Case Skid Steer Loader Service Manual Pgs 1192-1566

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic
4. Install the inner gear (1) with the chamfered side of

the gear facing the outside (facing away from the
wear plate). Align the shaft key on the coupling (2)
with the notch (3) on the inner gear.
83115514 4
5. Install the outer gear (1) with chamfered side facing

outward.
83115513 5
6. Replace the o-ring (1) on charge pump housing.
83115512 6
7. Install charge pump housing (1) using reference

mark from removal procedure.
83115510 7
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8. Install the flange (1).
83115503 8
9. Install and tighten the mounting flange bolts (1).
83115502 9
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Charge pump - Remove

SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro
hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls,
TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Prior operation:
To remove the hydrostatic pump, refer to Pump - Remove EH hydrostatic pump (C.20.F).
NOTE: Some of the pictures in the following procedure may vary from the pump you are repairing. The procedure is
the same.
1. Remove the mounting flange bolts (1).
83115502 1
2. Remove the flange (1).
83115503 2
3. Apply reference mark (1) on pump housing and

charge pump housing.
83115510 3
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4. Remove the charge pump housing (1).
83115511 4
5. Remove o-ring (1) from charge pump housing.
83115512 5
6. Remove the outer gear (1).
83115513 6
7. Remove the inner gear (1).
83115514 7
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8. Remove the coupler (1).
83115515 8
9. Apply reference mark (1) on wear plate.
83115516 9
10. Remove the wear plate (1).
83115517 10
Next operation:
For installation, refer to Charge pump - Install (C.20.F).
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Charge pump - Inspect

SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Prior operation:
Pump - Disassemble Sauer Danfoss 35cc mechanical pump (C.20.F)
Charge Pump Inspection

NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing.
The procedure is the same.
1. Inspect each part. If any part of the gerotor pump
is damaged, scored, or worn, replace the complete
charge pump as an assembly. Inspect and replace
any worn, or damaged o-rings
20105282N 1
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Motor - Remove Drive motor

SR130, SR150, SR175, SV185, SR200, SR220, SR250, SV250, SV300
WARNING
Crushing hazard!
Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable
jack stands. Be sure to position them properly.
Failure to comply could result in death or serious injury.
W0919A
DANGER
Crushing hazard!
Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify
that the loader arm support pin is engaged.
Failure to comply will result in death or serious injury.
D0020A
DANGER
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
D0076A
Prior operation:
Tilt system - Tilt (E.34.A).
1. The loader must be raised and supported with the

tires off the ground. Used adequate blocks or jack
stands to safely support the loader.
931002069 1
2. Remove the wheel hardware (1) and pull wheels from

hub.
931002070 2
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3. Place suitable container under chain tank drain plug

and remove drain plug (3) and drain chain oil.
931002081 3
4. Remove the six bolts (2) securing the drive chain

inspection cover and remove cover.
931002080 4
5. Remove front and rear axle housing hardware (4).
931002082B 5
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6. Remove front and rear axle housings
931002083B 6
7. Push the sprocket forward and remove chains from

drive sprocket, as shown.
931002084 7
931002085B 8
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NOTE: See PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A) to depressurize the hydraulic
system.
8. Label and disconnect hydraulic hoses (1) from hydro-
static drive motor and cap the open hoses and ports.
931002086 9
9. Disconnect shift tube (on 2 speed equipped models).

10. Remove and discard hydraulic motor mounting hard-
ware (2).
NOTE: DO NOT reuse motor mounting hardware after
tightening to spec. Hardware is permanently stretched
during tightening and must be discarded if loosened.
931002085B 10
11. DANGER
Heavy objects!
Lift and handle all heavy components us-
ing lifting equipment with adequate ca-
pacity. Always support units or parts with
suitable slings or hooks. Make sure the
work area is clear of all bystanders.
Failure to comply will result in death or
serious injury.
D0076A
Use acceptable lifting equipment and remove the

drive motor/brake assembly.
931002087 11
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Motor - Install Drive motor

DANGER
Crushing hazard!
D0020A
WARNING
Crushing hazard!
Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable
jack stands. Be sure to position them properly.
W0919A
DANGER
Heavy objects!
D0076A
1. Apply a bead of LOCTITE® 598 ULTRA BLACK adhe-

sive, (1), in corner between pilot and flange of motor,
around diameter of pilot, similar to o-ring, (approxi-
mately 12.5 ml (0.4 US fl oz) per motor).
931001687A 1
2. Apply a 3 mm (0.1 in) bead around the outside of

the bolt holes of the motor flange and 2 dabs per nut
between the nut and motors.
3. Use acceptable lifting equipment and move the drive
motor/brake assembly (1) into the chassis mounting
location (2). Refer to images one and two.
931002004 2
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4. Install new mounting hardware (1) and torque to 122

N·m (90 lb ft) plus 60 degrees.
NOTE: DO NOT reuse motor mounting hardware after
tightening to spec. Hardware is permanently stretched
during tightening and must be discarded if loosened.
931002085B 3
5. Connect the hydraulic hoses (1) to hydrostatic drive

motor to the correct ports
6. Connect shift tube (on 2 speed equipped models).
931002086 4
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7. Connect chains to drive sprocket
931002085B 5
8. Install front (1) and rear axle housings.
931002083B 6
9. Install front and rear axle housing hardware (1) and

Chain drive - Check (C)
931002082B 7
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10. Install chain oil drain plug (1). oil level is approxi-
mately mid-way up the inspection cover. Cover must
be installed before filling with oil.
931002081 8
11. Install chain inspection cover (1) and mounting hard-

ware (2)
12. Fill chain tank to correct level and install check plug.
931002080A 9
13. Install wheels (1) and wheel hardware (2)
931002070 10
14. Remove supports and lower skid steer
931002069 11
15. Disengage cab lock out and tilt cab down. See Tilt
system - Tilt cab, secure the lift arm in the raised
position. (E.34.A) for more information on Radial
working arm units
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16. Install bucket refer to Bucket - Install (J.20.B)
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Motor - Remove track drive motor

TR270, TR320, TV380
Prior operation:
Rubber track - Remove (D.50.B)
1. Loosen and remove the upper and lower mounting

bolts (1) which fasten the rear cover (2) to the main
frame (3).
bs05c139_1 1
2. Apply vacuum to the reservoir. Refer to Reservoir -

Apply vacuum (A.10.A)
NOTE: Clean the hydraulic lines, fittings, and connectors
and the area around motor connections to prevent dirt from
entering the hydraulic system before the lines are discon-
nected from the motor.
bs05c164_1 2
system.
3. Loosen and remove all of the hydraulic lines that are
connected to the drive motor. Place plugs in all of the
lines.
4. Stop the vacuum pump.
5. Loosen and remove all of the connectors from the
ports on the drive motor to allow room to slide the
drive motor out of the main frame. Install clean plas-
tic plugs into the ports (1) to avoid contamination.
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6. Make a reference mark on the drive motor (2) and the

main frame (3) to be used for alignment of the drive
motor during the installation procedure.
7. Loosen and remove the mounting bolts (1) which fas-
ten the drive motor (2) to the main frame (3).
8. Slide the drive motor (2) out of the main frame (3)
and place on the bench.
bs05c164_2 3
Next operation:
Motor - Install track drive motor (C.20.F)
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Motor - Install track drive motor

TR270, TR320, TV380
Prior operation:
Motor - Remove track drive motor (C.20.F)
1. Slide the drive motor (1) into the main frame (2)
mounting location. If the same motor is being in-
stalled, use the marks made during removal and
align the drive motor in the main frame. If a new
motor is being installed, transfer the reference mark
from the old motor to the same location on the new
motor and align the drive motor in the main frame.
bs05c164_3 1
2. Install the mounting bolts (1) into the main frame.
bs05c164_4 2
3. Tighten the mounting bolts to an initial torque of 67

- 163 Nm (50 - 120 lb ft) using the star tightening
sequence shown. After the initial torque is complete,
tighten the mounting bolts to a final torque of 183 -
205 Nm (136 - 153 lb ft) using the star tightening
sequence shown.
bs05c156_1 3
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4. Remove the plastic plugs from the motor ports (1).

Install the connectors into the motor ports (1) and
tighten the connectors.
bs05c164_1 4
5. Apply vacuum to the reservoir. Refer to Reservoir -

Apply vacuum (A.10.A)
6. Start the vacuum pump. Remove the caps from
the lines and connect the lines to the drive motor.
Tighten all of the hydraulic lines.
7. Stop the vacuum pump and remove the vacuum
pump from the reservoir.
8. Install rubber tracks. Refer to Rubber track - Install
(D.50.B)
9. Start and run the engine at low idle for 2 to 5 minutes
and check for any leaks.
10. Stop the engine.
11. Install the rear cover (2) onto the main frame (3).
Install the upper and lower mounting bolts (1) into
the rear cover (2). Tighten the mounting bolts (1).
bs05c139_1 5
12. Check the oil level in the hydraulic reservoir and add
hydraulic oil as required. Refer to : Reservoir - Fill-
ing (A.10.A)
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Motor - Assemble Single speed drive motor

1. If removed, install a new inner bearing cup in the front

case.
83115577 1
2. If removed, install a new outer bearing cup in the front

case.
83115578 2
3. Lubricate a new shaft seal with clean hydraulic oil.

Install the new shaft seal onto the shaft.
4. Place the shaft in a press. Warm the outer bearing.
Press the outer bearing onto the shaft.
5. Cover the splines on the shaft with tape to protect the
seal. Install the shaft into the front case. Remove the
tape from the splines.
6. Warm the inner bearing.
7. Press the inner bearing onto the shaft and into the
inner bearing cup. Press the bearing into the cup to
a preload of 5000 kg (11023.1 lb). Rotate the front
case during this procedure. Allow the assembly to
cool.
8. Place special tool 380001894 onto the shaft. Using
a press and apply a preload 2000 kg (4409.2 lb) to
the inner bearing.
83115575 3
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9. Install the split ring onto the shaft.
83115574 4
10. With the preload still applied, measure the gap be-
tween the split ring and the bearing.
83115574 5
11. Remove the split ring. Install a shim with a thickness

of 0.05 - 0.20 mm (0.002 - 0.008 in) greater than the
measured gap between the split ring and the bearing
surface.
83115574 6
12. Install the split ring on the shaft.
83115574 7
13. Release the preload from the bearing and remove

the front case assembly from the press.
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14. Check the shaft to make sure it rotates in the front

case assembly.
15. Install the cylinder block onto the shaft.
83115566 8
16. Lubricate the seal with clean hydraulic oil. Install the
seal on the front case.
83115572 9
17. Install the cam on the cylinder block. Be sure to align

the cam with the alignment mark on the front case.
83115571 10
18. Install the springs and the stop pin in the distributor.
83115570 11
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19. Lubricate the seals on the distributor with clean hy-

draulic oil. Install the distributor into the rear case.
Be careful not to dislodge the springs while installing
the distributor into the rear case. Make sure to the
stop pin is aligned with the hole in the rear case. Tap
the distributor with a soft hammer until it is seated in
the rear case.
83115569 12
seal on the rear case.
83115567 13
21. Use the marks made during disassembly and install

the rear case onto the cam.
83115566 14
22. Apply LOCTITE® 243 to the threads and install the

socket head cap screws into the rear case.
83115565 15
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23. Tighten the socket head cap screws alternately from

side to side to a torque of 117 - 122 N·m (86.3 - 90.0
lb ft).
83115564 16
24. Lubricate the spring and flushing poppet with clean

hydraulic oil. Install the spring and flushing poppet
into the port.
83115563 17
25. Lubricate the O-ring on the plug with clean hydraulic

oil. Install and tighten the plug.
83115561 18
26. Lubricate the springs and flushing spool with clean

hydraulic oil. Install the 2 springs, washer, and flush-
ing spool into the valve port.
83115560 19
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27. Lubricate the O-ring on the plug with clean hydraulic

oil. Install and tighten the plug.
83115558 20
28. Lubricate the O-ring with clean hydraulic oil. Install

the O-ring on the brake housing.
83115557 21
29. Lubricate with the brake discs and shims with clean
hydraulic oil. Install the brake discs and shims as
one unit on the shaft. Make sure all of the tabs on
the brakes discs are aligned.
83115556 22
30. Install the brake housing on the rear motor case.
83115555 23
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socket head cap screws into the brake housing.
Tighten the socket head cap screws alternately from
lb ft).
83115553 24
seal in the brake housing.
83115552 25
33. Lubricate the seals on the piston with clean hydraulic

oil and install the piston into the brake housing.
83115551 26
34. Install the disc spring on top of the piston.
83115549 27
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35. Install the gasket on the brake housing.
83115548 28
36. Install the cover plate onto the brake housing.
83115547 29
37. Install the socket head cap screws into the cover
plate. Tighten the socket head cap screws alter-
nately from side to side to a torque of 14 - 16 N·m
(10.3 - 11.8 lb ft).
83115546 30
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Motor - Disassemble Single speed drive motor

1. Make reference marks on the motor case for correct

alignment during assembly. Loosen and remove the
socket head cap screws alternately, one turn at a
time from the cover plate.
83115546 1
2. Remove the cover plate.
83115547 2
3. Remove the gasket.
83115548 3
4. Remove the disc spring.
83115549 4
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5. Use compressed air in the port to force the piston up

for removal.
83115550 5
6. Remove the piston
83115551 6
7. Remove the O-ring.
83115552 7
8. Loosen and remove the socket head cap screws and

washers from the brake housing.
83115553 8
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9. Use a soft hammer to loosen the brake housing.
83115554 9
10. Remove the brake housing from the motor case.
83115555 10
11. Remove the brake discs and shims as one unit from
the shaft.
83115556 11
83115557 12
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13. Loosen the plug for the flushing spool valve.
83115558 13
14. Remove the flushing spool valve plug.
83115559 14
15. Remove the flushing valve spool, 2 springs, and

washer from the valve port. Make a record of the
parts assembly for use during the assembly proce-
dure.
83115560 15
16. Loosen the plug for the flushing valve poppet.
83115561 16
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17. Remove the plug from the port.
83115562 17
18. Remove the spring and the flushing poppet.
83115563 18
19. Loosen the socket head cap screws.
83115564 19
20. Remove the socket head cap screws.
83115565 20
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21. Remove the rear motor case.
83115566 21
22. Remove the seal from the rear case.
83115567 22
23. Drop the rear case assembly from approximately 80

mm (3.1 in) onto a wooden or plastic surface. This
will release the distributor from the rear case.
83115568 23
24. Remove the distributor from the rear case.
83115569 24
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25. Make a record of the number of springs and the stop

pin location in the distributor for use during the as-
sembly procedure.
83115570 25
26. Remove the cam from the front case.
83115571 26
27. Remove the seal from the front case.
83115572 27
28. Remove the cylinder block from the front case.
83115573 28
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29. Place the front case assembly in the press. Remove

the split ring from the shaft.
83115574 29
30. Press the shaft out of the front case.
83115575 30
31. Press the seal out of the front case.
83115576 31
32. Press the outer bearing cup from the front case.
83115577 32
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33. Press the inner bearing cup from the front case. Mo-
tor - Visual inspection (C.20.F)
83115578 33
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Motor - Assemble Two speed drive motor

1. If removed, install a new outer bearing cup in the front

case.
83115575 1
2. If removed, install a new inner bearing cup in the front

case.
83115577 2
3. Lubricate a new shaft seal with clean hydraulic oil.

Install the new shaft seal onto the shaft.
4. Place the shaft in a press. Warm the outer bearing.
Press the outer bearing onto the shaft.
5. Cover the splines on the shaft with tape to protect the
seal. Install the shaft into the front case. Remove the
tape from the splines.
6. Warm the inner bearing.
7. Press the inner bearing onto the shaft and into the
inner bearing cup. Press the bearing into the cup to
a preload of 5000 kg (11023.1 lb). Rotate the front
case during this procedure. Allow the assembly to
cool.
8. Place special tool 380001894 onto the shaft. Using
a press and apply a preload 2000 kg (4409.2 lb) to
the inner bearing.
83115575 3
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9. Install the split ring onto the shaft.
20115834 4
10. With the preload still applied, measure the gap be-
tween the split ring and the bearing.
20115833 5
11. Remove the split ring. Install a shim with a thickness

of 0.05 - 0.20 mm (0.002 - 0.008 in) greater than the
measured gap between the split ring and the bearing
surface.
20115834 6
12. Install the split ring on the shaft.
20115834 7
13. Release the preload from the bearing and remove

the front case assembly from the press.
14. Check the shaft to make sure it rotates in the front
case assembly.
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15. Install the cylinder block onto the shaft.
83115573 8
seal on the front case. Install the cam on the cylinder
block. Be sure to align the cam with the alignment
mark on the front case.
83115571 9
17. Install the springs and the stop pin in the distributor.
83115709 10
18. Lubricate the seals on the distributor with clean hy-

draulic oil. Install the distributor into the rear case.
Be careful not to dislodge the springs while installing
the distributor into the rear case. Make sure to the
stop pin is aligned with the hole in the rear case. Tap
the distributor with a soft hammer until it is seated in
the rear case.
83115569 11
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seal on the rear case.
83115567 12
20. Use the marks made during disassembly and install

the rear case onto the cam.
83115583 13

socket head cap screws into the rear case.
83115565 14
22. Tighten the socket head cap screws alternately from

lb ft).
83115564 15
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23. Lubricate the two speed valve spring and spool with
clean hydraulic oil. Install the two speed valve spring
and spool into the valve port.
83115560 16
24. Lubricate the O-ring with clean hydraulic oil. Install

the O-ring on the brake housing.
83115557 17
25. Lubricate with the brake discs and shims with clean
hydraulic oil. Install the brake discs and shims as
one unit on the shaft. Make sure all of the tabs on
the brakes discs are aligned.
83115556 18
26. Install the brake housing on the rear motor case.
83115579 19
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socket head cap screws into the brake housing.
Tighten the socket head cap screws alternately from
lb ft).
83115553 20
seal in the brake housing.
83115552 21
29. Lubricate the seals on the piston with clean hydraulic

oil and install the piston into the brake housing.
83115551 22
30. Install the disc spring on top of the piston.
83115549 23
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31. Install the gasket on the brake housing.
83115548 24
32. Install the cover plate onto the brake housing.
83115547 25
33. Install the socket head cap screws into the cover
plate. Tighten the socket head cap screws alter-
nately from side to side to a torque of 14 - 16 N·m
(10.3 - 11.8 lb ft).
83115546 26
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Motor - Disassemble Two speed drive motor

1. Make reference marks on the motor case for correct

alignment during assembly. Loosen and remove the
socket head cap screws alternately, one turn at a
time from the cover plate.
83115546 1
83115547 2
3. Remove the gasket.
83115548 3
4. Remove the disc spring.
83115549 4
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5. Use compressed air in the port to force the piston up

for removal.
83115550 5
6. Remove the piston.
83115551 6
83115552 7
8. Loosen and remove the socket head cap screws and

washers from the brake housing.
83115553 8
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9. Use a soft hammer to loosen the brake housing.
83115554 9
10. Remove the brake housing from the motor case.
83115579 10
11. Remove the brake discs and shims as one unit from
the shaft.
83115556 11
83115580 12
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13. Remove the two speed spool valve and spring from
the valve port.
83115581 13
83115582 14
15. Loosen the socket head cap screws.
83115564 15
16. Remove the socket head cap screws.
83115565 16
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17. Remove the rear motor case.
83115708 17
18. Remove the seal from the rear case.
83115567 18
19. Drop the rear case assembly from approximately 80

mm (3.1 in) onto a wooden or plastic surface. This
will release the distributor from the rear case.
83115568 19
20. Remove the distributor from the rear case. Make

a record of the number of springs and the stop pin
location in the distributor for use during the assembly
procedure.
83115709 20
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21. Remove the cam from the front case.
83115571 21
22. Remove the seal from the front case.
83115572 22
23. Remove the cylinder block from the front case.
83115573 23
24. Place the front case assembly in the press. Remove

the split ring from the shaft.
83115574 24
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25. Press the shaft out of the front case.
83115575 25
26. Press the seal out of the front case.
83115576 26
27. Press the inner bearing cup from the front case.
83115577 27
28. Press the outer bearing cup from the front case.
83115578 28
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Motor - Assemble Track drive motor

TR270, TR320, TV380
1. Install the seal ring.
83115760ASSD 1
2. Install the seal ring into the flanged hub.
83115761HJL 2
3. Apply a thin coat of grease over the seal ring (1).
83115762 3
4. Install bearing.
83115763 4
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5. Seat the bearing into the flanged hub.
83115764GHK 5
6. Install the inner bearing ring onto the motor shaft.
83115765 6
7. Place the motor shaft into the bearing.
83115757 7
8. Place the 2 steel balls into their seats.
83115756 8
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9. Install the springs inside the pistons.
83115755 9
10. Install the 2 pistons in their housings (1).
83115754 10
11. Install the swash plate.
83115753 11
12. Install the three pins into the cylinder block (1).
83115752 12
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13. Install the spherical retainer.

