAP SCREW
GLAND
PISTON ROD
WEAR RING
SEAL
7.
8.
9.
10.
11.
PISTON
BACKUP RING
O-RING
RETAINING RING
PIN
12.
13.
14.
15.
16.
WIPER
WIDE SEAL
NARROW SEAL
BACKUP RING
O-RING
17.
18.
19.
20.
BUSHING
HARDENED WASHER
SEAL
BUSHING
BUCKET CYLINDER
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-9
Assembly
NOTE: If a new gland is being used, put the part
number of the cylinder on the new gland.
11
10
4
GS98J804
PISTON AND PISTON ROD HOLE ALIGNMENT
17. Install the pin (11) in the piston (7) and the piston
rod (4).
18. Install the retaining ring (10) in the pin (11).
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-10
19. Install a new wear ring (5) in the wide groove on
the OD of the piston (7).
20. Install a new seal (6) in the groove on the OD of
the piston (7).
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-11
Installation
4
2
1
2
BS01C003
1. WIPER
2. BUSHING
Bur 5-3280
Issued 8-06
Printed in U.S.A.
8006-12
2
1
1
2
Installation
4
1
2
1
BS03B201
1. WIPER
2. BUSHING
Bur 5-3280
Issued 8-06
Printed in U.S.A.
Section
8007
8007
Bur 6-42600
8007-2
TABLE OF CONTENTS
coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 6-42600
Issued 4-03
3
3
3
3
Printed in U.S.A.
8007-3
STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve.
STEP 12
Install nut (1) to secure solenoid (2).
STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3).
STEP 3
Remove valve cartridge (3) from valve housing (7).
STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).
4
6
STEP 6
6
6
5
STEP 7
5
7
STEP 8
Connect an ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve
cartridge (3) if ohmmeter indicates short or open
circuit.
Assembly
STEP 9
Install new O-rings (4 and 5) and back-up rings (6) as
shown.
GS98J818
1.
2.
3.
4.
NUT
SOLENOID
VALVE CARTRIDGE
O-RING
5. O-RING
6. BACKUP RING
7. VALVE HOUSING
STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
Bur 6-42600
Issued 4-03
Printed in U.S.A.
8007-4
NOTES
Bur 6-42600
Issued 4-03
Printed in U.S.A.
8013
Section
8013
RIDE CONTROL ACCUMULATOR
Bur 5-3000
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3000
Issued 8-06
3
3
3
4
5
5
5
5
7
Printed in U.S.A.
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)
SPECIAL TOOLS
94L95
Bur 5-3000
B786441M
Issued 8-06
Printed in U.S.A.
8013-4
94L95
Bur 5-3000
Issued 8-06
Printed in U.S.A.
8013-5
ACCUMULATOR
Disassembly
Assembly
7. Lubricate the seals (2) with clean oil and start the
gland (3) into the body (1).
Inspection
1. Clean body (1), gland (3), cap (8) and piston (4)
in cleaning solvent, refer to the illustration on
page 6.
2. Inspect the piston (4) for cracks, burrs or other
damage.
3. Inspect the bore of the body (1) for scratches or
scoring using a light.
Bur 5-3000
Issued 8-06
Printed in U.S.A.
8013-6
2
3
10
11
12
BS01B224
1.
2.
3.
4.
BODY
SEALS (2)
GLAND
PISTON
5.
6.
7.
8.
WEAR RING
BACKUP RING
O-RING
CAP
9.
10.
11.
12.
SCREW
O-RING
GUARD
PRESSURE VALVE
Bur 5-3000
Issued 8-06
Printed in U.S.A.
8013-7
GS98N801
1. VALVE C
2. TO NITROGEN TANK
3. VALVE A
4. VALVE B
5. VALVE D
6. TO ACCUMULATOR
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49 C (120 F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.
Bur 5-3000
Issued 8-06
Printed in U.S.A.
8013-8
1. Close the shutoff valve A by turning it all the way
to the left (counterclockwise), refer to the
illustration on page 7.
2. Open valve B by turning it out all the way to the
left (counterclockwise).
3. Close valve C by turning it all the way to the right
(clockwise).
4. Close the gauge valve D by turning it all the way
to the right (clockwise).
5. Connect the charging hose to the nitrogen supply
tank.