NOTE: Ensure the two splines are aligned
83115751 13
14. Piston orifice must be free of dust or dirt.
83115766 14
15. Install the pistons into the retainer plate.
83115767 15
16. Install the pistons and retainer plate into the cylinder
lock.
83115749 16
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17. Install the cylinder block into the flanged hub on the
motor shaft spline.
83115748 17
18. Install the brake disc package according to the fol-

lowing order: first insert one brake disc with internal
teeth.
83115745 18
19. Then insert an external toothed steel disc.
83115746 19
20. Repeat the steps until 3 brake discs and 2 steel discs
have been installed.
83115747 20
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21. Install the O-rings on the brake piston.
83115743 21
22. Install the O-ring on the brake spacer.
83115744 22
23. Install the brake spacer on the brake piston, paying

attention not to damage the O-rings already in place.
83115742 23
24. Install the brake piston into the flanged hub while
aligning the reference marks previously applied.
83115741 24
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25. Install O-ring.
83115739 25
26. Install the springs on the brake piston.
83115738 26
27. Install the bearing inner ring onto the motor shaft.
83115737 27
28. Install the bearing into the base plate (1).

29. Install the pins into the base plate (2).
83115735 28
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30. Install the valve plate on the base plate with the
bronze surface upwards.
83115734 29
31. Install the 3 O-rings for the oil passages on the

flanged hub.
32. Place the base plate on the flanged hub.
NOTE: Ensure the base plate is centered on the two pins
and the oil passages are matched together
83115732GSF 30
33. Install the base plate mount bolts and tightened to a

torque of 145 N·m (106.95 lb ft).
83115731 31
34. Install the 3 plugs located around the bottom of the

base plate. Torque plus to 2 - 3 N·m (17.7 - 26.6 lb
in).
83115730 32
NOTE: Assembly of the two speed control
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35. Install the spring (1) into the two-speed spool (2) .
83115727 33
36. Install the two speed spool (1) into the base plate.
NOTE: The spool will only fit through 1 of the 2 orifices.
83115726 34
37. Install the O-rings on the plugs.
83115721 35
38. Install and tighten the plugs to a torque of 49 - 59

N·m (36.1 - 43.5 lb ft).
83115725 36
NOTE: Assembly of the flushing valve
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39. Install the O-ring on the plug.
83115721 37
40. Install the spring into the base plate.
83115729_1 38
41. Install and tighten the plug to a torque of 88 - 96 N·m

(64.9 - 70.8 lb ft).
83115728 39
NOTE: Assembly of the flushing spool valve

42. Slide plunger (1) inside the base plate.
83115724 40
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43. Install the spring seats (1) on each end of the plunger
(2) .
83115723_2 41
44. Install the springs on each end of the plunger.
83115722 42
45. Install the O-rings on the 2 plugs.
83115721 43
46. Install and tighten the 2 plugs to a torque of 149 - 165

N·m (109.9 - 121.7 lb ft)
83115725_1 44
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47. Install the bushing into the gearbox (1).
83115768 45
48. Install the gears into the gearbox while aligning the
reference marks (1) previously applied to the gears.
83115717 46
49. Seat the gears.
83115769_1 47
50. Install the snap rings on the gears.
83115716 48
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51. Install the O-ring around the gearbox.
83115715 49
52. Install the gear plate.
83115714 50
53. Install the center gear.
83115713 51
54. Use reference marks (1) to align and install the cover
plate on the gearbox.
83115712 52
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55. Install the snap ring.
83115711 53
56. Service gearbox with 550 - 650 ml (18.6 - 22.0 US fl

oz) .of CASE AKCELA GEAR 135 H EP 85W-140.
57. Install and tighten the end cover plugs to a torque of
20 - 30 N·m (14.8 - 22.1 lb ft).
83115710 54
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Motor - Disassemble Track drive motor

TR270, TR320, TV380
1. Remove the 2 plugs from the cover plate.
83115710 1
2. Drain motor oil in an acceptable container.

3. Remove the snap ring.
83115711 2
4. Mark the position of the cover plate as a reference

for reassembly.
83115712VGFUKV 3
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6. Remove the center gear.
83115713 4
7. Remove the gear plate.
83115714 5
8. Remove and discard the O-ring.
83115715 6
9. Mark the position (1) of all the gears as a reference

for reassembly.
10. Remove the snap rings.
83115716_4 7
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11. Remove the gears.
83115717 8
12. Remove the bushing.
83115718 9
NOTE: Disassembly of the flushing spool valve

13. Remove the plugs.
83115725_2 10
14. Remove and discard the O-rings..
83115721 11
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15. Remove the springs from both ends of the plunger.
83115722 12
16. Remove the spring seats from both ends of the

plunger.
83115723_3 13
17. Remove the plunger assembly.
83115724_2 14
NOTE: Disassembly of the two speed control

18. Remove the plugs.
83115725_3 15
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19. Remove and discard the O-rings.
83115721 16
20. Remove the two speed spool (1).
83115726_3 17
NOTE: The two speed spool can only be removed from one opening.
21. Remove the spring (1).
83115727_3 18
NOTE: Disassembly of the flushing valve

22. Remove plug.
83115728_3 19
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83115721 20
24. Remove the spring.
83115729_3 21
NOTE: Disassembly of the base plate

25. Remove the three plugs from around the bottom of
the base plate.
83115730 22
26. Remove the base plate mount bolts.
83115731_2 23
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27. Carefully lift the base plate off the pins. Remove the
base plate.
83115732GSF 24
28. Turn the base plate upside down.
83115733 25
29. Remove the valve plate.
83115734 26
30. Remove the pins (1) from their seat..
83115733_3 27
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31. Remove bearing from the base plate.
83115736 28
NOTE: Disassembly of the motor shaft and cylinder block

32. Remove the bearing inner ring from the motor shaft.
83115737 29
33. Remove the springs from the brake piston.
83115738 30
83115739 31
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35. Mark the position of the brake piston as a reference

for reassembly.
83115740 32
36. Remove the brake piston.
83115741 33
37. Separate the brake spacer from the brake piston.
83115742 34
38. Remove and discard the O-rings from the brake pis-
ton.
83115743 35
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39. Remove and discard the O-ring from the brake

spacer.
83115744 36
NOTE: Remove the brake discs package

40. Remove the brake disc with internal teeth.
83115745 37
41. Then remove an external toothed steel disc.
83115746 38
42. Repeat the above steps until complete brake disc

package is removed.
NOTE: Brake disc package consists of 3 brake discs and
2 steel discs
83115747 39
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43. Remove the cylinder block.
83115748 40
44. Remove the pistons and retainer plate from the cylin-
der block.
83115749 41
45. Remove pistons from the retainer plate.
83115767 42
46. Remove the spherical retainer plate holder.
83115751 43
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47. Remove the 3 pins from the cylinder block (1) .
83115752 44
48. Remove the swash plate.
83115753 45
49. Remove the 2 pistons from their seat (1) .
83115754 46
50. Remove the springs from the pistons.
83115755 47
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51. Remove the 2 steel balls from their seats.
83115756 48
52. Remove the motor shaft.
83115757 49
53. Remove the inner bearing ring from the motor shaft.
83115758 50
54. Remove the bearing.
83115759 51
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55. Remove the seal ring.
83115760_2 52
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Sensing system - Remove Right hand swash plate sensor

Prior operation:
Tilt system - Tilt cab, secure the lift arm in the raised position. (E.34.A)
1. Locate the right hand swash plate sensor on the bot-

tom of the electro-hydraulic hydrostatic pump (1).
931001814 1
2. Label and disconnect the connector from the swash

plate sensor. The right hand swash plate sensor (1)
is located on the input shaft side of the hydrostatic
pump.
931001961 2
3. Remove the two screws (1) holding the swash plate

shield (2) and sensor.
931001961 3
4. Remove the swash plate sensor.
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Sensing system - Install Right hand swash plate sensor

1. Install the right hand swash plate sensor (1).
931001961 1
2. Place the swash plate shield (2) over the right hand
swash plate sensor. Insert the two screws (1) and
tighten to proper torque.
931001961 2
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Sensing system - Remove Left hand swash plate sensor

Prior operation:
1. Locate the left hand swash plate sensor on the bot-

tom of the electro-hydraulic hydrostatic pump (1).
931001814 1
2. Label and disconnect the connector from the swash

plate sensor. The left hand swash plate sensor (1) is
located near the auxiliary pump.
931001961 2
3. Remove the two screws (1) holding the swash plate

shield (2) and sensor.
931001961 3
4. Remove the swash plate sensor.
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Sensing system - Install Left hand swash plate sensor

1. Install the left hand swash plate sensor (1).
931001961 1
2. Place the swash plate shield (2) over the left hand
swash plate sensor. Insert the two screws (1) and
tighten to proper torque.
931001961 2
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TRANSMISSION Hydrostatic - Troubleshooting

Problem Possible Cause Correction
One Transmission (Right 1.If you have a EH unit perform EH pump A. Is there still a problem?
or Left) Works Correctly electrical check and verify that unit has No: Troubleshooting complete.
and the Other Does Not been properly calibrated. Yes: Go to Step 2.
Check the interlock valve power/function.
2. Check the brake valve power/function. Is there still a problem?
Make sure park brakes are released. No: Troubleshooting complete.
Yes: Go to Step 3.
3. Check the pressure setting of the cir- Do - Checking Circuit Relief Valve Pres-
cuit relief valve for the transmission with the sure.
problem. Refer to Relief valve - Pressure test
(C.20.F)
Is there still a problem?
No: Troubleshooting complete.
Yes: Go to Step 4.
4. Check the charge pressure. Do - Checking the Charge Pressure/Flow.
Refer to Charge pump - Pressure test
(A.10.A) to determine if the pump or drive
motor(s) have failed.
Machine does not have 1. If you have a EH unit perform EH pump Is there still a problem?
enough power electrical check and verify that unit has No: Troubleshooting complete.
been properly calibrated. Yes: Go to Step 2.
Check the interlock valve power/function.
2. Full throttle engine speed is OK, rated A. Problem in engine or fuel system. Repair
engine speed is low. as required.
B. Is there still a problem?
No: Troubleshooting complete.
Yes: Go to Step 3.
3. Check charge pressure. Refer to Charge pump - Pressure test
(A.10.A) to determine if the pump or drive
motor(s) have failed.
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Index
TRANSMISSION, DRIVE AND PTO OUT - C
TRANSMISSION Hydrostatic - 20.F

Charge pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185
Mechanical hydraulic controls
Charge pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro hydraulic
controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro
hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380
Electro hydraulic controls
Charge pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Command - Install Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Command - Install Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Command - Remove Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Command - Remove Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Motor - Assemble Single speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Motor - Assemble Track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
TR270, TR320, TV380
Motor - Assemble Two speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Motor - Disassemble Single speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Motor - Disassemble Track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
TR270, TR320, TV380
Motor - Disassemble Two speed drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Motor - General specification for 325cc 2 speed motor on medium frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SR175, SV185, SR200
Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SR130, SR150, SR175, SV185
Motor - General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames . . . . . 18
SR200, SR220, SR250, SV300
Motor - General specification for mechanical 470cc single speed motor on medium and large frames . . . . . . . . 16
SR200, SR220, SR250, SV250, SV300
Motor - General specification for track drive 2 speed motor on medium and large frames . . . . . . . . . . . . . . . . . . . 19
TR270, TR320, TV380
Motor - Install Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Motor - Install track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
TR270, TR320, TV380
Motor - Remove Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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Motor - Remove track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
TR270, TR320, TV380
Pressure release valve - Install High pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure release valve - Install Low pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure release valve - Remove High pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pressure release valve - Remove Low pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pump - Adjust EH Servo Piston Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pump - Adjust Hydraulic Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical
hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic
controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Pump - Adjust Servo Piston Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pump - Assemble Hydrostatic pump unit assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical
hydraulic controls, TV380 Mechanical hydraulic controls
Pump - Assemble Sauer Danfoss 35cc mechanical pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Pump - Disassemble Hydrostatic pump unit disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pump - Disassemble Sauer Danfoss 35cc mechanical pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pump - General specification 35cc EH Hydrostatic pump, used with small and medium frame models. . . . . . . . . 8
controls
Pump - General specification 46cc EH Hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SR220 Electro hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic
controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Pump - General specification 46cc EHF Hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . . 10
SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
Pump - General specification 46cc Hydrostatic tandem pump, used with large frame models. . . . . . . . . . . . . . . . 14
SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300
Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Pump - General specification 46cc Hydrostatic tandem pump, used with medium and large frame models. . . . . 12
SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250
Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical
hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Pump - General specification 53cc hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . . . . . . . 13
SR250 Electro hydraulic controls, SV300 Electro hydraulic controls, TV380 Electro hydraulic controls
Pump - General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium
frame models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Pump - Install Drive shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Pump - Install EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pump - Install Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Pump - Install mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pump - Overview Hydrostatic pump model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump - Remove Drive shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Pump - Remove EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pump - Remove Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pump - Remove mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pump - Travel adjust (Stopping machine creep) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Pump Left hand pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Pump Left hand pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Pump Left hand pump - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Pump Left hand pump - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Pump Right hand pump - Assemble Hydrostatic pump assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Pump Right hand pump - Disassemble Hydrostatic pump Sauer Danfoss 46cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Pump Right hand pump - Measure Hydrostatic pump - measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Pump Right hand pump - Visual inspection Hydrostatic pump visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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Relief valve - Pressure test (Machines Equipped with EH Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Relief valve - Pressure test Ground Drive Relief Valve - Manual control models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sensing system - Install Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Sensing system - Install Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Sensing system - Remove Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Sensing system - Remove Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
TRANSMISSION Hydrostatic - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TRANSMISSION Hydrostatic - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2011 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification
or equipment at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASE CONSTRUCTION Dealer.
84423866 25/07/2011
EN
SERVICE MANUAL
AXLES, BRAKES AND STEERING
SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 ,

TR270 , TR320 , TV380
84423866 25/07/2011
D
Contents
AXLES, BRAKES AND STEERING - D
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.15.A

SR130 , SR150 , SR175 , SR200 , SR220 , SR250 , SV185 , SV250 , SV300 , TR270 , TR320 , TV380
Final drive Hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.15.C

STEERING Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.B

PARKING BRAKE Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.C

WHEELS AND TRACKS Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.B

TR270 , TR320 , TV380
WHEELS AND TRACKS Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.C

84423866 25/07/2011
D
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Idler wheel - Install D.50.B / 20
84423866 25/07/2011
D
84423866 25/07/2011
D
Final drive - 15.A

TR270 , TR320 , TV380
84423866 25/07/2011
D.15.A / 1
Contents
Final drive - 15.A
SERVICE
Chain drive
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84423866 25/07/2011
D.15.A / 2
AXLES, BRAKES AND STEERING - Final drive
Chain drive - Check

Check the tension of the four drive chains after the first 250 hours of operation on a new machine or if new chains
have been installed and every 500 hours of operation.
1. With the machine blocked up, rotate each tire and

check for allowable movement. 6 - 12 mm (0.2 - 0.5
in) is the acceptable range.
63107489 1
Drive chain adjustment

2. WARNING
Jack stands can slip or fall over. Drop-
ping, tipping, or slipping of machine or its
components is possible.
DO NOT work under a vehicle supported
by jack stands only. Park machine on a
level surface. Block wheels. Support ma-
chine with safety stands. 931002280 2
Failure to comply could result in death or

serious injury.
W0069A
To adjust the final drive chains, jack up and block the

complete skid steer securely off the ground.
3. Each axle drive chain is adjustable by loosening the
retaining nuts (1) (left front shown) and sliding the
axle-hub assembly to remove the excessive slack.
To tighten the chains slide the front axle-hubs forward
and rear axle-hubs rearward.
Torque the axle retaining hardware to 244 N·m (180
lb ft).
93109317 3
84423866 25/07/2011
D.15.A / 3
Index
Final drive - 15.A

Chain drive - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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D.15.A / 4
Final drive Hydraulic drive - 15.C

TR270 , TR320 , TV380
84423866 25/07/2011
D.15.C / 1
Contents
FUNCTIONAL DATA
Command
Overview 2 Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SR175, SV185, SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
Overview Self Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overview Glide Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSTIC
Command
Testing Glide Ride Control Solenoid and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testing 2 Speed Switch and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing Self Level Switch and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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D.15.C / 2
AXLES, BRAKES AND STEERING - Final drive Hydraulic drive
Command - Overview 2 Speed Switch

The button (1) on the top surface of the left control handle, is pressed once to downshift from second gear to first
gear and again to shift from first gear back to second gear. This feature will only be possible when all of the following
conditions are met:
931002278A 1
• Operator is seated properly.

• Seat belt is latched or lap bar is in the down position.
• Hydraulics enabled is activated.
• Park brake is not applied.
• Ignition is on.
84423866 25/07/2011
D.15.C / 3
Command - Overview Self Level

The automatic parallel-lift feature maintains a constant angle between the loader bucket / work-tool and the machine
chassis as the loader arm is raised (one direction only). When in parallel lift mode, the loader operation is similar to
that of a mechanical tool carrier linkage.
Self level feature is engaged by pressing the On/Off switch mounted on left hand A post. The switch is illuminated
when Self Level is on.
84423866 25/07/2011
D.15.C / 4
Command - Overview Glide Ride control

Ride Control mode is enabled by a pressing a switch on the right hand joystick which opens a flow-path to an accu-
mulator from the loader arm cylinders. This flow path enables the loader arm to be cushioned by absorbing the quick
up and down motions of the machine as it travels across rough terrain.
Ride Control is engaged by pressing the momentary on button. To disengage, by pressing the momentary button the
second time.
The Loader-Arm Ride Control feature is always active when the ignition is on.
84423866 25/07/2011
D.15.C / 5
Command - Testing Glide Ride Control Solenoid and Switch

NOTE: Use schematics
Wiring harness - Electrical schematic frame 04 (A.30.A)
Wiring harness - Electrical schematic frame 28 (A.30.A) (EH)
N° Test Point Expected Result Other Result (Possible Cause)
1 Condition Result Result
Disconnect connector X-RDCTRL Normal resistance. 0 Ω, or greater than 1 K Ω
from the RIDE CONTROL SOLENOID Action Action
Y-010 Go to test 2 The RIDE CONTROL SOLENOID has
Check failed. Replace the solenoid.
for resistance between RIDE
CONTROL SOLENOID pins 1 and 2.
Disconnect connector X-406 (EH) For each resistance check, 0 Ω in 0 Ω in all positions or infinite resis-
X-402 (Mech) from the RIGHT HAND one position, infinite resistance in the tance in all positions.
CONTROL HANDLE. other. Action
Check Action The RIDE CONTROL / GLIDE RIDE
Using a multi-meter, check for re- Go to test 3 SWITCH has failed. Replace the
sistance between RIDE CONTROL / RIGHT HAND CONTROL HANDLE.
GLIDE RIDE SWITCH pins C and D
(EH) pins C and D (Mech) while cy-
cling the switch.
Use ELECTRICAL POWER SYS- No wire problems. Wire problems are found.
TEM - Testing General Wire Test- Action Action
ing (A.30.A) to Go to test 4 Locate and repair or replace bro-
Check ken wire 951/964/967 (Black) adja-
wire condition between connector cent wiring.
X-RDCTRL pin 2 and ground.
ing (A.30.A) to Go to test 5 Locate and repair or replace broken
Check wire 831 (White) or adjacent wiring.
wire condition between X-RDCTRL
pin 1 and connector X-406 pin D.
ing (A.30.A) to There is a problem in the DC distri- Locate and repair or replace broken
Check bution system upstream of IGNITION wire 832/357/351 (Orange) or adja-
wire condition between connector FUSE. cent wiring.
X-406 pin C (EH) X-402 pin 3 (Mech)
and MAIN POWER DISTRIBUTION FUSE
BLOCK 1 Z-2008 pin C4.
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D.15.C / 6
Command - Testing 2 Speed Switch and Indicator


Remove IGNITION FUSE from the 0Ω Fuse is blown.
MAIN POWER DISTRIBUTION FUSE Action Action
BLOCK 1 Z-2008. Go to test 2 Replace the fuse with same type and
Check amp rating.
for continuity across IGNITION FUSE.
With the fuse removed and ignition 12 V 0V
on, Action Action
Check Go to test 3 There is a problem in the DC distri-
for voltage from MAIN POWER bution system upstream of IGNITION
DISTRIBUTION FUSE BLOCK 1 Z-2008 FUSE.
pin C3 and ground.
Check wire 891/357/351 (Orange) or adja-
X-408 pin 4 (EH) X-405 pin A (Mech)
4 Check Result Result
Using a multi-meter, check for resis- 0 Ω in all positions or infinite resis-
For each resistance check, 0 Ω in
tance across 2 SPEED SWITCH S-024 tance in all positions.
one position, infinite resistance in the
while cycling the switch. other. Action
Action The 2 SPEED SWITCH has failed.
Go to test 5 Replace the LEFT HAND CONTROL
HANDLE.
Disconnect connector X-310 from No circuit problems. No change in circuit response, re-
the 2-SPEED INDICATOR. Connect a Action move jumper.
jumper between connector X-310 The 2-SPEED INDICATOR has failed. Action
pins 7 and 9. Replace the indicator. Go to test 6
Check
Check circuit operation.
Check wire 563 (White) / 565 (Violet) or ad-
wire condition between connector jacent wiring.
X-408 pin 9 (EH) X-405 pin D (Mech)
and connector X-310 pin 7.
ing (A.30.A) to Locate and repair or replace bro-
Check See the following for further testing ken wire 917/941/942/1094 (Black)
wire condition between connector • Command - Testing or adjacent wiring.
X-310 pin 9 and ground. Glide Ride Control
Solenoid and Switch
(D.15.C)
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D.15.C / 7
Command - Testing Self Level Switch and Valve

Remove ACCESSORY FUSE from the 0Ω Fuse is blown.
Check amp rating.
for continuity across ACCESSORY
FUSE.
With the fuse removed and Ignition 12 V 0V
on, Action Action
Check Go to test 3 There is a problem in the DC distribu-
for voltage from MAIN POWER tion system upstream of ACCESSORY
pin C1 and ground.
Check wire 405/134 (Orange) or adjacent
wire condition between connec- wiring.
tor X-317 pin B and MAIN POWER
DISTRIBUTION FUSE BLOCK 1 Z-2008
pin C2.
Disconnect connector X-317 from For each resistance check, 0 Ω in 0 Ω in all positions or infinite resis-
the SELF LEVEL SWITCH S-013. one position, infinite resistance in the tance in all positions.
Check other. Action
Using a multi-meter, check for resis- Action The SELF LEVEL SWITCH has failed.
tance between SELF LEVEL SWITCH Go to test 5 Replace the switch.
pins A and B while cycling the switch.
the SELF LEVEL VALVE Y-318. Re- Action move jumper.
connect all other connectors. Con- The SELF LEVEL VALVE has failed. Action
nect a jumper between connector Replace the valve. Go to test 6
X-318 pins 1 and 2.
Check
ing (A.30.A) to The fault may be intermittent. Visu- Locate and repair or replace broken
Check ally inspect the relevant harnesses wire 949/964/967 (Black) or adjacent
wire condition between connector and connectors for damage, bent or wiring.
X-318 pin 2 and ground. dislocated pins, corroded terminals
or broken wires. Verify that the con-
nectors are fully installed. Flex the
harnesses involved to reveal inter-
mittent breaks or shorts in the wiring
concerned. If no damage is found,
continue operation.
84423866 25/07/2011
D.15.C / 8
Index

Command - Overview 2 Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Command - Overview Glide Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Command - Overview Self Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Command - Testing 2 Speed Switch and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Command - Testing Glide Ride Control Solenoid and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Command - Testing Self Level Switch and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
84423866 25/07/2011
D.15.C / 9
84423866 25/07/2011
D.15.C / 10
STEERING Mechanical - 20.B

TR270 , TR320 , TV380
84423866 25/07/2011
D.20.B / 1
Contents
SERVICE
STEERING Mechanical
Adjust for hand controls with direct mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls,
SV185 Mechanical hydraulic controls
Adjust hand controls with servo operated pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320
Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Adjust Float Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SV185 Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls,
SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls, TR270
Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
Command
Remove Hand controls (Machines Equipped with ISO and H-Pattern EH Controls) . . . . . . . . . . . . . . . . . . 8
Install Hand controls (Machines Equipped with ISO and H-Pattern EH Controls) . . . . . . . . . . . . . . . . . . . . 9
84423866 25/07/2011
D.20.B / 2
AXLES, BRAKES AND STEERING - STEERING Mechanical
STEERING Mechanical - Adjust for hand controls with direct

mechanical hydrostatic pump
SR130 Mechanical hydraulic controls, SR150 Mechanical hydraulic controls, SR175 Mechanical hydraulic controls, SV185 Mechanical hydraulic controls
Adjustment preparation for hand controls

1. Raise machine off ground and place securely on jack
stands
2. Check spring caps to make sure they are pushing
against centering plate and there is no gap between
jam nuts and spring caps.
3. If there is any gap, loosen all 4 nuts and adjust
23112911 1
Adjustment for hand controls

1. Loosen Jam Nut (1).
2. Take engine to high idle.
3. Turn rod /spring assembly (2) until wheels just turn
in forward direction.
4. Turn rod (2) in opposite direction until wheels just
rotate in reverse direction. Count number of turns
of rod from forward motion to reverse.
5. Turn the rod back ½ the number of turns recorded in
the step prior.
6. Tighten jam nut (1) .
23112912 2
7. Move handle in both directions to confirm neutral is
set. Adjust if needed.
8. Repeat steps 4-7 for other pump. Please note the dif-
ferences between the right and left sides, as shown
in images 2 and 3. Keep these differences in mind
when repeating steps 4-7.
23112912 3
84423866 25/07/2011
D.20.B / 3
9. After Creep has been set use control rods (1) to set
handle position, by loosening the left hand side jam
nut (2) and right hand side jam nut (3). Rotate rod (1)
until the handle is in the correct position, and tighten
jam nuts (2) and (3).
23112913 4
10. Factory setting is 75 ° represented by (X).
23112914 5
Adjusting stop bolts.

NOTE: Images may or may not represent your exact machine configuration. This procedure is the same for all me-
chanically operated machines in any configuration.
11. Turn stop bolt (1) out several turns.
12. Push handle (2) full forward until pump is fully
stroked, hold handle in this position and turn stop
bolt in until it just contacts casting.
13. Repeat for other side
23112915 6
84423866 25/07/2011
D.20.B / 4
14. Operate machine – Record Drift

15. Use stop bolt to slow down fast side of machine.
23112916 7
NOTE: Stop bolt should just contact casting when pump is at full stroke.
84423866 25/07/2011
D.20.B / 5
STEERING Mechanical - Adjust hand controls with servo operated

pump
SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic controls,
SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1. Loosen bolts (1) attaching the self centering damp-

eners
2. Use the control rods to set handle position. First,
loosen the left hand side jam nut (3) and right hand
side jam nut (4). Rotate rod (2) until the handle is in
the correct position and then tighten both jam nuts
(3) and (4).
3. Tighten bolts attaching the self centering dampeners.
4. Repeat for other pump.
5. Set stop bolts and drift – same as direct mechanical.
STEERING Mechanical - Adjust for hand con-
23112921 1
trols with direct mechanical hydrostatic pump
(D.20.B)
6. After drift is set, adjust forward stop bolts on the
pump that was NOT adjusted in step 5, so that the
handles are aligned side to side when pushed full
ahead. Take note not to adjust the stop bolt to the
point where that side of the machine has slowed
down. This step should only reduce the dead band at
the end of handle stroke and not effect travel speed.
84423866 25/07/2011
D.20.B / 6
STEERING Mechanical - Adjust Float Detent

SV300 Mechanical hydraulic controls, TR270 Mechanical hydraulic controls, TR320 Mechanical hydraulic controls, TV380 Mechanical hydraulic controls
1. Angle between lift control rod and ear on jackshaft

must be 90 °or less when spoon is in neutral.
2. If angle is greater then 90 ° increase length of rod by
turning out the clevis ends on rod.
23112922A 1
3. If length of rod from ear on jackshaft to valve spool

is increased, the grip will need to be repositioned by
adjusting connecting rod.
23112923 2
4. If detent still does not hold check clearance between

rod end and pivot. If rod end is hitting, shorten con-
necting rod between grip and jack shaft. After de-
creasing length of connecting rod, you must check
to confirm grip does not hit window or side screen
during full raise.
23112924 3
84423866 25/07/2011
D.20.B / 7
Command - Remove Hand controls (Machines Equipped with ISO

and H-Pattern EH Controls)
Prior operation:
1. Remove control handle mounting hardware from the

sides of the control handle.
93111494 1
2. Disconnect electrical connector (1).
93111545 2
3. Remove the control handle.
93111496 3
84423866 25/07/2011
D.20.B / 8
Command - Install Hand controls (Machines Equipped with ISO and

H-Pattern EH Controls)
Prior operation:
1. Install the control handle onto the lever (1).
93111496 1
2. Install the control handle mounting hardware (1) on

the sides of the control handle.
93111494 2
3. Connect the electrical connector (1) to the harness.
93111545 3
84423866 25/07/2011
D.20.B / 9
Index

Command - Install Hand controls (Machines Equipped with ISO and H-Pattern EH Controls) . . . . . . . . . . . . . . . . . 9
Command - Remove Hand controls (Machines Equipped with ISO and H-Pattern EH Controls) . . . . . . . . . . . . . . . 8
STEERING Mechanical - Adjust for hand controls with direct mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . 3
STEERING Mechanical - Adjust Float Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STEERING Mechanical - Adjust hand controls with servo operated pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
84423866 25/07/2011
D.20.B / 10
PARKING BRAKE Hydraulic - 32.C

TR270 , TR320 , TV380
84423866 25/07/2011
D.32.C / 1
Contents
TECHNICAL DATA
Control valve
General specification of the EH track brake valve on medium and large frame . . . . . . . . . . . . . . . . . . . . . . 4
General specification of the EH 2 speed brake valve on medium and large frame . . . . . . . . . . . . . . . . . . . 4
SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro
hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls
General specification 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SR175, SV185, SR200, SR220, SR250, SV250, SV300
General specification of the EH single speed brake valve on small frame . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SR130, SR150
General specification of the Mechanical single speed brake valve on all frames except track models . . 8
FUNCTIONAL DATA
Electrical control
Overview Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE
Command
Remove Brake valve solenoid for models with single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install Brake valve solenoid for models with single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove 2speed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install 2speed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Remove Loader pilot interlock valve solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

hydraulic controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls,
Install Loader pilot interlock valve solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Remove Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track
brake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Install Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track
brake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control valve
Remove EH 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install EH 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Remove EH brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SR130, SR150
Install EH brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SR130, SR150
Remove 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Install 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Remove Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250
Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls
Install Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Mechanical hydraulic controls, SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250
Mechanical hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls
Sensing system
Pressure sensor - Remove Charge pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro
hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls,
SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro
hydraulic controls, TV380 Electro hydraulic controls
Pressure sensor - Install Charge pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SR130 Electro hydraulic controls, SR150 Electro hydraulic controls, SR175 Electro hydraulic controls, SV185 Electro
hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro hydraulic controls,
SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro
hydraulic controls, TV380 Electro hydraulic controls
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AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic
Control valve - General specification of the EH track brake valve on

medium and large frame
Brake Solenoid Valve Configuration: Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic
cartridge valve.
2 Speed Solenoid Valve Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic
Configuration: cartridge valve.
EH Interlock Solenoid Valve Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic
Hydraulic Requirements: Flow = 7.6 l/min (2 US gpm)
Charge Pressure = 25 bar (363 psi)
Brake Release Pressure = 15 bar (218 psi)
Electrical Requirements: Operating Voltage = 14 V
Maximum Power = 22 W
Polarity = Power: Pin 1 or A, Ground: Pin 2 or B
Brake Release Solenoid Connection Type: Deutsch DT series.
2 Speed Solenoid Connection Type :Packard Metri - Pack 150 Series
EH Interlock Release Solenoid Connection Type: Packard Metri - Pack
150 series .
Pressure Switch Requirements: Operating Voltage = 14 V
Maximum Current = 2 A @ 12 V nominal.
Switch is normally open
Switch opening pressure settings: 15.5 bar (225 psi)
Operating Temperature Range: -30 - 107 °C (-22 - 225 °F)
Port Identification Chart: (P) Supply Inlet
(T) Tank Return
(B1) Brake Motor 1
(B2) Brake Motor 2
(2 SPD) 2 Speed Shift
(LV) EH Pilot Pressure
(PS1) Charge Pressure Switch
(PS2) Brake Pressure Switch
Control valve - General specification of the EH 2 speed brake valve

on medium and large frame
SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic controls, SR250 Electro
hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls
cartridge valve.
Sequence Valve Pressure = 12 bar (174 psi)
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Brake Release Solenoid Connection Type: Deutsch DT series .
2 Speed Solenoid Connection Type :Packard Metri - Pack 150 Series
150 Series .
(T) Tank Return
(B1) Brake Motor 1
(B2) Brake Motor 2
(SPD) 2 Speed Shift
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Control valve - General specification 2speed brake valve

SR175, SV185, SR200, SR220, SR250, SV250, SV300
cartridge valve.

Brake Release Solenoid Connection Type: Deutsch DT series .
2 Speed Solenoid Connection Type: Packard Metri - Pack 150 Series must
(T) Tank Return
(B1) Brake Motor 1
(B2) Brake Motor 2
(SPD) 2 Speed Shift
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Control valve - General specification of the EH single speed brake

valve on small frame
SR130, SR150
cartridge valve.


Minimum On-Off Duty Cycle = 50,000 cycles
150 series.

Voltage Drop: 50 mV @ 2 A

(T) Tank Return
(B1) Brake Motor 1
(B2) Brake Motor 2
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Control valve - General specification of the Mechanical single

speed brake valve on all frames except track models
cartridge valve.


(T) Tank Return
(B1) Brake Motor 1
(B2) Brake Motor 2
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Electrical control - Overview Park Brake

The park brake enable switch allows the operator to turn on and off the park brake after the hydraulics are enabled.
The switch is located in the Right Hand Control Handle.
The button engages and disabling the ground drive brake system. The parking brake can be engaged independent
of the loader valve by a park brake switch on the joystick. The button will only toggle the park brake on and off if the
master enable switch is on. A LED will indicate that the park brake is on and the hydraulics enable has enabled the
machine.
The park brake switch can be activated when

1. Operator is seated properly
2. The seat belt is latched or lap bar in down position while operator in seat
3. The ignition is on
4. Hydraulics are enabled
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Command - Remove Brake valve solenoid for models with single

speed
DANGER
Crushing hazard!
Always install the safety lock before working under the raised attachment.
D0075A
1. Locate the single speed brake valve (1), on the floor

left side, underneath the operator's cab.
93111536 1
2. Remove the electrical connector (1) from the brake

valve solenoid.
931001725A 2
3. Unthread the cap (1) and slide the solenoid off.
931001725A 3
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Command - Install Brake valve solenoid for models with single

speed
DANGER
Crushing hazard!
D0075A
1. Place solenoid (1) onto valve block . Thread cap (2)

onto valve body.
931001725A 1
2. Connect the electrical connector (2) to the solenoid.
931001725A 2
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Command - Remove 2speed solenoid

DANGER
Crushing hazard!
D0075A
1. Locate the brake valve (1) on the floor. Located in

the front left corner, under the operator's seat.
931001728 1
2. Disconnect the connector (2) from the 2speed sole-

noid (1).
931001728 2
3. Unthread the cap (1) from the solenoid.
931001725A 3
4. Slide the solenoid off.
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Command - Install 2speed solenoid

DANGER
Crushing hazard!
D0075A
1. Slide the 2speed solenoid onto the valve body.

Thread cap (1) onto valve body.
931001727 1
2. Connect the connector (2) to the 2speed solenoid (1).
931001728 2
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Command - Remove Loader pilot interlock valve solenoid

hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro hydraulic controls, TR320 Electro hydraulic
controls, TV380 Electro hydraulic controls
DANGER
Crushing hazard!
D0075A
NOTE: This procedure can be used on models with EH 2speed brake valve or track models with EH track brake valve.
93111535 1
2. Disconnect the connector (1) from the pilot interlock

solenoid.
931001727 2
3. Unthread cap (1) from the solenoid.
93111535 3
4. Slide the solenoid off.
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Command - Install Loader pilot interlock valve solenoid

DANGER
Crushing hazard!
D0075A
1. Slide the solenoid onto the valve body. Thread cap

(1) onto the valve body.
93111535 1
2. Connect the connector (1) to the pilot interlock sole-

noid.
931001727 2
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Command - Remove Brake valve solenoid for models equipped

with EH brake valve/EH 2speed brake valve/EH track brake valve.
DANGER
Crushing hazard!
D0075A

93111535 1
2. Remove the electrical connector (1) from the brake

valve solenoid.
NOTE: The brake valve solenoid can be determined from
looking at the brake valve body. The ports for the brake
valve are labeled B1 and B2
931001725A 2
3. Unthread the cap (1) and slide the solenoid off.
931001725A 3
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Command - Install Brake valve solenoid for models equipped with

EH brake valve/EH 2speed brake valve/EH track brake valve.
DANGER
Crushing hazard!
D0075A
1. Slide the solenoid onto the valve body. Thread the

cap (1) onto the valve body.
931001725A 1
2. Connect the electrical connector (1) to the brake

valve solenoid.
NOTE: The brake valve solenoid can be determined from
looking at the brake valve body. The ports for the brake
valve are labeled B1 and B2
931001725A 2
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Control valve - Remove EH 2speed brake valve

WARNING
Pressurized system!
System is still under pressure. Release pressure according to instructions in this manual.
W1044A
Prior operation:
PRIMARY HYDRAULIC POWER SYSTEM - Depressurising (A.10.A)
1. Label and disconnect hydraulic hose (1) from back

side of valve.
931001727 1
2. Label and disconnect four hoses (A), (B), (C), (D)

and one tube (E) from right hand side of valve.
931001726 2
3. Label and disconnect the drain hose (2).
931001726 3
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4. Label and disconnect five electrical connections, as

shown.
931001731 4
5. Remove mounting hardware (3).
931001728 5
6. Remove valve.
931001729 6
Next operation:
Control valve - Install (D.32.C)
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Control valve - Install EH 2speed brake valve

WARNING
Pressurized system!
W1044A
Prior operation:
Control valve - Remove (D.32.C)
1. Locate correct position on body to mount valve.