6. SLOWLY turn valve A clockwise while watching
the high pressure gauge. Stop turning valve A
when the needle on the gauge reaches 31 bar
(450 psi).
NOTE: If the needle goes over the needed pressure,
quickly open and close valve D and check the
pressure setting again.
The charging kit is now ready to be installed on the
accumulator.
7. Remove the two cap screws (9) and the
protection bracket (11) from the body (1) on the
accumulator, refer to the illustration on pages 6.
8. Remove the valve cap from the pressure valve
(12) on the accumulator.
9. Back off the needle valve on the accumulator end
of the charging hose by tur ning it
counterclockwise to the maximum amount. This
prevents nitrogen from escaping from the
accumulator when the charging hose is attached
to the accumulator gas charging valve.
10. Install the charging hose fitting onto the
accumulator pressure valve (12).
11. Tighten the needle valve by turning it clockwise.
Slowly open the gauge valve D and observe the
reading on the gauge. This reading is the
nitrogen pressure level inside the accumulator.
Bur 5-3000
CHARGE PRESSURE
1606 KPA
233 PSI
1634 KPA
237 PSI
1669 KPA
242 PSI
1696 KPA
246 PSI
1724 KPA
250 PSI
1751 KPA
254 PSI
1779 KPA
258 PSI
1813 KPA
263 PSI
1841 KPA
267 PSI
1868 KPA
271 PSI
1896 KPA
275 PSI
Issued 8-06
Printed in U.S.A.
8014
Section
8014
RIDE CONTROL VALVE
Bur 5-3010
8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3010
Issued 8-06
3
3
3
4
Printed in U.S.A.
8014-3
10
11
13 12
7
15
14
5
4
16
3
2
17
BC05B015.
1.
2.
3.
4.
5.
PLUG
CAP SCREW
BUSHING
SPRING CARRIER
SPRING
6.
7.
8.
9.
SPRING
SPOOL
PLUG
PLUG
10.
11.
12.
13.
Dissasembly
14.
15.
16.
17.
POPPET
ORFICE
VALVE BLOCK
RELIEF VALVE
STEP 8
Remove the pressure relief valve (17).
STEP 1
Remove ride control valve, refer to section 8001.
STEP 2
Inspection
1. Discard all O-rings.
STEP 3
STEP 4
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).
Bur 5-3010
Issued 8-06
Printed in U.S.A.
8014-4
Assembly
STEP 6
STEP 1
Install new O-rings.
STEP 2
STEP 7
STEP 3
STEP 9
STEP 4
Install and torque orifice (15) to 15 Nm (11 lb-ft),
install poppet (14), install and torque orifice (13) to
15 Nm (11 lb-ft).
STEP 8
STEP 10
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.
Bur 5-3010
Issued 8-06
Printed in U.S.A.
SECTION INDEX
MOUNTED EQUIPMENT
Section Title
Section Number
Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant . . . . . . . . . . . . .9002
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010
CASE, LLC.
700 State Street
Racine, WI 53404 U.S.A.
Bur 5-3290
9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM
CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT
Bur 5-4030
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-4030
Issued 8-06
3
5
6
6
8
8
9
10
11
12
12
13
13
13
14
14
15
16
16
17
17
18
18
18
19
19
20
20
21
22
22
23
23
24
24
25
25
26
Printed in U.S.A.
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
M171B
PERSONAL INJURY OR DEATH.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-4
299L7C
A22094
A22090
109L7
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-5
OPERATION
The refrigerant circuit of the air conditioning system
contains five major components: compressor,
condenser, receiver-drier, expansion valve and
evaporator. These components are connected by
tubes and hoses and operate as a closed system.
The air conditioner system is charged with HFC-134a
refrigerant.
3
5
4
208L95
1. EXPANSION VALVE
2. EVAPORATOR
Bur 5-4030
3. COMPRESSOR
4. CONDENSER
5. RECEIVER-DRIER
Issued 8-06
Printed in U.S.A.
9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check
the following and correct as necessary:
1. - Obtain service history if possible.