2. Install mounting hardware (1).
NOTE: There is two mounting bolts securing the valve.
931001728 1
3. Connect the five electrical connections to the correct

outlets as previously labeled.
931001731 2
4. Connect drain hose (2).
931001726 3
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5. Connect the four hoses (A), (B), (C), (D) and one
tube (E) to the correct locations as previously la-
beled.
931001728 4
6. Connect hydraulic hose (3) to the back side of valve.
931001727 5
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Control valve - Remove EH brake valve

SR130, SR150
DANGER
Crushing hazard!
D0075A
WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can
result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately.
W0358A
system.
side of valve. Cap open ports.
931001727 1
2. Label and disconnect switch connections (1) on the

brake valve.
931001727 2
3. Label and disconnect solenoid connections (1) on

the brake valve.
931001728 3
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4. Label and disconnect hoses (1) from valve. Cap

open ports.
931001726AA 4
5. Label and disconnect the drain hose (1). Cap open

ports.
931001726AA 5
931001728 6
7. Remove valve.
931001729A 7
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Control valve - Install EH brake valve

SR130, SR150
1. Place brake valve into machine, left front corner on

the floor.
931001729A 1
2. Insert mounting hardware (1).
931001728 2
3. Connect the drain hose (1).
931001726AA 3
4. Connect hoses (1) to the valve.
931001726AA 4
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5. Connect solenoid (1) connections onto the brake

valve.
931001728 5
6. Connect switch connections (1) onto the brake valve.
931001727 6
7. Connect the hydraulic hose (1) to the back side of

valve.
931001727 7
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Control valve - Remove 2speed brake valve

Prior operation:
Tilt system - Tilt (E.34.A)
system.
931001727 1

the brake valve.
931001728 2

open ports.
931001726AA 3
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ports.
931001726AA 4
931001728 5
6. Remove valve.
931001729A 6
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Control valve - Install 2speed brake valve

1. Place brake valve into machine, left front corner on

the floor.
931001729A 1
2. Insert mounting hardware (1).
931001728 2
931001726AA 3
4. Connect hoses (1) to the valve.
931001726AA 4
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5. Connect solenoid connections (1) onto the brake

valve.
931001728 5
6. Connect the hydraulic hose (1) to the back side of

valve.
931001727 6
7. Lower cab and lift arms refer to Tilt system - Tilt cab,
secure the lift arm in the raised position. (E.34.A)
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Control valve - Remove Brake valve

SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic
controls, SV300 Mechanical hydraulic controls
Prior operation:
system.
931001726B 1

the brake valve.
931001725A 2

open ports.
931001726C 3
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ports.
931001726C 4
931001726B 5
6. Remove valve.
931001729B 6
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Control valve - Install Brake valve

SR200 Mechanical hydraulic controls, SR220 Mechanical hydraulic controls, SR250 Mechanical hydraulic controls, SV250 Mechanical hydraulic
controls, SV300 Mechanical hydraulic controls
1. Place valve onto floor of machine, front left floor.
931001729B 1
2. Insert and tighten mounting hardware (1).
931001726B 2
931001726C 3
4. Connect hoses (1) to valve.
931001726C 4
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5. Connect solenoid connector (1) to the brake valve

solenoid.
931001725A 5
6. Connect hydraulic hose (1) to the back side of valve.
931001726B 6
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Sensing system Pressure sensor - Remove Charge pressure switch

WARNING
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support
strut. Lower the lift arms onto the support strut.
W0230A
Prior operation:
NOTE: Removing the charge pressure switch is the same procedure for the EH brake valve and EH 2speed brake
valve. This procedure uses the EH 2speed brake valve.
1. Locate the brake valve.
93107498 1
2. Locate the charge pressure switch, port PS1. Dis-

connect the connector (1) from the harness.
931001731 2
3. Unscrew the pressure sensor from the valve body.
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Sensing system Pressure sensor - Install Charge pressure switch

NOTE: Installing the charge pressure switch is the same procedure for the EH brake valve and EH 2speed brake
valve. This procedure uses the EH 2speed brake valve.
1. Thread and tighten the charge pressure switch into
the brake valve body port PS1.
2. Connect the charge pressure connector to the elec-
trical harness.
931001731 1
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Index

Command - Install Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track
brake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SR175 Electro hydraulic controls, SV185 Electro hydraulic controls, SR200 Electro hydraulic controls, SR220 Electro hydraulic
controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls, TR270 Electro
hydraulic controls, TR320 Electro hydraulic controls, TV380 Electro hydraulic controls
Command - Install Brake valve solenoid for models with single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Command - Install 2speed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Command - Install Loader pilot interlock valve solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Command - Remove Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH
track brake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Command - Remove Brake valve solenoid for models with single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Command - Remove 2speed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Command - Remove Loader pilot interlock valve solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control valve - General specification 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SR175, SV185, SR200, SR220, SR250, SV250, SV300
Control valve - General specification of the EH 2 speed brake valve on medium and large frame . . . . . . . . . . . . . 4
controls, SR250 Electro hydraulic controls, SV250 Electro hydraulic controls, SV300 Electro hydraulic controls
Control valve - General specification of the EH single speed brake valve on small frame . . . . . . . . . . . . . . . . . . . . . 7
SR130, SR150
Control valve - General specification of the EH track brake valve on medium and large frame . . . . . . . . . . . . . . . . 4
Control valve - General specification of the Mechanical single speed brake valve on all frames except track models
.................................................................................................. 8
Control valve - Install 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control valve - Install Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls
Control valve - Install EH 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control valve - Install EH brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SR130, SR150
Control valve - Remove 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control valve - Remove Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
hydraulic controls, SV250 Mechanical hydraulic controls, SV300 Mechanical hydraulic controls
Control valve - Remove EH 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Control valve - Remove EH brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SR130, SR150
Electrical control - Overview Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Sensing system Pressure sensor - Install Charge pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Sensing system Pressure sensor - Remove Charge pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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WHEELS AND TRACKS Tracks - 50.B
TR270
TR320
TV380
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Contents
SERVICE
Drive sprocket
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rubber track
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Track tensioning mechanism

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Track adjustment mechanism

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TR270, TR320, TV380
Roller
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Idler wheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
84423866 25/07/2011
D.50.B / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Idler wheel - Install D.50.B / 20
84423866 25/07/2011
D.50.B / 3
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks
Drive sprocket - Remove

1. Prior operation: Refer to Rubber track - Tension

adjust (D.50.B) and completely loosen the tension
on the track.
Make reference marks on the cover (1) and the drive
sprocket (2) to be used for alignment and the bolt
torque procedure during installation.
231002477A 1
2. Loosen and remove the socket head cap screws (1)

from the drive sprocket (2). Use acceptable lifting
equipment and lift the track above the drive sprocket
to allow the guide teeth to disengage from the drive
sprocket. Slide the drive sprocket off of the hub and
remove the drive sprocket.
231002477A 2
84423866 25/07/2011
D.50.B / 4
Drive sprocket - Install

NOTE: Photos are for reference only. Photo shows socket head cap screws installed on the drive sprocket.
1. Slide the drive sprocket over the hub. If the same
sprocket that was removed is being installed, use the
alignment marks made during removal to align the
drive sprocket on the hub. Lift the track above the
drive sprocket to allow the drive sprocket to engage
the guide teeth (1) on the track. Make sure the drive
sprocket is between the guide teeth (1) on the track.
231002477A 1
2. Install the socket head cap screws (1) into the drive
sprocket (2).
231002477A 2
3. Use the reference mark on the hub as the starting

point and tighten the socket head cap screws to a
torque of 67 - 163 Nm (50 - 120 lb ft) in the sequence
shown.
231002477A 3
4. Tighten the socket head cap screws to a final torque

of 285 - 320 Nm (208 - 235 lb ft) in the sequence
shown.
Next operation: After the drive sprocket has been in-
stalled, follow the procedure - Rubber track - Ten-
sion adjust (D.50.B) and adjust the tension of the
track.
231002477A 4
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D.50.B / 5
Rubber track - Remove

1. Park the machine on a level surface with the bucket

approximately 125 mm (5 in) off of the ground and
stop the engine.
231002469 1
2. Place 101 mm (4 in) blocks on the ground under

the bucket. Enter the operators compartment and
start the engine and lower the bucket until the front
of the machine is raised off the ground. Stop the
engine and exit the operators compartment. Place
a floor jack under the rear of the machine and raise
the rear of the machine until the tracks are completely
off of the ground. Install blocks under the machine to
securely block the machine in the raised position with
the tracks off the ground.
3. Remove the screws (1) from the adjuster cover (2)
and remove the cover.
231002468A 2
4. Slowly loosen the grease valve (1) on the adjuster (2)

until the grease begins to discharge from the adjuster
(2). Allow the grease to completely discharge from
the adjuster (2) to release the tension on the track as
the idler wheel moves rearward.
NOTE: DO NOT remove the grease valve body from the
adjuster. Internal parts (ball, spring, and poppet) may be
lost.
231002478 3
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D.50.B / 6
5. The idler wheel (1) can be moved farther rearward

either by pushing the idler wheel rearward or by lifting
on the center (2) of the track.
231002469 4
6. Lift the track (2) off of the drive sprocket (1) to allow
room for the drive sprocket (1) to slide off of the hub.
Next operation: Refer to Drive sprocket - Remove
(D.50.B) and remove the drive sprocket (1).
231002469 5
7. Remove the rubber track from the main frame (2)
231002469 6
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D.50.B / 7
Rubber track - Install

1. Follow the procedure in Steps 1 and 2 of Rubber

track - Remove (D.50.B) and raise and install blocks
under the machine to securely block the machine
in the raised position so that the tracks are off the
ground.
231002469 1
2. Install the track around the rear idler wheel (1). Make
sure the rear idler wheel is between the guide teeth
(2) on the track.
231002473 2
3. Continue towards the front idler wheel (1) engaging

the track guide teeth (3) between the rollers (2) and
then around the front idler wheel (1). Make sure the
front idler wheel (1) is between the guide teeth (3) on
the track.
Next operation: Refer to Drive sprocket - Install
(D.50.B) and install the drive sprocket.
Next operation: Refer to Rubber track - Tension
adjust (D.50.B) and adjust the tension of the track.
231002474 3
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D.50.B / 8
Rubber track - Tension adjust

1. Follow the procedure in Steps 1 and 2 of Rubber

track - Remove (D.50.B) and raise and install blocks
under the machine to securely block the machine
in the raised position so that the tracks are off the
ground.
231002469 1
2. Remove the screws (1) from the adjuster cover (2)

and remove the cover (2).
231002468A 2
3. Tighten the grease valve (1) to a torque of 90 ± 10

Nm (66 ± 10 lb ft). Install a power grease gun on the
grease zerk (3) on the grease valve (1).
231002478 3
4. To tighten the track, apply grease to the adjuster (2)

to increase the tension to the track.
231002478 4
84423866 25/07/2011
D.50.B / 9
5. Apply grease to the adjuster until the distance from

the bottom of the 2 center rollers (1) to the top surface
(2) of the track is within 12 - 19 mm (0.47 - 0.75 in)
231002475 5
6. To loosen the track, loosen the grease valve on the

adjuster until grease discharges from the adjuster.
Allow the grease to discharge from the adjuster until
the distance from the bottom of the two center rollers
to the top surface of the track is within 12 - 19 mm
(0.47 - 0.75 in) as shown in the step above. When
the distance is within the specifications, tighten the
grease valve to a torque of 90 ± 10 Nm (66 ± 10 lb
ft) .
NOTE: DO NOT remove the grease valve body from the
adjuster. Internal parts (ball, spring, and poppet) may be
lost.
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D.50.B / 10
Track tensioning mechanism - Remove

Prior operation:
Refer to Rubber track - Remove (D.50.B) and remove the track from the machine
1. Remove the track from the machine.
231002469 1
2. Slide the track tension assembly (2) out of the main

frame (1).
231002470 2
3. Slide the yoke assembly (2) off of the track tension

assembly (1).
231002470 3
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D.50.B / 11
Track tensioning mechanism - Install

1. Slide the yoke assembly (2) onto the track tension

assembly (1).
231002471 1
2. Slide the track tension assembly (2) into the main

frame (1).
231002470 2
Next operation:
Refer to Rubber track - Install (D.50.B) and install the track.
After the track has been installed, follow the procedure Rubber track - Tension adjust (D.50.B) and adjust the tension
of the track.
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D.50.B / 12
Track adjustment mechanism - Adjust

TR270, TR320, TV380
1. Make sure all paint is removed from contact surface

on end cap and shaft.
23112927 1
2. Inspect inside edge at all roller locations for any ex-

cess paint or rough edges. Remove as required.
23112928 2
23112929 3
3. Add one Keeper to each end of the rear idler. Two

Keepers total are required.
23112930 4
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D.50.B / 13
4. Start both bolts, but do not tighten.
23112931 5
5. Insert one shim (1) on each end of the rear idler (2). A
total of two shims are needed, the arrows show there
location. Be sure to add medium strength thread
locker (3)
23112932 6
23112933 7
6. Move Idler as far back in holes as possible and

tighten bolts.
23112934 8
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D.50.B / 14
7. Make sure the idler end cap ears are not pinched by
track frame after bolts are tight.
23112935 9
8. Install roller with out bolts and push roller against

inside track frame wall.
9. Use shim as guide to determine the required number
of shims needed to fill gap between the roller and the
track frame wall.
10. Maximum of one shim on each end of the roller.
11. If only one shim is required, install between roller and
the outside track frame wall.
12. Install shim as shown
23112937 10
13. Install bolts in roller, but do not tighten. Repeat shim

procedure for all three rollers, then add medium
strength thread lock, before tightening all of the
bolts.
23112938 11
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D.50.B / 15
14. Spin all rollers by hand.
23112939 12
NOTE: Rollers should spin easily by hand, using only your palm to grip the roller.
If a roller does not spin freely

15. Remove edge of track frame wall for 2 inches on
each side of roller hole.
16. Install roller and confirm roller spins freely.
23112940 13
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D.50.B / 16
Roller - Remove
Prior operation:
Refer to Rubber track - Remove (D.50.B) and remove the track from the machine.
NOTE: Photos are for reference only. Photo shows track installed on the machine.
1. After the track has been removed from the machine,
loosen and remove the cap screws and washers (1)
from the roller (2). Remove the roller (2) from the
track assembly.
231002476 1
2. Repeat the procedure above and remove the remain-

ing rollers (1) from the track assembly.
231002476 2
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D.50.B / 17
Roller - Install
NOTE: Photos are for reference only. Photo shows track installed on the machine.
NOTE: Apply Locktite 243 to the threads of the roller mounting bolts prior to installation.
1. Install the roller (2) into the mounting location in the
track frame. Install the cap screw (1) and washer
into the track frame and through the roller pilot hole.
Tighten the mounting bolt (1) to a torque of 336 - 371
Nm. (248 - 274 lb ft)
231002476 1
2. Install the remaining rollers in the track frame mount-

ing locations. Install the cap screw and washer into
the track frame and through the roller pilot hole.
Tighten the mounting bolt to a torque of 336 - 371
Nm. (248 - 274 lb ft)
231002476 2
Next operation:
After the track has been installed, follow the procedure Rubber track - Tension adjust (D.50.B) and adjust the tension
of the track.
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D.50.B / 18
Idler wheel - Remove

Prior operation:
Refer to Rubber Track - Rubber track - Remove (D.50.B) and remove the track from the machine.
1. Front Idler Wheel:

Remove the track from the machine. Slide the track
tension assembly (2) out of the main frame (1).
231002470 1
2. Loosen and remove the mounting screw (1) in the

yoke (2) which fastens the front idler wheel (3) to the
yoke (2). Remove the front idler wheel (3) from the
yoke (2).
231002471 2
3. Rear Idler Wheel:

Loosen and remove the cap screw (1) and washer
from the rear idler wheel (2). Remove the rear idler
wheel (2) from the main frame (3).
231002472 3
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D.50.B / 19
Idler wheel - Install

NOTE: Apply LOCTITE® 243 to the threads of the front and rear idler wheel mounting bolts prior to installation.
1. Front Idler Wheel:
Install the front idler wheel (3) into the yoke (2). Install
the screw into the yoke and into the front idler wheel.
Tighten the screw (1) to a torque of 183 - 205 Nm
(136 - 153 lb ft)
231002471 1
2. Slide the track tension assembly (2) into the main

frame (1).
231002470 2
3. Rear Idler Wheel:

Install the rear idler wheel (2) into the main frame (3).
Install the screw (1) into the main frame and into the
rear idler wheel (2). Tighten the screw (1)to a torque
of 555 - 620 Nm (406 - 460 lb ft).
231002472 3
Next operation:
After the track has been installed, follow the procedure - Rubber track - Tension adjust (D.50.B) and adjust the
tension of the track.
84423866 25/07/2011
D.50.B / 20
Index

Drive sprocket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive sprocket - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Idler wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Idler wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Roller - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Roller - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rubber track - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rubber track - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rubber track - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Track adjustment mechanism - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TR270, TR320, TV380
Track tensioning mechanism - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Track tensioning mechanism - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
84423866 25/07/2011
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84423866 25/07/2011
D.50.B / 22
WHEELS AND TRACKS Wheels - 50.C

TR270 , TR320 , TV380
84423866 25/07/2011
D.50.C / 1
Contents
SERVICE
WHEELS AND TRACKS Wheels

Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84423866 25/07/2011
D.50.C / 2
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
WHEELS AND TRACKS Wheels - Service instruction

WARNING
Explosion hazard!
Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the
recommended pressure. Excessive pressure could result in tire failure.
W0109A
WARNING
Explosion hazard!
Tires must be replaced by skilled personnel with the proper tools and technical knowledge. Unskilled
personnel replacing wheels or tires could result in serious physical injuries, tire damage, and/or wheel
distortion. Always have a qualified tire mechanic service wheels and tires.
W0171A
1. The skid steer will be hard to turn and the tires will
wear faster if the correct pressure is not maintained.
When a worn or damaged tire is replaced, the re-
placement must be the same size and tread design
as the other tires on the machine. Two different sized
tires on one side of the machine will cause acceler-
ated tire wear, loss of power, and excessive strain
on the drivetrain. Replace worn tires in pairs with the
two new tires used on the same side of the loader. If
this tilts the loader too much, replace all four tires.
Adding air to the tires

NOTICE: Tire pressure gauges should be checked at regular intervals for calibration and accuracy.
TIRE SIZE PRESSURE

XD2002 10x16.5 40 - 60 psi
XD2002 12x16.5 40 - 60 psi
Beefy Baby II 10x16.5 40 - 60 psi
Beefy Baby II 12x16.5 40 - 60 psi
Hulk 10x16.5 40 - 60 psi
Hulk 12x16.5 40 - 60 psi
Bulky Hulk 33/15.5x16.5 40 - 60 psi
King Kong 10x16.5 40 - 60 psi
King Kong 12x16.5 40 - 60 psi
Hippo 31/15.5x16.5 40 - 60 psi
Hippo 33/15.5x16.5 40 - 60 psi
84423866 25/07/2011
D.50.C / 3
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
Wheel torque
Wheel taper nut torque 169.5 N·m (125 lb ft)
Flange nut 203.5 N·m (150 lb ft)
This procedure is only for adding air to the tire. If the tire
has lost most or all of the air, do the following.
1. Before you add air, have the wheel correctly installed
on the machine or put the wheel in a restraining de-
vice (tire inflation cage).
2. Use an air hose with a remote shutoff valve, self-
locking air chuck and wear eye protection.
3. Stand BEHIND the tread of the tire and make sure
ALL persons are away from the side of the tire before
you start to add air.
4. Inflate the tire to the recommended air pressure. DO
NOT inflate the tire more than the recommended
maximum pressure given on the tire.
84423866 25/07/2011
D.50.C / 4
Index

WHEELS AND TRACKS Wheels - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84423866 25/07/2011
D.50.C / 5
PRINTED IN U.S.A.
84423866 25/07/2011
EN
SERVICE MANUAL
FRAME AND CAB

TR270 , TR320 , TV380
84423866 25/07/2011
E
Contents
FRAME AND CAB - E
FRAME Primary frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.10.B

SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.20.A
USER CONTROLS AND SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.A

USER CONTROLS AND SEAT Operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.C

USER PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.34.A

ENVIRONMENT CONTROL Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.40.B

ENVIRONMENT CONTROL Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.40.C

SAFETY SECURITY ACCESSORIES Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.50.B

84423866 25/07/2011
E
FRAME AND CAB - E
FRAME Primary frame - 10.B

TR270 , TR320 , TV380
84423866 25/07/2011
E.10.B / 1
Contents
FRAME AND CAB - E
FUNCTIONAL DATA
FRAME Primary frame

Overview Model Frame Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84423866 25/07/2011
E.10.B / 2
FRAME AND CAB - FRAME Primary frame
FRAME Primary frame - Overview Model Frame Identification

Model Frame Size Engine
SR130 Small ISM 34 kW (46.2 Hp)
Radial boom architecture
SR150 Small ISM 39 kW (53.0 Hp)

SR175 Medium ISM 45 kW (61.2 Hp)

SV185 Medium ISM 45 kW (61.2 Hp)

Vertical boom architecture
SR200 Medium F5C 55 kW (74.8 Hp)