Problem: No Cooling
Compressor Runs
No
Yes
Internal System Problem
See Pressure Testing, Page 13
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-7
Problem:
Not Enough Cooling
Problem:
Erratic Cooling
MECHANICAL
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.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-8
SYSTEM CHECKS
Mechanical Compressor Check
Compressor and Fan Belts
Compressor Clutch
1. The
compressor
pulley
and
the
compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Use a straight edge to check pulley
alignment. Adjust the compressor
mounting bracket if needed.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-9
Blower Motor
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-10
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-11
Condenser
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-12
Evaporator/Heater Core
Evaporator/Heater Core
Filters
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-13
PRESSURE TESTING
Manifold Gauge Set
NOTE: The gauge set is not accurate enough to
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether
undercharge or overcharge exists, and then
evacuate, reclaim and recharge system with the
recommended quantity (charge) of HFC-134a.
The manifold gauge set is the most important tool
used to service the air conditioning system. The
manifold gauge set is used to measure the high and
low pressures of the system, as a tool to troubleshoot
for correct refrigerant charge quantity, system
diagnosis, and operating efficiency. The manifold
gauge set can read both the high (discharge) and low
(suction) sides at the same time, since pressure must
be compared in order to make a diagnosis of system
operation.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-14
PRESSURE-TEMPERATURE CHART
AIR LOUVER (BEHIND
SEAT)
MAXIMUM TEMP.
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION
F (C)
psi (bar)
psi (bar)
F (C)
AMBIENT
NORMAL LOW
NORMAL HIGH
80 (27)
9 to 12
145 to 165
(0.62 to 0.83)
(10 to 11.53)
11 to 15
190 to 210
(0.76 to 1.04)
(13.10 to 14.48)
16 to 18
210 to 230
(1.10 to 1.24)
(14.48 to 15.86)
17 to 19
235 to 255
(1.17 to 1.31)
(16.2 to 17.58)
20 to 21
260 to 280
(1.38 to 1.45)
(17.93 to 19.31)
22 to 24
290 to 310
(1.93 to 2.14)
(20 to 21.37)
90 (32)
95 (35)
100 (38)
105 (41)
110 (43)
55 (14)
61 (18)
63 (20)
66 (22)
68 (23)
72 (25)
LOW PRESSURE
GAUGE
HIGH PRESSURE
GAUGE
SEE
PAGE
NO COOLING
VERY LOW
VERY LOW
16
NO COOLING
HIGH
HIGH
17
NORMAL TO HIGH
NORMAL
19
LOW
LOW
20
HIGH
LOW
22
HIGH
HIGH
23
INTERMITTENT COOLING
NORMAL
NORMAL
24
NOISE IN SYSTEM
NORMAL TO HIGH
HIGH
25
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-15
STEP 4
STEP 5
STEP 2
STEP 6
STEP 3
Connect the hose from the low pressure gauge to the
port on the suction hose.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-16
PROBLEM: NO COOLING
VERY LOW
VERY LOW
476L7
Yes
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-17
HIGH
HIGH
476L7
Yes
air
to
remove
oil
from
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible
problems.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-18
on
evaporator
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
table represent the boiling point for HFC-134a.
Refrigerant Contamination
50 (10)
55 (13)
60 (16)
65 (18)
70 (21)
75 (24)
80 (27)
85 (29)
90 (32)
95 (35)
100 (38)
102 (39)
104 (40)
106 (41)
108 (42)
110 (43)
112 (44)
114 (46)
116 (47)
118 (48)
120 (49)
45 (3.1)
51 (3.5)
57 (3.9)
64 (4.4)
71 (4.9)
78 (5.4)
88 (6.1)
95 (6.6)
104 (7.2)
114 (7.9)
124 (8.6)
129 (8.9)
133 (9.2)
138 (9.5)
142 (9.8)
147 (10.1)
152 (10.5)
157 (10.8)
162 (11.2)
167 (11.5)
172 (11.9)
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-19
NORMAL TO
SLIGHTLY HIGH
NORMAL
476L7
4. Replace receiver-drier.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
7. Charge system with new refrigerant. See
Section 9003.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-20
LOW
LO W
476L7
or
frost
on
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-21
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-22
HIGH
LOW
476L7
4. Replace compressor.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-23
HIGH
HIGH
476L7
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-24
NORMAL
NORMAL
476L7
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-25
NORMAL
TO HIGH
HIGH
476L7
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9002-26
3/8 inch
1/2 inch
5/8 inch
THREAD SIZE
M10 -1.25
5/8-18
3/4-18
OR
3/4-16
7/8-18
OR
7/8-14
1-14
STEEL TO STEEL
31-36 Nm
31-36 Nm
40-46 Nm
45-52 Nm
45-52 Nm
ALUMINUM TO BRASS
10-14 Nm
10-14 Nm
24-30 Nm
30-37 Nm
45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.
Bur 5-4030
Issued 8-06
Printed in U.S.A.
9003
Section
9003
AIR CONDITIONER SYSTEM SERVICE
Bur 5-3030
9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3030
Issued 8-06
3
3
4
5
7
10
Printed in U.S.A.
9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)
SPECIAL TOOLS
A22094
Bur 5-3030
109L7
Issued 8-06
Printed in U.S.A.
9003-4
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
M171B
PERSONAL INJURY OR DEATH.
ATTENTION: Only authorized technicians certified
by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems. It is mandatory that all
refrigerant must be RECOVERED and RECYCLED
when removed from a system during servicing.
Refrigerant HFC-134a is the most stable and easiest
to work with of the refrigerants now used in air
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFCs) which are
harmful to the Earths ozone layer.
Safety procedures must be followed when working
with refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
Liquid refrigerant getting into the eyes can cause
ser ious injur y. Do the following if you get
refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.
Bur 5-3030
Issued 8-06
Printed in U.S.A.
9003-5
STEP 3
STEP 1
A22114
STEP 4
BD03A213
STEP 2
A22107
BD03B001
Bur 5-3030
Issued 8-06
Printed in U.S.A.
9003-6
STEP 5
STEP 7
A22112
A22110
Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
STEP 8
STEP 6
A22111
STEP 9
A22108
BD03A213
Bur 5-3030
Issued 8-06
Printed in U.S.A.
9003-7
STEP 11
STEP 10
A22113
STEP 12
BD03B001
A22115
Bur 5-3030
Issued 8-06
Printed in U.S.A.
9003-8
STEP 13
STEP 16
A22113
A22123
Program 3.5 lbs and press the enter key. The display
will flash once indicating the programmed data has
been accepted.
STEP 14
STEP 17
STEP 15
A22113
A22107
Bur 5-3030
Issued 8-06
Printed in U.S.A.
9003-9
STEP 18
STEP 21
A22114
BD03B001
STEP 22
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure
indicator lamp will illuminate when the relay is
actuated by a low or high pressure and the
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.
BD03B213
STEP 20
A22117
Issued 8-06
Printed in U.S.A.
9003-10
AIR LOUVER
MAXIMUM TEMP.
F (C)
80 (27)
9 to 12
(0.62 to 0.83)
145 to 165
(10 to 11.5)
55 (14)
90 (32)
11 to 15
(0.76 to 1.04)
190 to 210
(13.1 to 14.5)
61 (18)
95 (35)
16 to 18
(1.10 to 1.24)
210 to 230
(14.5 to 15.8)
63 (20)
100 (38)
17 to 19
(1.17 to 1.31)
235 to 255
(16.2 to 17.6)
66 (22)
105 (41)
20 to 21
(1.38 to 1.45)
260 to 280
(17.9 to 19.3)
68 (23)
110 (43)
22 to 24
(1.93 to 2.14)
290 to 310
(20 to 21.4)
72 (25)
Bur 5-3030
Issued 8-06
Printed in U.S.A.
Bur 5-3040
9004
Section
9004
9004-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPANSION VALVE, EVAPORATOR/HEATER CORE,
HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3040
Issued 8-06
3
4
5
5
6
8
9
14
19
19
20
Printed in U.S.A.
9004-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
M171B
PERSONAL INJURY OR DEATH.
ATTENTION: Only authorized technicians certified
by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems. It is mandatory that all
refrigerant must be RECOVERED and RECYCLED
when removed from a system during servicing.
Refrigerant HFC-134a is the most stable, and easiest
to work with of the refrigerants now used in air
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFCs) which are
harmful to the earths ozone layer.
Safety procedures must be followed when working
with Refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
Liquid refrigerant getting into the eyes can cause
ser ious injur y. Do the following if you get
refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-4
SPECIAL TOOLS
A22094
Bur 5-3040
BS03H012
Issued 8-06
Printed in U.S.A.
9004-5
COMPRESSOR
Removal
STEP 4
STEP 1
Place the master disconnect switch in the OFF
position.