SR220 Large F5C 61 kW (82.9 Hp)

SR250 Large F5C 67 kW (91.1 Hp)

SV250 Large F5C 61 kW (82.9 Hp)

SV300 Large F5C 67 kW (91.1 Hp)

TR270 Medium F5C 55 kW (74.8 Hp)

TR320 Large F5C 67 kW (91.1 Hp)

TV380 Large F5C 67 kW (91.1 Hp)

84423866 25/07/2011
E.10.B / 3
Index
FRAME AND CAB - E

FRAME Primary frame - Overview Model Frame Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84423866 25/07/2011
E.10.B / 4
FRAME AND CAB - E
SHIELD - 20.A

TR270 , TR320 , TV380
84423866 25/07/2011
E.20.A / 1
Contents
FRAME AND CAB - E
SHIELD - 20.A
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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FRAME AND CAB - SHIELD
Engine hood - Remove

1. Remove fuel lines (1) from support strap.
931001670 1
2. Remove hardware (2) from filter base and remove

from door
931001668 2
3. Disconnect back up alarm electrical connections (3).
931001672 3
4. Disconnect rear light electrical connections (4).
931001675 4
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5. Remove door hardware (5).
931001676 5
6. Remove rear door and grill assembly (6).
931001678 6
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Engine hood - Install

1. Install rear access door and grill assembly in mounts
931001678 1
2. Install door hardware, bolt (1) and nut (2) to the upper
and lower mounts.
931001676 2
3. Connect rear light electrical connections (3).
931001675 3
4. Connect back up alarm electrical connection (4).
931001673 4
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5. Mount fuel filter base to door using bolts (B) and nuts
(A).
931001671 5
6. Support the fuel lines (6) to the back door using wire
ties (5).
931001670 6
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Index
FRAME AND CAB - E
SHIELD - 20.A
Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FRAME AND CAB - E
USER CONTROLS AND SEAT - 32.A

TR270 , TR320 , TV380
84423866 25/07/2011
E.32.A / 1
Contents
FRAME AND CAB - E
SERVICE
Console
Left - Remove Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Left - Install Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Instrument panel
Digital instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Digital instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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FRAME AND CAB - USER CONTROLS AND SEAT
Console Left - Remove Left hand side console

1. Locate the left hand console (1), inside operator's
cab front left side cab frame post
93107448A 1
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2. Remove left console mounting hardware (1).
93109327Z 2
3. Remove connector from the switch (1).
20111506 3
4. Unclip the switch from the console.
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Console Left - Install Left hand side console

1. Insert switch into console. Connect the connector to
the switch (1).
20111506 1
2. Insert the mounting hardware into the left side (1) and
right side of the console (2).
93109327Z 2
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Instrument panel Digital instrument cluster - Remove

1. Locate instrument cluster (1) on the right hand frame
post inside operator's cab.
931002055 1
2. Remove hardware (1) retaining the instrument clus-

ter on to the right hand frame post.
93109330 2
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E.32.A / 6
3. Disconnect connector X-C23 from the instrument

cluster (1).
93105890B 3
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Instrument panel Digital instrument cluster - Install

Prior operation:
Instrument panel Digital instrument cluster - Remove (E.32.A)
1. Connect connector X-C23 to the instrument cluster

(1).
93105890B 1
2. Place instrument cluster (1) into right hand frame

post. Place hardware (2) into instrument cluster to
secure to frame post.
93109330 2
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Instrument panel - Remove Right hand side console

1. Locate instrument cluster (1) on the right hand frame
post inside operator's cab.
931002055 1
2. Remove the mounting hardware from the left side (1)

and right side (2) of the right hand console.
93109330 2
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3. Disconnect connector from the switch. Remove

switch from the right hand console (1).
20111505 3
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Instrument panel - Install Right hand side console

1. Insert switch into the right hand console (1). Connect
the connector to the switch.
20111505 1
2. Insert the mounting hardware into the left side (1) and
right side (2) of the right hand console. Tighten to
proper torque.
93109330 2
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Index
FRAME AND CAB - E

Console Left - Install Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Console Left - Remove Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Instrument panel - Install Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Instrument panel - Remove Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Instrument panel Digital instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instrument panel Digital instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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FRAME AND CAB - E
USER CONTROLS AND SEAT Operator seat - 32.C

TR270 , TR320 , TV380
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E.32.C / 1
Contents
FRAME AND CAB - E
DIAGNOSTIC
Command
Testing Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Testing Operator Restraint Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Heater
Testing Seat Heat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Command - Testing Seat Switch

NOTE: The seat switch may become misaligned and not function properly, due to switch mounting or seat cushion
compression. Ensure proper switch mounting before replacing switch.
connector X-58A. Connect a jumper Action move jumper.
between connector X-58 pins 3 and The SEAT SWITCH S-002 or connect- Action
4. ing wiring has failed. Replace the Go to test 2
Check switch or failed wiring.
for circuit operation.
Check wire 315/317/313 (Red) or adjacent
wire condition between connector wiring.
X-C23 pin 3 and connector X-58 pin
3.
Check wire 323/328 (Yellow) (EH) 323 (Yel-
wire condition between connector low) (Mech) or adjacent wiring.
X-C23 pin 12 and connector X-58
pin 4.
Use Data bus - General specifica- No resistance problems. Resistance problems are found.
tion Instrument Cluster pin infor- Action Action
mation (A.50.A) to The SEAT SWITCH S-002 or connect- Replace the INSTRUMENT CLUSTER.
Check ing wiring has failed. Replace the
INSTRUMENT CLUSTER pins 3 and 12. switch or failed wiring.
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Command - Testing Operator Restraint Switch

NOTE: For EH machines follow steps 1-5. For Mechanical machines follow steps 6-8.
1 Condition Result Action
Disconnect connector X-104 from No circuit problems No change in circuit response, re-
the OPERATOR RESTRAINT SWITCH Action move jumper.
S-043. Connect a jumper between The OPERATOR RESTRAINT SWITCH Go to test 2
connector X-104 pins 1 and 2. has failed. Replace the switch.
Check
Disconnect connector X-99 from the Test satisfactory. Diode is faulty.
EH LAP BAR DIODE V-005. Action Action
Check Go to test 3 Replace the diode.
the diode using ELECTRICAL
POWER SYSTEM - Testing Diode
Testing (A.30.A).
Check wire 317/316 (Red) / 313 (Yellow) or
wire condition between X-104 pin 1 adjacent wiring.
and connector X-C23 pin 3.
Check wire 314 (Yellow) or adjacent wiring.
wire condition between X-99 pin A
and connector X-104 pin 2.
TEM - Testing General Wire Test-Action Action
Check ally inspect the relevant harnesses wire 524 (Yellow) or adjacent wiring.
and connectors for damage, bent or
wire condition between X-CN4A pin
10 and connector X-99 pin B. dislocated pins, corroded terminals
continue operation.
6 Condition Result Action
Disconnect connector X-104 from No circuit problems No change in circuit response, re-
the OPERATOR RESTRAINT SWITCH Action move jumper.
S-011. Connect a jumper between The OPERATOR RESTRAINT SWITCH Go to test 7
connector X-104 pins 1 and 2. has failed. Replace the switch.
Check
84423866 25/07/2011
E.32.C / 4

Check wire 317/316 (Red) / 313 (Yellow) or
wire condition between X-104 pin 1 adjacent wiring.
and connector X-C23 pin 3.
Check ally inspect the relevant harnesses wire 314 (Yellow) or adjacent wiring.
wire condition between X-C23 pin 13 and connectors for damage, bent or
and connector X-104 pin 2. dislocated pins, corroded terminals
continue operation.
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Heater - Testing Seat Heat Switch

NOTE: See schematics
Place the SEAT HEAT SWITCH to the Bulb comes on. Bulb does not light.
on position. Action Action
Check The seat heat wiring has developed Go to test 2
for indicator bulb illumination. an open, or the SEAT HEAT ELEMENT
R-001 has failed. Replace the SEAT
HEAT ELEMENT or faulty wiring.
Remove ACCESSORY FUSE from the 0 Ω Fuse is blown.
BLOCK 1 Z-2008 Go to test 3 Replace the fuse with same type and
Check amp rating.
for continuity across ACCESSORY
FUSE.
With the fuse removed, and ignition 12 V 0V
on, Action Action
DISTRIBUTION FUSE BLOCK 1 Z-2008 FUSE
pin C1 and ground.
Use ELECTRICAL POWER SYS- No wire problems Wire problems are found.
ing (A.30.A) to check wire condition Go to test 5 Locate and repair or replace broken
between MAIN POWER DISTRIBUTION wire 134/152/756 (Orange) or adja-
FUSE BLOCK 1 Z-2008 pin C2 and cent wiring.
connector X-58 pin 1.
ing (A.30.A) to check wire condition Go to test 6 Locate and repair or replace broken
between connector X-58 pin 2 and wire 933/1088/1093 (Black) or adja-
cab ground. cent wiring.
While cycling the SEAT HEAT Infinite resistance with switch in off Open in both positions.
SWITCH, position, low resistance with switch Action
Check in on position. The SEAT HEAT SWITCH S-003 has
resistance between connector X-58 Action failed. Replace the switch.
pin 1 and connector X-58 pin 2. The seat heat wiring has developed
an open, or the SEAT HEAT ELEMENT
R-001 has failed. Replace the SEAT
HEAT ELEMENT or faulty wiring.
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Index
FRAME AND CAB - E

Command - Testing Operator Restraint Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Command - Testing Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heater - Testing Seat Heat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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FRAME AND CAB - E
USER PLATFORM - 34.A

TR270 , TR320 , TV380
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Contents
FRAME AND CAB - E
FUNCTIONAL DATA
Door, window and windscreen

Overview Door Switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Tilt system
Tilt cab, secure the lift arm in the raised position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSTIC
Cigar lighter
Testing Accessory Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Door, window and windscreen
Testing Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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FRAME AND CAB - USER PLATFORM
Door, window and windscreen - Overview Door Switch - Overview

If a unit has a door, the Door Switch Function will prevent the operator from operating the loader arm and bucket while
the door is open. This will prevent damage to the machine because when the door is open it is directly in the path of
the implement.
The operator can open the door at any time and the joystick control of loader and bucket will be shut off over software
and the port locks will engage. Once the door is closed the operator will regain control of the attachment.
The Door Switch is a magnetic reed switch. The switch operates on low current, and closes in the presence of metal.
The switch mush be adjusted properly to function correctly.
The Door Switch Function is active when Ignition is ON.
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Tilt system - Tilt cab, secure the lift arm in the raised position.
DANGER
Crushing hazard!
Loader lift arm is unsupported during support strut removal. Do not enter or exit the operator's com-
partment with an unsupported loader lift arm. Two persons are required during storage. One person
should remove and store the support strut while the operator remains in the operator's compartment.
D0021A
WARNING
Crushing hazard!
W0230A
To secure the lift arms up and install the support lock pin on radial lift machines.
1. Remove any attachment.
2. Park the machine on firm and level surface.
3. See the instructional decal on the inside of the right
lift arm, just above the support strut. Read and un-
derstand these instructions before you perform this
procedure.
4. Remove the retaining clip (1) that secures the lift arm
support strut.
93106848A 1
5. Lay the support (1) down on the lift arm tubing and
cylinder, as shown.
6. Slowly raise the lift arms until the support strut drops
down onto the cylinder, as shown.
7. Install retaining clip (2) to secure support strut to the
lift arm cylinder. Gently, lower the lift arms down until
the support strut is in contact with the cylinder.
93106854A 2
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To secure the lift arms up and install the support lock pin on vertical lift machines.
DANGER
Crushing hazard!
D0020A
1. Remove any attachment.

2. Park machine on firm level surface.
3. See instructional decal (2) located by the lift arm lever
lock.
4. Raise the loader arm until loader link is above the
lock pins.
5. Rotating mechanical lift arm lock lever (1) towards
the inside of the machine will extend the pins and
the lift arms will be LOCKED.
6. Slowly lower lift arm until it rests on the lock pins.
93109334 3
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Move operator protective structure to service position.

1. The operators compartment may be tilted forward,
for service access, only with the lift arms raised. Fol-
lowing instruction provided to access the engine, hy-
drostatic pumps, motors and control linkage.
2. To tilt the cab, confirm that the following steps have
been completed.
3. The machine is on firm, level ground.
4. The lift arms are up with the support strut or lock pin
in lock position.
5. Use a 24 mm (15/16 in) socket or wrench to remove
the two rear ROPS retaining nuts (1).
6. Use the cab entry hand holds and pivot the cab for-
ward as shown.
7. Confirm red lock tube (1) has lowered over pivot link-
age.
93107498 4
93105463 5
93107499A 6
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Tilt system - Lower

DANGER
Crushing hazard!
D0021A
WARNING
Crushing hazard!
W0230A
To lower the cab

1. To place the cab and loader lift arms back into the
work position raise the red lock tube over the cab
pivot linkage.
2. Confirm red lock tube (1) is raised over pivot linkage.
93107499A 1
3. Use the cab entry hand holds and pivot the cab down
onto frame.
4. Use a 24mm socket or wrench to install the two
rear ROPS retaining nuts (1) to a torque of 170 N·m
(125.4 lb ft) .
931001633 2
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To lower the working arms and disengage the support lock pin on vertical lift machines.
DANGER
Crushing hazard!
D0020A
1. While sitting in the operator's seat with the seat belt

fastened and the engine running, Raise the lift arm
(4) high enough to clear the lift arm lock pins (3).
Rotate the mechanical lift arm lock lever away from
the seat (counter - clockwise) to retract the lock pins.
93107457 3
93109334 4
NOTICE: See the instructional decal (2) located by the mechanical lift arm lock lever.
2. Slowly lower the lift arm until the lift arms are on the
ground or floor.
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To lower the working arms and disengage the support bracket on radial lift machines.
WARNING
Crushing hazard!
W0230A
DANGER
Crushing hazard!
D0021A
1. See the instructional decal on the inside of the right

lift arm, just above the support strut. Read and un-
derstand these instructions before you perform this
procedure.
NOTE: Two people are required for this procedure.

2. One person should remove retaining clip (1) from
support strut while the operator remains in the op-
erator's compartment.
93106854A 5
3. Slowly raise the lift arms until the support strut sepa-
rates from the cylinder.
4. Have the person outside the unit raise support strut
and secure through tab with retaining clip (1), as
shown.
5. Once the second person has cleared the area, the
working arm can be lowered.
93106848A 6
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Cigar lighter - Testing Accessory Power Outlet

Remove ACCESSORY / BEACON FUSE 0Ω Fuse is blown.
from the MAIN POWER DISTRIBUTION Action Action
FUSE BLOCK 1 Z-2008. Go to test 2 Replace the fuse with same type and
Check amp rating.
for continuity across ACCESSORY /
BEACON FUSE.
With the fuse removed and Ignition 12 V 0V
on, Action Action
DISTRIBUTION FUSE BLOCK 1 Z-2008 / BEACON FUSE.
pin D5 and ground.
Check wire 801/115/196 (Red) or adjacent
wire condition between connec- wiring.
tor X-ACC pin B and MAIN POWER
DISTRIBUTION FUSE BLOCK 1 Z-2008
pin D6.
ing (A.30.A) to The ACCESSORY POWER OUTLET Locate and repair or replace broken
Check Z-008 has failed. Replace the wire 952/842/1094 (Black) or adja-
wire condition between connector ACCESSORY POWER OUTLET. cent wiring.
X-ACC pin A and ground.
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Door, window and windscreen - Testing Door Switch

the DOOR SWITCH. Connect a jumper Action move jumper.
between connector X-505 pins 1 and The DOOR SWITCH has failed. Re- Action
2. place the switch. Go to test 2
Check
ing (A.30.A) to Go to test 3 Repair or replace broken wire 1016/
Check 910/966 (Black).
wire condition between connector
X-505 pin 2 and ground.
Disconnect connector X-502 from No wire problems. Wire problems are found.
the DOOR WIPER MOTOR. Use ELEC- Action Action
TRICAL POWER SYSTEM - Test- Go to test 4 Repair or replace broken wire 250/
ing General Wire Testing (A.30.A) 251 (Yellow) or wire 220 (Yellow).
to
Check
X-505 pin 1 and connector X-C23
pin 17.
Use Data bus - General specifica- No resistance problems. Resistance problems are found.
tion Instrument Cluster pin infor- Action Action
mation (A.50.A) to The fault may be intermittent. Visu- Replace the INSTRUMENT CLUSTER.
Check ally inspect the relevant harnesses
INSTRUMENT CLUSTER pin 17. and connectors for damage, bent or
dislocated pins, corroded terminals
continue operation.
84423866 25/07/2011
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Index
FRAME AND CAB - E

Cigar lighter - Testing Accessory Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Door, window and windscreen - Overview Door Switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Door, window and windscreen - Testing Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tilt system - Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tilt system - Tilt cab, secure the lift arm in the raised position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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FRAME AND CAB - E
ENVIRONMENT CONTROL Heating system - 40.B

TR270 , TR320 , TV380
84423866 25/07/2011
E.40.B / 1
Contents
FRAME AND CAB - E
SERVICE
Heater
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SR130, SR150
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SR200, SR220, SR250, SV250, SV300, TR270, TR320, TV380
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SR175, SV185
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SR130, SR150
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SR175, SV185
84423866 25/07/2011
E.40.B / 2
FRAME AND CAB - ENVIRONMENT CONTROL Heating system
Heater - Install
SR130, SR150
Prior operation:
1. Tip cab and remove seat; remove the cover plate

behind the seat, if equipped. If unit has EH controls
remove the control towers.
93104685 1
2. Remove HVAC switch blanking decal from left hand

side console. (No image available.)
3. Take left hand side console loose from the a-post.
Add heater control decal (1), fan switch (2), and tem-
perature control potentiometer (3) and knob (4).
93104687 2
4. The right hand side console and headliner must be

removed in order to install the deluxe cab harness
and roof foam for added sound reduction. If neither
are needed the right hand side console and headliner
may be left in place.
5. If converting from an open cab without radio, remove
and replace the cab harness. Part not included. Or-
der deluxe harness separately.
6. [Optional] Clean and degrease underside of roof
panel and install roof foam (1) using firm even pres-
sure.
93104646 3
84423866 25/07/2011
E.40.B / 3
7. Remove the blocking plates that cover the fresh air

intake hole and plumbing holes in the firewall and cab
floor.
8. Install the heater box sealing foam (1) at the back of
the cab floor.
93104647 4
9. Using two M6x 30 carriage bolts (1), two M6 hex nuts

(2) and two washers (3) install the air intake duct (4)
to the firewall.
93104686 5
10. Using four M6 x 40 screws (1) and three washers

(2), install the heater (3) to the firewall. Be careful to
ensure that the plumbing ports are inserted properly
through the hole in the cab floor.
93104686 6
11. Connect heater box electrical connector to the cab

harness.
84423866 25/07/2011
E.40.B / 4
12. Install ducts (1) and (2) to heater box using bolts (3)
and anchor to side of cab using fir tree fasteners (4).
Ensure that wiring harness is not pinched between
the ducts and the cab side.
93104691 7
93104640 8
13. Install six directional louvers (1) in the ducts (2).
93104640 9
14. Reinstall headliner and consoles.

15. Remove silicone from bottom of J tubes (A) inside
the rear of the cab.
93104685 10
84423866 25/07/2011
E.40.B / 5
16. Install the rear trim panel (1) over the heater box and
washer bottle. Cap must be removed from washer
bottle to install, then replaced once the panel is se-
cure. Ensure the seat belt is routed through the slot
in the panel and the upper lip of the panel is under
the air filter access cover. Secure the panel with fir
tree fasteners (2).
93104640 11
17. Apply silicone to bottom of J tubes (A) at back exte-

rior of cab and in the front corners of the upper chas-
sis. Fill drain hole (B) in tube with silicone.
93112374 12
18. Clean and degrease front surface of the chassis

crossmember behind the cab. Apply crossmember
foam (1) with firm even pressure.
93104643 13
19. Remove floorplate. Cab lift struts have to be re-

moved in order to remove floorplate. Do not remove
the cab tip safety lock!
20. Using four M6 x 25 flange bolts (1) and four M6 hex
nuts (2), install the water valve (3) to the water valve
bracket (4) and bolt the bracket under the floorboard.
Ensure that the water valve is facing with the outlet
rearward.
93104689 14
84423866 25/07/2011
E.40.B / 6
93112373 15
21. Connect the chassis harness electrical connector to

the water valve.
22. Drain the existing coolant from the engine and radi-
ator. Save for reuse.
23. Remove the plug from the thermostat housing on the
right side of the engine and install the 90 ° hose nip-
ple adapter (1). Use pipe thread compound on the
threads.
93104689 16
24. On naturally aspirated engines, remove the plug from

the top of the water pump and install the straight hose
nipple adapter (1). Use pipe thread compound on the
threads.
25. On turbocharged engine, cut the existing coolant re-
turn hose under the injector lines and route the two
halves over top of the injector lines.
26. Install the “Y” fitting (2) between two halves of return
hose.
93104688 17
84423866 25/07/2011
E.40.B / 7
27. Route the heater supply (1) and new return hoses
(2) from the engine to the front of the machine. Both
hoses route under the engine between the flywheel
side engine mounts. The cab side end of the return
hose has plastic spiral hose guard installed. The
cordura sleeve (3) must be installed over both hoses
where they pass under the engine and tandem pump.
93104689 18
93104688 19
28. Using ctb clamps (1), connect the supply hose (2) to
the hose nipple (3) on the thermostat housing and to
the inlet of the water valve (4).
93104689 20
29. If installing on turbocharged unit, cut return hose (1)

to a length of 2740 mm, where the Y hose fitting (2)
is located. Naturally aspirated units use the hose full
length.
93104688 21
84423866 25/07/2011
E.40.B / 8
30. Connect the return hose (1) to the straight nipple (2)
on the water pump (naturally aspirated) or to the “Y”
fitting (turbocharged).
93104688 22
31. Connect the other end of the return hose to the right
hand side hose stub (outlet hose) on the heater box
using one nylon hose elbow (1).
93104688 23
32. Connect the cab supply hose to the water valve outlet
and to the heater box inlet using the other nylon hose
elbow (1).
93104688 24
33. Install the carriage bolt (1) to the square hole in the
seat pan and hold in place with a flange nut.
34. Place a p-clamp (2) over both hoses and attach to the
carriage bolt on the seat pan. Order of installation is
washer, then p-clamp, then flange nut.
93104689 25
84423866 25/07/2011
E.40.B / 9
35. Install the spring mount brackets (1) to the second

from top front mounting bolt on the left drive motor
and bottom front mounting bolt on the right drive mo-
tor. Use thin nuts (2) to secure in place.
93104689 26
36. Slide one eyelet of each spring on the straight sec-

tion of the other p-clamp, and install the p-clamp (1)
over both hoses . There should be 350 mm between
p-clamps.
93104689 27
37. Connect the other end of each spring to a spring

mounting bracket (1) on each motor . On mechan-
ical units route the springs under the tandem pump
control rods so that the springs fall down away from
the control rods when the cab is lowered.
93104689 28
38. [OPTIONAL] Install the seat pan mat.

39. Reinstall the seat.
40. Refill the cooling system and run the engine to check
for leaks.
41. Reinstall the floor pan and re-connect the cab lift
strut.
42. [OPTIONAL] Install the heelplate mat followed by the
floormat.
84423866 25/07/2011
E.40.B / 10
43. Install the front cleanout hole blockoff plate (1).

44. Put 2 rows of seal strip (2) all around the edge of
blockoff plate (1).
45. Bolt to the front of the chassis using bolts (3).
93104642 29
23111106 30
46. Set the cab down and tip it up again to ensure that the
hoses are dropping into the chassis correctly without
kinking.
47. Close up and clean up.
84423866 25/07/2011
E.40.B / 11
Heater - Install
Prior operation:

from behind the seat, if equipped. If unit has EH
controls remove the control towers.
console.
93104685 1
3. Take the left hand console loose from the a-post. Add
heater control decal (1), fan switch (2), temperature
control potentiometer (3), and knobs (4), and (5).
4. The right hand console and headliner must be re-
moved in order to install the deluxe cab harness and
roof foam for added sound reduction. If neither are
needed the right hand console and headliner may be
left in place.
and replace the cab harness with a deluxe cab har-
ness and remove the rear cover from behind the seat,
if equipped.
93104650 2
panel and install roof foam using firm even pressure.
floor.
8. Install the heater box sealing foam at the back of the
cab floor.
9. Bolt the air intake duct (1) to the firewall.
93104649 3
84423866 25/07/2011
E.40.B / 12
10. Bolt the heater box (2) to the firewall. Be careful to

ensure that the plumbing ports are inserted properly
through the hole in the cab floor.
harness.
12. Install ducts (1) and (2) to heater box using bolts (3)
and anchor to side of cab using fir tree fasteners (4).
Ensure that wiring harness is not pinched between
the ducts and the cab side.
93104691 4
13. Install directional louvers (5) in the ducts.

15. Remove silicone from bottom of J tubes inside the
rear of the cab.
16. Install the rear trim panel (6) over the heater box
and washer bottle using push in fasteners (7). Cap
must be removed from washer bottle to install, then
replaced once the panel is secure. Ensure the seat
belt is routed through the slot in the panel and the
upper lip of the panel is under the air filter access
cover. Secure the panel with fir tree fasteners.
93104640 5
17. Apply silicone to bottom of J tubes (A) (fill drain hole

(B) in tube with silicone) at back exterior of cab and
in the front corners of the upper chassis.
93112374 6
84423866 25/07/2011
E.40.B / 13
18. Apply silicone in seam (Y) of upper chassis on both

left hand and right hand sides.
19. Apply silicone in corner hole (Z) of assembled upper
and lower chassis on both left hand and right hand
sides.
93104644 7

21. Remove floorplate. Cab lift struts may have to be re-
93104643 8
84423866 25/07/2011
E.40.B / 14
23112404 9
22. Install the water valve (1) to the water valve bracket
(2) using bolts (3) and nuts (4), and bolt under the
floorboard with bolts (5) and nuts (6). Ensure that
the water valve is facing with the inlet to the left.
the water valve.
24. Connect the short guarded heater return hose (7)
between the front port of the water valve (1) and the
straight section of the "Y" fitting (8), securing with
constant tension clamps (9).
25. Secure the short guarded return hose (7) and "Y"
fitting (8) to the front mounting bolt of the water valve
bracket (2) using a p-clamp (10). Leave the rear
mounting bolt of the water valve bracket off until the
return hose to the engine is installed.
27. Remove the EGR coolant return hose (C). Save the
p-clamp from the starter mount bolt (D) for reuse.
84423866 25/07/2011
E.40.B / 15
23112404A 10
28. Install the hose barb splice connector (11) on the

small end of the short formed heater supply hose
(12). Secure with a constant tension clamp (9).
29. Install the large end of the short formed heater supply
hose onto the EGR coolant outlet and secure with a
hose clamp (13).
30. Route heater supply hose (14) from the connector
(15) to the water valve (1).
31. Route the heater supply and return hoses from the
engine to the front of the machine. Both hoses (16)
and (14) route under the engine between the flywheel
side engine mounts. The cordura sleeve (17) must
be installed over both hoses where they pass under
the engine and tandem pump.
32. Secure the supply hose (14) to the starter mount bolt
with the p-clamp (18) previously removed and route
the hose through the loop of the EGR coolant supply
hose before connecting to the EGR.
33. Connect the supply hose (14) to the hose barb splice
connector (11) on the short formed heater supply
hose (12) and to the inlet of the water valve (1). Se-
cure with constant tension clamps (9).
34. Connect the return hose (16) to the open hose nipple
on the engine coolant inlet tube (X) where the EGR
coolant return hose was previously removed. Secure
with a constant tension clamp (9).
84423866 25/07/2011
E.40.B / 16
23112404B 11
35. Connect the other end of the return hose (1) to the
straight section of the "Y" fitting (2) under the water
valve (3) using a constant tension clamp (4). Secure
to the rear mounting bolt of the water valve bracket
with a p-clamp (5), a flange bolt (6) and a square nut
(7).
36. Connect the guarded cab supply hose (8) to the wa-
ter valve (3) outlet and to the heater box inlet using
a nylon hose elbow (9) and constant tension clamps
(4). On medium frame wheeled units route the hose
between the left side chain tank and the motor loop
hoses.
37. Connect the guarded cab return hose (10) to the
branch of the "Y" fitting (2) and to the heater box inlet
using a nylon hose elbow (9) and constant tension
clamps (4). On medium frame wheeled units route
the hose between the left side chain tank and the
motor loop hoses.
seat pan and hold in place with a flange nut (2).
carriage bolt on the seat pan. Order of installation is
washer (4), then p-clamp, then flange nut (2).
23112404C 12
84423866 25/07/2011
E.40.B / 17
NOTE: The next three steps apply to large frame units only.
40. Install the large spring mount bracket (5) between the
brake control valve and the chassis nut cages that
the valve mounts to.
41. Install another p-clamp (3) over both hoses, securing
one end of each spring (6) on the closing bolt (7) of
the p-clamp. There should be 350 mm between this
p-clamp and the p-clamp mounted to the seat pan.
42. Connect the other end of the spring to the spring
mounting bracket (5) on the loader valve and the
brake valve.
43. Install the shields (1) and (2) below the heel plate.
44. Hook the spring (3) into the hole on the left hand
control shield
46. Reinstall the seat.
for leaks.
48. Reinstall the floor pan.
floormat. 23112407 13
a. Apply 2 rows of seal strip (1) around the outside edge of

plate (2).
23111106 14
50. Install the front cleanout hole blockoff plate (2) using
4 bolts (3).
kinking.
93104642 15
84423866 25/07/2011
E.40.B / 18
Heater - Install
SR175, SV185
Prior operation:

from behind the seat, if equipped. If unit has EH
controls remove the control towers.
console.
93104685 1
3. Take left hand console loose from the a-post. Add

heater control decal (1), fan switch (2), and temper-
ature control potentiometer (3) and knob (4).
4. The right hand console and headliner must be re-
moved in order to install the deluxe cab harness and
roof foam for added sound reduction. If neither are
needed the right hand console and headliner may be
left in place.
and replace the cab harness. Not included in kit.
Purchase separately.
93104664 2

panel and install roof foam (1) using firm even pres-
sure.
floor.
93104646 3
84423866 25/07/2011
E.40.B / 19
8. Install the heater box sealing foam (1) at the back of

the cab floor.
93104647 4
9. Using two of each, bolts (1), nuts (2), and washers

(3) install the air intake duct (4) to the firewall.
93104663 5
10. Using four of each, screws (1) and washers (2) install
the heater box (3) to the firewall. Be careful to ensure
that the plumbing ports are inserted properly through
the hole in the cab floor.
harness.
93104663 6
84423866 25/07/2011
E.40.B / 20
12. Install the left hand and right hand ducts (1) and (2)
to heater box using four bolts (3) and anchor to side
of cab using eight fir tree fasteners (4). Ensure that
wiring harness is not pinched between the ducts and
the cab side. Then install six directional louvers (5)
in the ducts.
93104691 7
93104640 8
14. Remove silicone from bottom of J tubes (A) inside

the rear of the cab.
93112374 9
15. Install the rear trim panel (1) over the heater box and
washer bottle. Cap must be removed from washer
bottle to install, then replaced once the panel is se-
cure. Seat belt is routed through the slot in the panel
and the upper lip of the panel is under the air filter ac-
cess cover. Secure the panel with fir tree fasteners.
16. Apply silicone to bottom of J tubes at back exterior
of cab and in the front corners of the upper chassis
(see figure 9).
93104640 10
84423866 25/07/2011
E.40.B / 21

18. Remove floorplate. Cab lift struts have to be re-
93104643 11
19. Install the water valve (1) to the water valve bracket
(2) with bolts (3) and nuts (4) and bolt the bracket un-
der the floorboard using bolts (5) and nuts (6). En-
sure that the water valve is facing with the outlet rear-
ward.
the water valve.
23112387C 12
22. Remove the plug from the thermostat housing on the

right side of the engine and install the 90 ° hose nip-
ple adapter (1). Use pipe thread compound on the
threads.
23112385A 13
23. Cut the existing coolant return hose (1) under the
injector lines and route the two halves over top of the
injector lines.
23112382D 14
84423866 25/07/2011
E.40.B / 22
24. Using ctb clamps (1), install the “Y” fitting (2) between
the two halves of return hose (3).
23112382E 15
25. Route the heater supply (1) and new return hoses
(2) from the engine to the front of the machine. Both
hoses route under the engine between the flywheel
side engine mounts. The cab side end of the return
hose has plastic spiral hose guard installed. The
hose guard (3) must be installed over both hoses
where they pass under the engine and tandem pump.
26. Using two ctb clamps (4), connect the supply hose
(1) to the hose nipple (5) on the thermostat housing
and to the inlet of the water valve (6).
23112387D 16
27. Using a ctb clamp (1), connect the new return hose
(2) to the “Y” fitting (3).
23112382F 17
28. Using a ctb clamp (1), connect the other end of the
return hose (2) to the right hand hose stub (outlet
hose) on the heater box using a nylon hose elbow
(3).
29. Using ctb clamps (1), connect the cab supply hose
(2) to the water valve (5) outlet and to the heater box
inlet using a nylon hose elbow (3).
23112387E 18
84423866 25/07/2011
E.40.B / 23
seat pan and hold in place with a flange nut (2).
carriage bolt (1) on the seat pan. Order of installation
is washer (4), then p-clamp, then flange nut (2).
23112384 19
32. Install the small spring mount bracket (1) to the top
front mounting bolt on the right drive motor. Use a
thin nut (2) to secure in place.
33. Install the large spring mount bracket (3) between the
brake control valve and the chassis nut cages that
the valve mounts to.
23112384A 20
34. Slide one eyelet of the spring (2) on the straight sec-
tion of the other p-clamp (4), and install the p-clamp
over both hoses. There should be 350 mm (14 in)
between p-clamps.
35. Connect each end of spring to the spring mounting
brackets (1) and (3) on the right side motor and the
brake valve. On mechanical units route the springs
under the tandem pump control rods so that the
springs fall down away from the control rods when
the cab is lowered.
37. Reinstall the seat. 23112384B 21
for leaks.
39. Reinstall the floor plate and lift struts.
floormat.
84423866 25/07/2011
E.40.B / 24
a. Place 2 rows of seal strip (1) around the outside edge of

plate (2).
23111106 22
41. Install the front cleanout hole blockoff plate (2) using
4 bolts (3).
93104642 23
kinking.
84423866 25/07/2011
E.40.B / 25
Heater - Remove
SR130, SR150
Prior operation:
1. Remove the operators seat. If unit is equipped with

EH controls remove the control towers.
93104685 1
2. At the front of the chassis, remove the cleanout hole

blockoff plate (1), by removing the four hardware
bolts (2).
93104642 2
3. Remove the cab lift strut and floor pan. Do not re-
move the cab tip safety lock!
5. Remove heater hoses (1), from the back exterior of
the cab and the front corners of the upper chassis,
and silicone fittings.
93112374 3
84423866 25/07/2011
E.40.B / 26
6. Disconnect the cab supply hose (1),from the heater

box.
93104688 4
7. Disconnect the cab return hose (1), from the heater

box.
93104688 5
8. Disconnect heater supply hose (1), from the thermo-

stat housing and install a plug fitting.
93104688 6
9. Disconnect the heater return hose (1), from the water

pump.
93104688 7
84423866 25/07/2011
E.40.B / 27
10. Remove the heater hoses (1), and heater hose hard-
ware from the machine. The hoses are mounted
under the engine, between the flywheel side engine
mounts.
93104689 8
11. Disconnect the chassis harness electrical connector

from the water valve.
12. Remove the headliner and left hand and right hand
consoles.
13. Remove three fir tree fasteners, to remove the rear
trim panel (1), over the heater box and washer bottle.
NOTE: Washer bottle cap (2), must be removed first.
93104640 9
14. Remove the six directional louvers (1), in the ducts

(2).
93104640 10
84423866 25/07/2011
E.40.B / 28
15. Remove the fir tree fasteners (1), from cab side, and
bolts (2) from the heater box. Remove ducts (3), and
(4), from the heater box.
93104691 11
93104640 12
16. Disconnect heater box electrical connector from the

cab harness.
17. Remove the heater box (1), from firewall.
93104686 13
18. Remove air intake duct (1), from firewall.
93104686 14
84423866 25/07/2011
E.40.B / 29
Heater - Remove
Prior operation:

93104685 1

bolts (2).
93104642 2
4. Remove spring (3), from the hole on left hand side
control shield. Remove shields (1), and (2), from
below the heel plate.
23112407 3

84423866 25/07/2011
E.40.B / 30

the cab and the front corners of the upper chassis.
Cap open ports.
93112374 4
7. Disconnect the cab supply hose (1), and cab return

hose (2) from the heater box (3).
23112404 5
8. Disconnect the heater supply hose (1), from the ther-

mostat housing and install plug fitting. Disconnect
the heater return hose (2), from the engine coolant
inlet tube (3), and connect EGR coolant hose.
23112404 6
9. Remove the heater hoses (1), and all heater hose

hardware from the machine. The hoses are mounted
mounts.
23112404 7

consoles.
84423866 25/07/2011
E.40.B / 31

93104640 8

(2).
93104640 9
93104691 10
93104640 11

cab harness.
84423866 25/07/2011
E.40.B / 32
16. Remove the heater box (1), from the firewall.
93104649 12
93104649 13
84423866 25/07/2011
E.40.B / 33
Heater - Remove
SR175, SV185
Prior operation:

93104685 1

bolts (2).
93104642 2
the cab and the front corners of the upper chassis.
Silicone open ports.
93112374 3
84423866 25/07/2011
E.40.B / 34
6. Disconnect the cab supply hose (1), and cab return

hose (2) from the heater box (3).
23112382 4
7. Disconnect the heater supply hose (1), from the ther-

mostat housing and install plug fitting.
23112385 5
84423866 25/07/2011
E.40.B / 35
8. Disconnect the heater return hose (2), from water

pump housing.
23112382 6
9. Remove the heater hoses (1), and all heater hose

hardware from the machine. The hoses are mounted
mounts.
23112387D 7
consoles.
93104640 8
84423866 25/07/2011
E.40.B / 36

(2).
93104640 9
93104691 10
93104640 11

cab harness.
16. Remove the heater box (1), from the firewall.
93104663 12
84423866 25/07/2011
E.40.B / 37
93104663 13
84423866 25/07/2011
E.40.B / 38
Index
FRAME AND CAB - E

Heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SR130, SR150
Heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SR175, SV185
Heater - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SR130, SR150
Heater - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Heater - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SR175, SV185
84423866 25/07/2011
E.40.B / 39
84423866 25/07/2011
E.40.B / 40
FRAME AND CAB - E
ENVIRONMENT CONTROL Air-conditioning system - 40.C

TR270 , TR320 , TV380
84423866 25/07/2011
E.40.C / 1
Contents
FRAME AND CAB - E
TECHNICAL DATA
ENVIRONMENT CONTROL Air-conditioning system

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Overview HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview HVAC Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview HVAC Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electronic A/C control
Overview HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Evacuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor
Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SR130, SR150, SR175, SV185
DIAGNOSTIC

Problem solving HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compressor
Testing A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Condenser
Testing HVAC Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electronic A/C control
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Testing Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Testing HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Testing HVAC Heat Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sensing system
Testing HVAC High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
ENVIRONMENT CONTROL Air-conditioning system - General

specification
Air Temperature (F) Entering A/C Inlet - Outlet Temperature Inlet - Outlet Temperature
Unit Differential Differential
(Fresh or Recirculated) (Low Humidity) (High Humidity)
50 10 10
60 15 10
70 20 15
80 25 20
90 30 25
100 30 25
110 35 30
Ambient Air Temperature (F) Suction Pressure (PSIG) at Discharge Pressure (PSIG) at
Entering Condenser Evaporator Outlet Compressor Outlet
50 5-15 75-125
60 5-15 100-150
70 10-20 125-175
80 10-20 150-225
90 15-25 175-250
100 15-25 200-275
110 15-30 225-352
NOTE: The pressure temperature chart is based on the following conditions:
(1) Engine operating at 1500 rpm. No engine load.