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD06F116
STEP 5
BD06F113
BD06F117
BD06F114
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-6
Installation
STEP 6
STEP 9
Place the compressor into position on the machine.
STEP 10
BD06F117
STEP 7
BD06F117
STEP 11
BD06F117
STEP 8
Remove the compressor from the machine.
Bur 5-3040
BD06F117
Issued 8-06
Printed in U.S.A.
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
BD06F117
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-8
7
4
2
1
8
9
10
18
17
12
14
11
13
16
15
BS06G118
1.
2.
3.
4.
5.
6.
Bur 5-3040
EVAPORATOR
UPPER BOX PPE
COVER PPE
SOLENOID DRIVER
UPPER BOX
BOLT
7.
8.
9.
10.
11.
12.
WASHER
GROMMET
HEATER CORE
HEATER VALVE 24V
THERMOSTAT
LOWER BOX
13.
14.
15.
16.
17.
18.
Issued 8-06
Printed in U.S.A.
9004-9
Removal
STEP 23
STEP 17
Park the machine on a level surface and lower the
bucket to the floor.
STEP 18
If changing any air conditioning components,
discharge the air conditioning system according to
the instructions in Section 9003.
STEP 19
BD06G212
STEP 24
BD02N160
BD06G213
STEP 20
Place the master disconnect in the OFF position.
STEP 25
STEP 21
Disconnect the wiring harness from the operators
seat (if equipped with air seat option).
STEP 22
BD06G214
STEP 26
BD06G202
Issued 8-06
Printed in U.S.A.
9004-10
STEP 27
STEP 30
BD06G215
BD06G217
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,
closed, position.
STEP 28
STEP 31
BD06G216
BD06G218
STEP 29
STEP 32
BD06G240
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-11
STEP 33
STEP 36
BD06G219
BD06G203
STEP 34
Remove the upper box up and rest it against the
console.
STEP 37
STEP 35
BD06G236
BD06G220
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-12
NOTE: If replacing the heater control valve, heater
core, air conditioning expansion valve, air
conditioning evaporator core do steps 38 through 47,
if replacing electrical components go to step 48.
STEP 40
STEP 38
BD06G206
STEP 41
BD06G204
STEP 39
BD06G237
STEP 42
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
BD06G236
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-13
STEP 43
STEP 49
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
the control valve.
STEP 47
Remove and discard the O-rings from the heater
control valve.
BD06G208
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
the vain. Remove the mounting screws and remove
the motor.
STEP 50
STEP 48
1
3
2
BD06G209
BD06G207
1. RESISTORS
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR
Bur 5-3040
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
switches as required.
Issued 8-06
Printed in U.S.A.
9004-14
Installation
STEP 53
STEP 51
1
1
2
3
3
2
BD06G207
BD06G209
1. RESISTORS
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR
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
BD06G236
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-15
STEP 59
STEP 61
3
BD06G237
STEP 60
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
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
BD06G204
STEP 63
BD06G238
Issued 8-06
Printed in U.S.A.
9004-16
STEP 64
STEP 67
BD06G210.
BD06G203
STEP 65
STEP 68
BD06G239
BD06G241
STEP 66
STEP 69
BD06G216
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-17
STEP 70
STEP 74
BD06G242
BD06G214
STEP 71
STEP 75
BD06G215
BD06G213
STEP 72
STEP 76
BD06G243
Install the right rear floor mat into the cab, if machine
is equipped with air ride seat make sure to pull the
wiring up above the mat for the seat.
BD06G202
STEP 73
Install the remainder of the floor mat.
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-18
STEP 77
STEP 79
STEP 78
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-19
STEP 85
STEP 80
Park the machine on a level surface and lower the
bucket to the ground.
STEP 81
Place the master disconnect switch in the OFF
position.
STEP 82
Discharge the air conditioning system according to
the instructions in Section 9003.
BS03A107
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.
STEP 83
STEP 86
STEP 87
BD01D142
1. COVER
2. CONDENSER
STEP 84
BS03A109
BD03A109
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-20
Installation
STEP 88
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.
STEP 90
Disconnect the trinary switch, remove the mounting
bolt, remove the receiver drier and bracket.
BS03A109
STEP 93
BS03A107
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.
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-21
STEP 97
STEP 98
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 99
Place the master disconnect switch in the ON
position.
BD06G211
Bur 5-3040
Issued 8-06
Printed in U.S.A.
9004-22
NOTES
Bur 5-3040
Issued 8-06
Printed in U.S.A.
Section
9006
9006
LOADER
Bur 5-3300
9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-3300
Issued 8-06
3
3
3
3
3
4
5
7
9
Printed in U.S.A.
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
3
7
3
2
10
9
7
B0740A88J
1.
2.
3.
4.
5.
RETAINING RING
TOOTH POINT
TOOTH SHANK
NUT
HARDENED WASHER
6.
7.
8.
9.
10.
BOLT
CUTTING EDGE
PLOW BOLT
NUT
CORNER TOOTH
Issued 8-06
Printed in U.S.A.
9006-4
2
6
1
3
4
BS01C083
3. TARGET BAR
4. PROXIMITY SWITCH MOUNTING BRACKET
5. PROXIMITY SWITCH
6. PROXIMITY SWITCH GUARD
Bur 5-3300
Issued 8-06
Printed in U.S.A.
9006-5
5
6
3
2
1
BS01C081
3. PROXIMITY SWITCH
4. LIFT ARM
Issued 8-06
Printed in U.S.A.
9006-6
2
A
3
B
BS01C082
MACHINE
APPROXIMATE
RESULTING RETURN TO
TRAVEL HINGE PIN
HEIGHT
821E
56 mm (2.2 inches)
APPROXIMATE
RESULTING HEIGHT
CONTROL HINGE PIN
HEIGHT
42 mm (1.6 inches)
Bur 5-3300
Issued 8-06
Printed in U.S.A.
9006-7
BD01G009
1
2
1. ELECTRICAL CONNECTION
2. PROXIMITY SWITCH
Bur 5-3300
Issued 8-06
Printed in U.S.A.
9006-8
10
19
18
22
20 18
8
16
6
15
17
2
11
1
21
5
4
14
5
12
3
13
23
BS01G022
1.
2.
3.
4.
5.
6.
CROSS MEMBER
LOADER FRAME
PIVOT PIN
LIFT CYLINDER
PIVOT PIN
LIFT CYLINDER
7.
8.
9.
10.
11.
12.
PIVOT PIN
BUCKET CYLINDER
PIVOT PIN
PIVOT PIN
BELL CRANK
BOLT
13.
14.
15.
16.
17.
18.
WASHER
SPACER
BOLT
WASHER
SPACER
WASHER
19.
20.
21.
22.
23.
BOLT
WASHER
SPACER
WIPER
DUMP LINK
Bur 5-3300
Issued 8-06
Printed in U.S.A.
9006-9
15. Install the pivot pin (7) in the bell crank (11) and
the piston rod eye of the bucket cylinder (8).
16. Install the bolt (15), washer (16), and spacer (17)
that fasten the pivot pin (7). Tighten the bolt.
Bur 5-3300
27. Remove the driver and install the pivot pin (3).
28. Install the bolt (12), washer (13), and spacer(14)
that fasten the pivot pin (3). Tighten the bolt.
29. Repeat Steps 26, 27, and 28 for the other lift
cylinder (4 or 6). Stop the engine.
30. Lubricate the pivot pins with molydisulfide
grease.
31. Disconnect the chain hoist from the cross
member (1) of the loader frame (2).
32. Tighten the filler plug in the reservoir.
33. If the machine is equipped with auxiliary
hydraulics, start the engine and run the engine at
low idle.
34. Slowly extend and retract the clam cylinders four
times to remove air from the auxiliary circuit.
35. Stop the engine, check the level of the oil in the
reservoir, and check for leaks. Add oil to the
reservoir as required.
Issued 8-06
Printed in U.S.A.
9006-10
NOTES
Bur 5-3300
Issued 8-06
Printed in U.S.A.
Section
9007
9007
Bur 5-4070
9007-2
TABLE OF CONTENTS
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . .
CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bur 5-4070
Issued 8-06
3
3
4
4
9
Printed in U.S.A.
9007-3
Bur 5-4070
Issued 8-06
Printed in U.S.A.
9007-4
STEP 5
STEP 1
Park machine on a level surface and lower bucket to
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
BD06G191
STEP 2
STEP 6
BD01F143
BD06G186
STEP 3
STEP 7
STEP 4
BD06G189
BD01F184
Bur 5-4070
Issued 8-06
Printed in U.S.A.