(2) Fan speed control in maximum position (full clockwise) and all louvers open.
(3) Cab temperature control set to maximum cooling (full counterclockwise).
(4) A/C switch ON. Cab door open.
(5) All panels and access doors installed and closed.
(6) Cab filter clean and installed. Heater valve closed.
(7) Measurements taken 15 minutes after start-up.
(8) The warmest inlet air temperature (Fresh or Recirculated) should be used for the differential equations.
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ENVIRONMENT CONTROL Air-conditioning system - Overview

HVAC System
NOTE: For more information on the mechanical operation of the HVAC system see: ENVIRONMENT CONTROL Air-
conditioning system - Overview HVAC Mechanical (E.40.C) and for more information on the electrical operation of
the HVAC system see: ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C).
The function of the HVAC system is to improve the operator's comfort by conditioning the air inside the cab.
In AC mode, temperature control is achieved by absorbing the heat within the cab into a refrigerant and then allowing
the heat absorbed by the refrigerant to be transferred to the outside air.
In heat mode, temperature control is achieved by air absorbing heat from a heat exchanger (heater core).
The BLOWER SWITCH S-020 can provide 4 speed levels (off, low, medium, high) to the Electric Fan Motor (2) (internal
to HVAC Box). Low and medium speeds are provided through a Resistor (internal to HVAC Box).
The fan blows a mix of outside and cab air (1) across an evaporator (3) and across the heater core (4), providing
conditioned air entering the cab through vents (5), and is energized anytime the ignition is on.
ACPATHSL57 1
HVAC air flow path
In AC mode, with the AC SWITCH S-017 on, and an Electric Fan speed selected, the HVAC CONDENSER FAN and A/C
COMP are energized, starting the refrigeration cycle and providing cool air to the cab.
In heat mode, with AC Switch off and the TEMPCONTROL Z-017 potentiometer to “hot”, the potentiometer provides a
control signal to the WATER VALVE Z-019 which directs hot engine coolant to flow to the heater core. The Electric Fan
Motor (internal to HVAC Box) blows air across the evaporator (not in use) and hot heater core, providing hot air to cab.
If both AC switch is on and Tempcontrol potentiometer is turned to "hot", both the Water Valve and AC components
are energized, and the air will cool across the Evaporator, then heat across the heater core, then enter the cab.
The Blower Switch, AC Switch, and Tempcontrol potentiometer are all located on the Left Console.
There are three safety switches in the system that protect the compressor. The Single-Level Pressure Switch (internal
to HVAC Box) protects from a liquid lock condition in the refrigeration cycle. The HVAC HIGH PRESSURE SWITCH
protects against an overpressure condition caused by a system blockage or compressor failure. The Thermostat
(internal to HVAC Box) is a freeze sensor, located on the condenser, that cycles the A/C COMPRESSOR off preventing
an ice over condition, which would prevent heat transfer.
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HVAC Mechanical
The principal components of an air conditioning system are
• Refrigerant
• Evaporator
• Compressor
• Condenser
• Expansion Valve
To achieve the absorption and the release of heat, which is, in essence, the function of an air conditioning system,
requires the use of a suitable refrigerant, a liquid that has a relatively low temperature boiling point, plus certain de-
sirable safety and stability features. The refrigerant used in the air conditioning system is R-134a.
The refrigerant starts as a low temperature, low pressure liquid and enters the evaporator. The evaporator (1) consists
of a number of turns of continuous coils mounted in a series of thin cooling fins to provide a maximum heat transfer
area in a minimum amount of space.
Low temperature refrigerant in the evaporator absorbs heat from the hotter air in the cab, cooling the air.
The Electric Fan Motor (internal to HVAC Box) blows a mix of outside air and recirculated cab air across the evaporator
and blows this cool air into the cab.
The refrigerant now changes to a high temperature, low pressure vapor and leaves the evaporator, moving to the
suction (low pressure) side of the compressor.
REFCYCLESL57 1
Refrigeration Cycle
The compressor (2) acts as a pump which raises the refrigerant temperature and pressure by compression to a higher
degree of temperature than the ambient (outside air) temperature and provides the driving force required to circulate
the volume of refrigerant through the system.
Refrigerant is drawn into the compressor as a high temperature, low pressure vapor which is compressed and then
pumped out as a high temperature, high pressure vapor to the condenser. The Thermostat (internal to HVAC Box)
cycles power to the A/C COMPRESSOR via removing power to compressor relay control.
The condenser (3) consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide
a maximum of heat transfer in a minimum area of space.
The condenser receives the high temperature, high pressure refrigerant vapor from the compressor. The hot vapor
passes through the condenser coils and outside air is pushed across the condenser by the HVAC CONDENSER FAN.
Heat moves from the hot refrigerant vapor into the cooler outside air flowing across the condenser coils and fins.
When the refrigerant vapor reaches the pressure and temperature that will induce a change of state to a liquid, a large
quantity of heat is transferred to the outside air and the refrigerant changes to a low temperature, high pressure liquid.
The refrigerant from the condenser enters the expansion valve (4) as a low temperature, high pressure liquid. The
expansion valve allows the refrigerant to expand rapidly, which causes the pressure and temperature of the refrigerant
to be reduced and the refrigerant leaves the expansion valve as a low temperature, low pressure liquid.
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HVAC Electrical
NOTE: See schematic Wiring harness - Electrical schematic frame 17 (A.30.A)
The HVAC system has several power inputs. One line of source power comes from the ACCESSORY RELAY K-018 to
the HVAC BOX A-003 on pin 11. This energizes the Auxiliary Relay for Electric Fan coil (internal to HVAC Box). The
Accessory Relay is powered from the INSTRUMENT CLUSTER when the ignition is on, which shuts the Auxiliary Relay
for Electric Fan.
NOTE: See HVAC Box overview for more information Electronic A/C control - Overview HVAC Box (E.40.C)
The Auxiliary Relay for Electric Fan main power comes directly from the BATTERY via HVAC FUSE F-001 through
HVAC Box pin 14. The Auxiliary Relay for Electric Fan is shut anytime the ignition is on, allowing power to WATER
VALVE Z-019 and TEMPCONTROL Z-017 potentiometer, also allowing power to BLOWER SWITCH S-020 from HVAC Box
pin 10. Power is provided to the AC SWITCH S-017, from the Blower Switch, anytime a fan speed is selected. The
Blower Switch, AC Switch, and Tempcontrol potentiometer are all located on the Left Console.
Since the Water Valve and Tempcontrol are energized, cab heat is available anytime the ignition is on.
When the AC Switch is turned “on” and an Electric Fan speed is selected,
power is provided to HVAC Box pin 6, through Single-Level Pressure Switch (internal to HVAC Box), through Ther-
mostat (internal to HVAC Box), out HVAC Box pin 7 to HVAC HIGH PRESSURE SWITCH back into HVAC Box pin 8 to
the Compressor Relay coil (internal to HVAC Box), shutting the Compressor Relay (internal to HVAC Box). When
Compressor Relay is shut, this allows
battery power via COMPRESSOR FUSE F-002 through HVAC Box pin 2 to the Compressor Relay, out HVAC box pin 12,
to the A/C COMP.
When the AC Switch is turned “on” and an Electric Fan speed is selected,
power is also applied to the CONDENSER RELAY coil, shutting the Condenser Relay, providing battery power via fuse
F-002 to the CONDENSER FAN.
The Blower Switch, since energized, can provide 4 speed levels (off, low, medium, high) through HVAC box pins 3,
4, and 5 (low, medium, and high) to the Electric Fan Motor (internal to HVAC Box). This is done through a Resistor
(internal to HVAC Box).
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Electronic A/C control - Overview HVAC Box

NOTE: See X-HVC1 and X-HVC2 for connector information
NOTE: See ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C)for electri-
cal flowpath description.
Components in HVAC BOX A-003

Designation Component
(1) Compressor Relay
(2) Auxiliary Relay for Electric Fan
(3) Resistor
(4) Electric Fan Motor
(5) No-Frost Electronic Thermostat
(6) Single-Level Pressure Switch
(7) Connector X-HVC2
HVACBOXSCHEMSL5 1
HVAC BOX A-003 Schematic
HVAC Box Pin Information (numbered from top to bottom on schematic)

Pin Number Wire Description
3 Power to Low Speed portion of Resistor from BLOWER
SWITCH S-020
4 Power to Medium Speed portion of Resistor from
BLOWER SWITCH S-020
5 High Speed power to Electric Fan Motor from BLOWER
SWITCH S-020
2 Power to Compressor Relay from COMPRESSOR FUSE
F-002
10 Power to BLOWER SWITCH S-020, TEMPCONTROL Z-017
potentiometer, and WATER VALVE Z-019 from Auxiliary
Relay for Electric Fan
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14 Power to Auxiliary Relay for Electric Fan from HVAC

FUSE F-001
9 Ground path from Thermostat
12 Power to A/C COMPRESSOR from Compressor Relay
11 Power to Auxiliary Relay for Electric Fan coil from
ACCESSORY RELAY K-018
6 Power to Single-Level Pressure Switch and Thermostat
from AC SWITCH S-017
1 Ground for Compressor Relay coil
Ground for Auxiliary Relay for Electric Fan coil
Ground for Electric Fan Motor
13 not used
8 Power to Compressor Relay coil from HVAC HIGH
PRESSURE SWITCH
7 Power to HVAC HIGH PRESSURE SWITCH from Thermostat
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ENVIRONMENT CONTROL Air-conditioning system - Install

1. Position the air condition (A/C) unit in the cab.
931001773 1
2. Connect A/C electrical connection (1).
931001771 2
3. Install left and right hand side A/C mounting hard-

ware (2).
931001769 3
4. Install left hand side and right hand side duct work
and secure with hardware (3).
931001763 4
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5. Install the rear panel (4).
931001774 5
6. Install rear panel hardware (5).
931001751 6
7. Install window washer bottle lid (6).
931001775 7
8. Install cover and mounting screws (7).
931001752 8
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9. Position operators seat in the cab.
931001755 9
10. Connect seat safety switch electrical connection (A).
931001793 10
11. Install operators seat hardware (2).
931001759 11
12. Connect heater hoses (3).
931001757 12
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13. Connect air condition hoses (4).
931001757 13
14. After the heater/air conditioning assembly has been

installed refer to Radiator - Filling (B.50.A) and refill
the cooling system.
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ENVIRONMENT CONTROL Air-conditioning system - Remove

Prior operation:
Bucket - Remove (J.20.B)
1. Raise cab to disconnect air conditioning system

hoses (1) and cap open ports.
NOTE: If R134A is still in system, it should be drained and
captured prior to disconnecting hoses.
931001817 1
2. Label and disconnect heater hoses (2) and cap open

ports.
NOTE: Drain coolant into a suitable container prior to dis-
connecting heater hoses.
931001817 2
3. Remove seat hardware (3).
931001759 3
4. Disconnect seat safety switch electrical connection

(4).
931001793 4
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5. Remove operators seat.
931001756 5
6. Remove mounting screws (5) and remove cover (6).
931001752 6
7. Remove rear panel hardware (7).
931001751 7
8. Remove window wash bottle lid (8).
931001775 8
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9. Remove rear panel exposing air conditioning unit.
931001774 9
10. Remove left hand side and right hand side duct work
hardware (9).
931001763 10
11. Remove air condition unit mounting hardware (10).
931001769 11
12. Disconnect air condition electrical connector (11).
931001771 12
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13. Remove air condition unit.
931001773 13
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ENVIRONMENT CONTROL Air-conditioning system - Discharging

1. Recovered refrigerant passes through an oil separa-
tor and filter-drier before entering the refrigerant tank.
The moisture indicator will turn green when dry refrig-
erant passes over it.
2. If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
3. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on
the suction hose and pressure hose.
4. Make sure the charging station manifold gauge
valves are in the closed position. Connect the hose
from the low pressure gauge to the port on the suc-
tion hose. Connect the hose from the high pressure
gauge to the port on the discharge hose . Turn in
both thumbscrews to depress the service valves.
5. Open the high and low valves.
6. Make certain the refrigerant tank gas and liquid
valves are open.
7. Connect the main power plug to a 115 volt AC outlet.
Move the main power switch to the ON position and
depress the recovery start switch. The compressor
will shut OFF automatically when recovery is com-
plete. Wait for five minutes and observe the mani-
fold pressure gauges for a pressure rise. If pressure
rises above zero PSI, depress the hold/cont switch.
Then wait for the compressor to automatically shut
OFF.
8. Drain the oil separator of the A/C system oil. Open
the air purge valve long enough to let some of the
compressor discharge pressure back into the sepa-
rator.
9. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
10. Fill the A/C compressor with fresh PAG oil equal to
the amount in the reservoir.
11. Disconnect the hoses from the service ports and in-
stall the caps.
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ENVIRONMENT CONTROL Air-conditioning system - Charging

1. The correct system refrigerant charge capacity is
828.5 ml (28.0 US fl oz).
Press the charge key to begin refrigerant charging.
Automatic and Charge will appear on the display.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, the display shows CPL.
2. Completely close the high and low pressure manifold
valves.
3. Start the engine and run at 1500 rpm. Operate the air
conditioner system at maximum cooling setting and
blower speed with the door and windows open.
NOTE: The compressor will not operate if the system pres-
sure is too low or too high. If the compressor fails to op-
erate and the condenser blowers also fail to operate when
you actuate the A/C switch, check the system pressure to
determine if refrigerant is present. Check for continuity at
the pressure switch located at the receiver-dryer and the
temperature switch located at the evaporator.
4. Observe the pressure gauge readings to determine
that the correct amount of refrigerant has entered the
system. See chart on ENVIRONMENT CONTROL
Air-conditioning system - General specification
(E.40.C) for temperature and pressure variations.
NOTICE: Check the OEM equipment manual before
performing this step to avoid damaging recovery unit.
Pressure reading should be obtainable with valves closed.
Damage may occur if the machine is started with the
valves accidently open or if either or both valves are
opened while the A/C system operating.
5. Stop the engine, close any open valves and carefully
remove the manifold gauge hoses.
6. Install the caps on the service ports on the suction
hose, and discharge hose.
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ENVIRONMENT CONTROL Air-conditioning system - Leakage test

WARNING
Avoid injury!
Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge
occurs, ventilate the work area before resuming service.
W1000B
1. Shut off the engine.

2. Use an electronic leak detector to inspect all con-
nections. Use instructions from manufacturer of leak
finding tool.
NOTE: When checking compressor seal for a leak, remove
the dust cover and rotate the clutch shaft clockwise.
NOTE: To properly check the expansion valve for leaks,
remove the insulation tape.
3. Repair all leaks and recharge the system.
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ENVIRONMENT CONTROL Air-conditioning system - Evacuate

1. Recovered refrigerant passes through an oil separa-
tor and filter-drier before entering the refrigerant tank.
The moisture indicator will turn green when dry refrig-
erant passes over it.
2. If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
3. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service port on the
suction and from the service port pressure hoses.
tion hose . Connect the hose from the high pressure
gauge to the port on the discharge hose . Turn in
5. Open the high and low valves.
6. Make certain the refrigerant tank gas and liquid
valves are open.
Move the main power switch to the ON position and
depress the recovery start switch. The compressor
will shut OFF automatically when recovery is com-
plete. Wait for five minutes and observe the mani-
fold pressure gauges for a pressure rise. If pressure
rises above zero PSI, depress the hold/cont switch.
Then wait for the compressor to automatically shut
OFF.
8. Drain the oil separator of the A/C system oil. Open
the air purge valve long enough to let some of the
compressor discharge pressure back into the sepa-
rator.
9. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
10. Fill the A/C compressor with fresh PAG oil equal to
the amount in the reservoir.
11. Disconnect the hoses from the service ports and in-
stall the caps.
12. Replace the receiver-drier if one or more of the fol-
lowing conditions occurs before you remove the air
and moisture from the system.
(A.) The system has been opened for service before.
(B.) Receiver-drier has operated two or more years.
(C.) Disassembly of compressor shows small parti-
cles of moisture removing material (gold or brown
particles).
(D.) Large system leak (broken hose, break in line).
(E.)Too much air or moisture in system.
(F.) Removal of compressor caused the system to be
open (uncapped) longer than 5 minutes.
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tion hose. Connect the hose from the high pressure
gauge to the port on the discharge hose. Turn in
14. Removal of air and moisture from the system is nec-
essary after the refrigerant has been removed from
the system after the system has been opened for
maintenance. Air enters the system when the system
is opened. Air has moisture that must be removed to
prevent damage to the system components.
15. Air and moisture are removed from the system by a
vacuum pump. A vacuum pump is on the only equip-
ment made that will lower the pressure in a system
enough to change the moisture to a vapor so that the
moisture can be removed.
NOTE: Refer to the vacuum pump manufacturer's user
manual for additional information.
Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 minutes and press the Enter key. The display
will flash once indicating the programmed data has
been accepted.
17. Press the Charge Key. Program and Charge will ap-
pear on the display.
18. Program 828.5 mL( 28 oz) and press the enter
key. The display will flash once indicating the pro-
grammed data has been accepted.
19. Full open the low and high pressure valves.
20. Open the red (vapor) and blue (liquid) valves on the
tank.
21. Press the Vacuum key. Automatic will show on the
display and after a slight delay, the vacuum pump
will start. The display will show the amount of time
programmed and begin a countdown to zero.
22. When the programmed time has elapsed, an auto-
matic hold occurs. Check the low pressure gauge to
see that the A/C system maintains a 28 - 291/2 inof
mercury (Hg). The low pressure gauge must not in-
crease faster than one inch of mercury (Hg) in 15
minutes. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See ENVIRONMENT CONTROL Air-condi-
tioning system - Leakage test (E.40.C) for a leak
test.
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Compressor Belt - Tension adjust

Check the alternator belt tension after the first 10 hours of operation on a new machine or if a new belt has been
installed. Measure the deflection of the belt at center of span with perpendicular load of applied, and adjust as
necessary. Check alternator belt tension every 50 hours. Measure deflection and adjust as necessary. Inspect
for cracks and damage.
1. Use the following procedure to adjust the poly V/ser-

pentine belt tension for F5C engines.
1. Loosen the upper and lower mounting
bolts on the alternator (1).
2. Loosen the adjusting bolt jam nut (2).
3. Rotate the adjusting bolt (3) until the belt
has a deflection equal to the width of the
belt when a 1 kg (2.2 lb) force is applied
perpendicular to the belt.
4. Tighten the adjusting bolt jam nut.
5. Tighten the alternator mounting bolts.
73092896 1
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Compressor Belt - Tension adjust

SR130, SR150, SR175, SV185
Check the alternator belt tension after the first 10 hours of operation on a new machine or if a new belt has been
installed. Measure the deflection of the belt at center of span with perpendicular load of applied, and adjust as
necessary. Check alternator belt tension every 50 hours. Measure deflection and adjust as necessary. Inspect
for cracks and damage.
1. Use the following procedure to adjust the V Belt ten-

sion for ISM engines.
1. Loosen the adjusting bracket bolt (2).
2. Pull the alternator toward the outside of
the machine to tighten belt (1) . The belt
is tightened properly when a force of 1 kg
(2.2 lb) is applied perpendicular to the belt
at the center of the span with a 3 mm
(0.118 in) deflection.
3. Tighten the adjusting bracket bolt (2)
93109316 1
84423866 25/07/2011
E.40.C / 24
ENVIRONMENT CONTROL Air-conditioning system - Problem

solving HVAC
OPERATION
To understand the electrical flowpaths and help narrow down the troubleshooting efforts, refer to HVAC System Elec-
trical overview ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C).
TROUBLESHOOTING
Before troubleshooting ensure that