9007-5
STEP 8
STEP 11
BD06G194
BD06G192
STEP 9
STEP 12
2
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
BD06F207
STEP 13
STEP 10
BD06F208
BD06G193
Issued 8-06
Printed in U.S.A.
9007-6
STEP 14
STEP 19
BD06F209
BD06G187
STEP 15
STEP 20
BD06F210
BD06G188
STEP 16
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
Bur 5-4070
Issued 8-06
Printed in U.S.A.
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
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.
Bur 5-4070
Issued 8-06
Printed in U.S.A.
9007-8
1
2
1
2
4
4
5
5
6
6
BC06G031
1. NUT
2. WASHER
3. RUBBER MOUNT
Bur 5-4070
4. RUBBER MOUNT
5. WASHER
6. BOLT
Issued 8-06
Printed in U.S.A.
9007-9
Installation
STEP 32
STEP 26
Check rubber mounts (3 an 4) for deterioration, tears,
defor mation, or other damage; replace rubber
mounts as necessary.
STEP 27
BD06G188
STEP 33
BD01D388
STEP 28
Install washers, bolts, and nuts to secure cab to rear
chassis. Tighten bolts to a torque of 773 to 854 Nm
(570 to 630 pound feet)
STEP 29
BD06G192
STEP 34
STEP 30
Remove lifting eyes.
STEP 31
BD06G193
BD06G185
Issued 8-06
Printed in U.S.A.
9007-10
STEP 35
STEP 38
3
BD06G186
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
STEP 36
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
STEP 37
BD06G194
Bur 5-4070
Issued 8-06
Printed in U.S.A.
9007-11
8
4
6
7
1
5
5
2
1
8
3
6
4
BC05M092
Bur 5-4070
Issued 8-06
Printed in U.S.A.
9007-12
4
3
4
6
2
7
7
1
7
1
5
BC05M091
1.
2.
3.
4.
5.
6.
7.
Bur 5-4070
1.
2.
3.
4.
5.
6.
7.
Issued 8-06
Printed in U.S.A.
9007-13
1
5
4
2
1
3
2
3
4
5
BC05M090
1.
2.
3.
4.
5.
6.
Bur 5-4070
1.
2.
3.
4.
5.
6.
Issued 8-06
Printed in U.S.A.
9007-14
STEP 40
STEP 43
BD06F210
BD06F208
STEP 44
STEP 41
BD06F209
STEP 42
BD06F207
STEP 45
BD06G187
Bur 5-4070
BD06G191
Issued 8-06
Printed in U.S.A.
9007-15
STEP 46
STEP 49
Start engine and run engine at low idle. Run engine
at operating temperature for approximately five
minutes to completely mix Ethylene Glycol and
water. When coolant is at operating temperature,
stop engine. When engine has cooled, check coolant
level at reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.
BD01F184
STEP 50
Put articulation lock in OPERATING position.
STEP 47
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
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.
Bur 5-4070
Issued 8-06
Printed in U.S.A.
9007-16
NOTES
Bur 5-4070
Issued 8-06
Printed in U.S.A.
Section
9010
Bur 6-42710
9010
9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bur 6-42710
Issued 4-03
Printed in U.S.A.
9010-3
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must
be installed within 5 minutes. If the glass is not
installed within the 5 minute period, the adhesive
must be removed and applied again.
1. Apply a 10 mm (3/8 inch) diameter bead of
adhesive (345-135) to the pr imed surface
approximately 12 mm (1/2 inch) from edge.
2. The adhesive may be applied either to the
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
Bur 6-42710
Issued 4-03
Printed in U.S.A.
9010-4
4
498L93
3. SILICONE BEFORE
SMOOTHING
4. SILICONE AFTER
SMOOTHING
6 MM
(1/2 INCH) R
120
120
4 MM
(3/16 INCH) R
496L93
Issued 4-03
Printed in U.S.A.
9010-5
2
1
3
4
6
2
497L93
NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
Bur 6-42710
Issued 4-03
Printed in U.S.A.
9010-6
NOTES
Bur 6-42710
Issued 4-03
Printed in U.S.A.
Vended Schematic
5-3310
English
Part Number 84299244
Printed in U.S.A. Rac
2009 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America