1. HVAC FUSE F-001 is good.
2. COMPRESSOR FUSE F-002 is good.
3. ACCESSORY RELAY K-018 is good. See ELECTRICAL POWER SYSTEM - Component identification Relay
Index (A.30.A).
4. Switches are operated in accordance with Operator's Manual.
No heat Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC
Heat Components (E.40.C)
Faulty WATER VALVE Z-019 Electronic A/C control - Testing HVAC
Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC
Box (E.40.C)
Poor Heat Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC
Faulty WATER VALVE Z-019 Electronic A/C control - Testing HVAC
Poor cooling No voltage at connector X-74 pin B. Faulty CONDENSER RELAY or associated
wiring. See Fuse and relay box - Testing
Relay Testing (A.50.A) and Fuse and
relay box - Testing Condenser Relay
Control (A.30.A)
Faulty HVAC CONDENSER FAN Condenser - Testing HVAC Condenser
Fan (E.40.C)
Thermostat (internal to HVAC Box) not cy- Electronic A/C control - Testing HVAC
cling correctly Box (E.40.C)
Poor cooling after engine Faulty WATER VALVE Z-019 Electronic A/C control - Testing HVAC
is at normal temperature Heat Components (E.40.C)
Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC
No cooling Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC
Box (E.40.C)
Faulty BLOWER SWITCH S-020 Electronic A/C control - Testing Blower
Switch (E.40.C)
Faulty AC SWITCH S-017 Electronic A/C control - Testing A/C
Switch (E.40.C)
Faulty Single-Level Pressure Switch (inter- Electronic A/C control - Testing HVAC
nal to HVAC Box) Box (E.40.C)
Faulty Thermostat (internal to HVAC Box) Electronic A/C control - Testing HVAC
Box (E.40.C)
Faulty HVAC HIGH PRESSURE SWITCH Sensing system - Testing HVAC High
Pressure Switch (E.40.C)
Faulty Compressor Relay (internal to HVAC Electronic A/C control - Testing HVAC
Box) Box (E.40.C)
Faulty A/C COMPRESSOR Compressor - Testing A/C Compressor
(E.40.C)
No fan speeds available No voltage at HVAC Box pin 14 Faulty HVAC FUSE F-001 or associated
wiring
84423866 25/07/2011
E.40.C / 25

No voltage at HVAC Box pin 11 Faulty ACCESSORY RELAY K-018 or asso-
ciated wiring. See Fuse and relay box -
Testing Relay Testing (A.50.A) and Fuse
and relay box - Testing Accessory Relay
Control (A.30.A)
Faulty BLOWER SWITCH S-020 Electronic A/C control - Testing Blower
Switch (E.40.C)
Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC
Box (E.40.C)
Faulty Electric Fan Motor (internal to HVAC Electronic A/C control - Testing HVAC
box) Box (E.40.C)
Faulty HVAC Box ground wiring Use ELECTRICAL POWER SYSTEM -
Testing General Wire Testing (A.30.A) to
ensure proper ground from HVAC Box pin
1
Only high speed fan Faulty Resistor (internal to HVAC Box) Electronic A/C control - Testing HVAC
available Box (E.40.C)
Only one fan speed is not Wiring problem common to HVAC BOX Use ELECTRICAL POWER SYSTEM -
available A-003 (Resistor) and BLOWER SWITCH Testing General Wire Testing (A.30.A) to
S-020 locate faulty wire
84423866 25/07/2011
E.40.C / 26
Compressor - Testing A/C Compressor

NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A)
With ignition off, use ELECTRICAL No wire problems. Wire problems are found.
POWER SYSTEM - Testing Gen- Action Action
eral Wire Testing (A.30.A) to Go to test 2 Locate and repair or replace broken
Check ground wire.
wire condition between A/C
COMPRESSOR ground pin and
ground.
Disconnect connector X-AC_COMP 12 V 0V
from the A/C COMPRESSOR. With ig- Action Action
nition on, The A/C COMPRESSOR has failed. Go to test 3
Check Replace the compressor.
for voltage from connector
X-AC_COMP power pin and ground.
With ignition off, use ELECTRICAL No wire problems. Wire problems are found.
POWER SYSTEM - Testing Gen- Action Action
eral Wire Testing (A.30.A) to Locate and repair or replace broken
Check See the following for further testing wire 841 (White).
wire condition between A/C • ENVIRONMENT CON-
COMPRESSOR power pin and TROL Air-conditioning
X-HVC1 pin 12. system - Problem solv-
ing HVAC (E.40.C)
• Electronic A/C control
- Testing HVAC Box
(E.40.C)
84423866 25/07/2011
E.40.C / 27
Condenser - Testing HVAC Condenser Fan

NOTE: Without the Condenser Fan, the Air Conditioning will work poorly. If Air Conditioning does not work at all, see
ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC (E.40.C)
Disconnect connector X-74 from the No wire problems. Wire problems are found.
HVAC CONDENSER FAN. Use ELEC- Action Action
TRICAL POWER SYSTEM - Test- Go to test 2 Locate and repair or replace broken
ing General Wire Testing (A.30.A) wire 1084 (Black).
to
Check
ground wire condition between X-74
pin A and ground.
With ignition on, 12 V 0V
Check Action Action
for voltage from connector X-74 pin The HVAC CONDENSER FAN has Go to test 3
B and ground. failed. Replace the fan.
Disconnect connector X-111 from No wire problems. Wire problems are found.
the CONDENSER RELAY. Use ELEC- Action Action
TRICAL POWER SYSTEM - Test- Locate and repair or replace broken
ing General Wire Testing (A.30.A) See the following for further testing wire 237 (White).
to • Fuse and relay box -
Check Testing Condenser Re-
wire condition between X-74 pin B lay Control (A.30.A)
and X-111 pin 87.
• ENVIRONMENT CON-
TROL Air-conditioning
system - Problem solv-
ing HVAC (E.40.C)
84423866 25/07/2011
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Electronic A/C control - Testing Blower Switch

NOTE: Ensure Electronic A/C control - Testing HVAC Box (E.40.C) test is satisfactory prior to performing this test
Disconnect connector X-270 from 0 Ω when selecting a fan speed, no Any other readings
the BLOWER SWITCH S-020. continuity when fan is selected off. Action
Check Action The BLOWER SWITCH has failed. Re-
for resistance between BLOWER Go to test 2 place the switch.
SWITCH
pins 1 and 2 while cycling the Blower
Switch.
for resistance between BLOWER For each resistance check, 0 Ω in 0 Ω in more than one position or infi-
SWITCH one position, infinite resistance in all nite resistance in all positions.
pins 2 and 3 (Low) others. Action
pins 2 and 4 (Medium) Action The BLOWER SWITCH has failed. Re-
pins 2 and 5 (High) Go to test 3 place the switch.
while cycling the BLOWER SWITCH.
ing (A.30.A) to Locate and repair or replace broken
Check See the following for further testing wire 821/846/842 (Orange) or adja-
wire condition between X-HVC1 pin • ENVIRONMENT CON- cent wiring.
10 and connector X-270 pin 2. TROL Air-conditioning
ing HVAC (E.40.C)
- Testing HVAC Box
(E.40.C)
84423866 25/07/2011
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Electronic A/C control - Testing A/C Switch

NOTE: See schematic
NOTE: Ensure Electronic A/C control - Testing Blower Switch (E.40.C) test is satisfactory prior to performing this
test
Use ENVIRONMENT CON- Light on Light not on
TROL Air-conditioning system - Action Action
Overview HVAC System (E.40.C) Go to test 3 Go to test 2
to set up conditions for the AC sys-
tem to turn on.
Check
that AC switch indicator light is on.
Disconnect connector X-275 from 12 V 0V
the AC SWITCH S-017. Use ENVI- Action Action
RONMENT CONTROL Air-condi- Go to test 3 There is an open on wire 825 (Or-
tioning system - Overview HVAC ange). Repair the wire.
System (E.40.C) to set up condi-
tions for the AC system to turn on.
Check
for voltage between X-275 pins 1
and ground.
Disconnect connector X-275 from No circuit problems. No change in circuit response.
the AC SWITCH S-017. Connect a Action Action
jumper between connector X-275 The AC SWITCH S-017 has failed. Go to test 4
pins 1 and 2. Replace the switch.
Check
ing (A.30.A) to Locate and repair or replace bro-
Check See the following for further testing ken wire 829/837 (White) or adjacent
wire condition between X-275 pin 2 • ENVIRONMENT CON- wiring.
and connector X-HVC1 pin 6. TROL Air-conditioning
ing HVAC (E.40.C)
- Testing HVAC Box
(E.40.C)
84423866 25/07/2011
E.40.C / 30
Electronic A/C control - Testing HVAC Box

NOTE: Ensure HVAC FUSE F-001
COMPRESSOR FUSE F-002 and
ACCESSORY RELAY K-018 are working correctly prior to performing this test.
NOTE: See Electronic A/C control - Overview HVAC Box (E.40.C) for additional information
Disconnect connector X-HVC2 from 12 V for each check 0V
X-HVC1. With the ignition on, Action Action
for voltage from connector X-HVC1 bution system upstream of X-HVC1
pin 2 and ground, 11 and ground, pin 2, 11, or 14.
and 14 and ground.
for resistance between HVAC BOX 0Ω Greater than 15 Ω
A-003 pins 1 and 8 and from pins 1 Action Action
and 11. Go to test 3 Either the Compressor Relay or Fan
Relay, both internal to the HVAC
Box, has failed. Replace the ser-
viceable component.
for resistance between HVAC BOX Open 0Ω
A-003 pins 2 and 12 and from pins Action Action
10 and 14. Go to test 4 Either the Compressor Relay or Fan
Relay, both internal to the HVAC
Box, has failed. Replace the ser-
viceable component.
for resistance between HVAC BOX The sum of the resistances from pins For any other readings,
A-003 3 and 4 and from pins 4 and 5 should Action
pins 3 and 4 equal the resistance from pins 3 and The Resistor, internal to the HVAC
pins 4 and 5 5. Box, has failed. Replace the service-
pins 3 and 5. Action able component.
Go to test 5
for resistance between HVAC BOX 10 Ω Either 0 Ω or greater than 1000 Ω
A-003 pins 1 and 5 Action Action
Go to test 6 The Electric Fan Motor, internal to
the HVAC Box, has failed. Replace
the serviceable component.
Check wire 1012 (Black/White) or adjacent
X-HVC1 pin 9 and ground.
Check See the following for further testing wire 935/1087 or 935/1088 (Black)
wire condition between connector • ENVIRONMENT CON- or adjacent wiring.
X-HVC1 pin 1 and ground. TROL Air-conditioning
ing HVAC (E.40.C)
84423866 25/07/2011
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Electronic A/C control - Testing HVAC Heat Components

the TEMPCONTROL Z-017 poten- Action Action
tiometer. With ignition on, Go to test 2 Go to test 3
Check
for voltage from connector X-252 pin
3 and ground.
the WATER VALVE Z-019. With igni- Action Action
tion on, Go to test 4 Go to test 3
Check
for voltage from connector X-271 pin
A and ground.
Check See the following for further testing wire 823 (Pink) or 822/846/842 (Or-
wire condition between X-HVC1 pin • ENVIRONMENT CON- ange) or adjacent wiring.
10 and connector X-271 pin A and TROL Air-conditioning
between X-HVC1 pin 10 and con- system - Problem solv-
nector X-252 pin 3. ing HVAC (E.40.C)
- Testing HVAC Box
(E.40.C)
for resistance between Varying resistance with potentiome- 0 Ω, or infinite resistance, or con-
TEMPCONTROL Z-017 potentiometer ter movement. stant value
pins 2 and 3 while moving poten- Action Action
tiometer. Go to test 5 The TEMPCONTROL potentiometer
has failed. Replace the potentiome-
ter.
for resistance between WATER 20 Ω 0 Ω, or greater than 1 K Ω
VALVE Z-019 pins A and C. Action Action
Go to test 6 The WATER VALVE has failed. Re-
place the valve.
Check wire 824 (Yellow).
signal wire condition between X-252
pin 2 and connector X-271 pin D.
ing (A.30.A) to The WATER VALVE has failed. Re- Locate and repair or replace broken
Check place the valve. wire 912 (Black) or 1013 (Black).
ground wire condition between
X-252 pin 1 and ground and between
connector X-271 pin C and ground.
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Sensing system - Testing HVAC High Pressure Switch

NOTE: Ensure the HVAC system has no mechanical problems before following this procedure. See ENVIRONMENT
CONTROL Air-conditioning system - Overview HVAC System (E.40.C) for more information on the HVAC System.
Disconnect connector X-76 from the No circuit problems. No change in circuit response, re-
HVAC HIGH PRESSURE SWITCH. Con- Action move jumper.
nect a jumper between connector The HVAC HIGH PRESSURE SWITCH Action
X-76 pins A and B. has failed. Replace the switch. Go to test 2
Check
Use ENVIRONMENT CON-
TROL Air-conditioning system -
Overview HVAC System (E.40.C)
to set up conditions for the A/C
system to turn on. Check circuit op-
eration.
ing (A.30.A) to Go to test 3 Repair or replace broken wire 834
Check (White).
X-76 pin B and connector X-HVC1
pin 8.
ing (A.30.A) to Repair or replace broken wire 833
Check See the following for further testing (White).
wire condition between connector • ENVIRONMENT CON-
X-76 pin A and connector X-HVC1 TROL Air-conditioning
pin 7. system - Problem solv-
ing HVAC (E.40.C)
- Testing HVAC Box
(E.40.C)
84423866 25/07/2011
E.40.C / 33
Index
FRAME AND CAB - E

Compressor - Testing A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Compressor Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Compressor Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SR130, SR150, SR175, SV185
Condenser - Testing HVAC Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ENVIRONMENT CONTROL Air-conditioning system - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENVIRONMENT CONTROL Air-conditioning system - Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENVIRONMENT CONTROL Air-conditioning system - Evacuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ENVIRONMENT CONTROL Air-conditioning system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENVIRONMENT CONTROL Air-conditioning system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENVIRONMENT CONTROL Air-conditioning system - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENVIRONMENT CONTROL Air-conditioning system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electronic A/C control - Overview HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electronic A/C control - Testing A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electronic A/C control - Testing Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electronic A/C control - Testing HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electronic A/C control - Testing HVAC Heat Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sensing system - Testing HVAC High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
84423866 25/07/2011
E.40.C / 34
FRAME AND CAB - E
SAFETY SECURITY ACCESSORIES Safety - 50.B

TR270 , TR320 , TV380
84423866 25/07/2011
E.50.B / 1
Contents
FRAME AND CAB - E
SERVICE
Back up alarm
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC
Audible alert
Testing Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84423866 25/07/2011
E.50.B / 2
FRAME AND CAB - SAFETY SECURITY ACCESSORIES Safety
Back up alarm - Remove

1. Locate and open engine hood (1) and rear service
door (2).
93107449A1 1
2. Remove electrical leads (1) from the backup alarm

H-002 (2).
931001672 2
3. Remove hardware (1) retaining backup alarm H-002

(2).
4. Remove backup alarm H-002 (2).
931001673 3
84423866 25/07/2011
E.50.B / 3
Back up alarm - Install

1. Insert retaining hardware and tighten bolts (1) secur-
ing the backup alarm H-002 (2).
931001673 1
2. Connect connectors X-BKUP-GND (1) and

X-BKUP-PWR (2) to the backup alarm H-002 (3).
931001672 2
84423866 25/07/2011
E.50.B / 4
Audible alert - Testing Horn


Remove IGNITION FUSE from the 0Ω Fuse is blown.
Check amp rating.
for continuity across IGNITION FUSE.
on, Action Action
for voltage from MAIN POWER bution system upstream of IGNITION
pin C3 and ground.
Check wire 891/357/351 (Orange) or adja-
X-408 pin 4 (EH) X-405 pin A (Mech)
Using a multi-meter, check for resis- For each resistance check, 0 Ω in 0 Ω in all positions or infinite resis-
tance between HORN SWITCH S-023 one position, infinite resistance in the tance in all positions.
X-408 pins 4 and 8 (EH) X-405 pins other. Action
A and B (Mech) while cycling the Action The HORN SWITCH has failed. Re-
switch. Go to test 5 place the LEFT HAND CONTROL
HANDLE.
Check wire 892 (White) or adjacent wiring.
X-408 pin 8 (EH) X-405 pin B (Mech)
and connector X-HORN-PWR pin 1.
ing (A.30.A) to The HORN has failed. Replace the Locate and repair or replace broken
Check HORN. wire 955/968/983 (Black) or adjacent
X-HORN-GND pin 1 and ground.
84423866 25/07/2011
E.50.B / 5
Index
FRAME AND CAB - E

Audible alert - Testing Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Back up alarm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Back up alarm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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84423866 25/07/2011
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PRINTED IN U.S.A.
84423866 25/07/2011
EN
SERVICE MANUAL
FRAME POSITIONING

TR270 , TR320 , TV380
84423866 25/07/2011
F
Contents
FRAME POSITIONING - F
STABILISING Ballasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F.20.B

84423866 25/07/2011
F
STABILISING Ballasting - 20.B

TR270 , TR320 , TV380
84423866 25/07/2011
F.20.B / 1
Contents
SERVICE
Rear ballasting
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SR130, SR150
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SR130, SR150
84423866 25/07/2011
F.20.B / 2
FRAME POSITIONING - STABILISING Ballasting
Rear ballasting - Remove

DANGER
Heavy objects!
D0076A
Prior operation:
Battery - Remove (A.30.A).
1. Remove left hand side corner mounting hardware

(1).
931001655 1
2. Remove left hand side counterweight.
931001658 2
NOTE: Perform the same operation on the right hand side.

3. Remove center bumper mounting hardware (1).
931002063 3
84423866 25/07/2011
F.20.B / 3
4. Remove center bumper (3).
931001656 4
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F.20.B / 4
Rear ballasting - Install

DANGER
Heavy objects!
D0076A
1. Place rear center bumper (1) in position.
931001656 1
2. Install center bumper mounting hardware (2).
931002063 2
3. Install left hand side counterweight and secure in

place with mounting hardware (3).
931001655 3
NOTE: Perform the same operation on right hand side.
Next operation:
Battery - Install (A.30.A).
84423866 25/07/2011
F.20.B / 5
Rear ballasting - Remove

SR130, SR150
DANGER
Heavy objects!
D0076A
1. With proper support under the bumper weight re-

move mounting hardware (1).
931002063 1
2. Remove center bumper (1).
931001656 2
84423866 25/07/2011
F.20.B / 6
Rear ballasting - Install

SR130, SR150
DANGER
Heavy objects!
D0076A
1. Place rear center bumper (1) in position.
931001656 1
2. Install center bumper mounting hardware (2).
931002063 2
84423866 25/07/2011
F.20.B / 7
Index

Rear ballasting - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear ballasting - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SR130, SR150
Rear ballasting - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear ballasting - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SR130, SR150
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PRINTED IN U.S.A.
84423866 25/07/2011
EN
SERVICE MANUAL
TOOL POSITIONING

TR270 , TR320 , TV380
84423866 25/07/2011
G
Contents
TOOL POSITIONING - G
LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.10.A
TILTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.20.A
LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.30.A
SECONDARY FUNCTIONS Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.90.C

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G
LIFTING - 10.A

TR270 , TR320 , TV380
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Contents
LIFTING - 10.A
TECHNICAL DATA
Cylinder
SR130, SR150
SR175
SR200, TR270
SR220, SR250, TR320
SV250, SV300, TV380
SV185
SV185
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SV250, SV300, TV380
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TOOL POSITIONING - LIFTING
Cylinder - General specification

SR130, SR150
Cylinder Lift
Collapsed length 989 mm (38.9 in)
Stroke length 645 mm (25.4 in)
Tube bore diameter 57.2 mm (2.3 in)
Rod diameter 34.9 mm (1.4 in)
Tube end pin diameter 38.3 mm (1.5 in)
Rod end pin diameter 38.3 mm (1.5 in)
Rod end width 40 mm (1.6 in)
Tube end width 40 mm (1.6 in)
Tube port size 3/4-16 SAE O-ring boss
Rod port size 3/4-16 SAE O-ring boss
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SR175
Cylinder Lift
Stroke length 804.9 mm (31.7 in)
End width 40.0 mm (1.6 in)
Supply port size 3/4-16 SAE O-ring boss
Return port size 3/4-16 SAE O-ring boss
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SR200, TR270
Cylinder Lift
Collapsed length 1158.7 mm (45.6 in)
Tube end width 40.0 mm (1.6 in)
Rod end width 50.0 mm (2.0 in)
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SR220, SR250, TR320
Cylinder Lift
Extended length 1976.1 mm (77.8 in)
Tube end diameter 38.3 mm (1.5 in)
Rod end diameter 38.3 mm (1.5 in)
Rod end width 50.8 mm (2 in)
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SV250, SV300, TV380
Cylinder Lift
Rod end width 50.8 mm (2 in)
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SV185
Cylinder Lift
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SV185
Cylinder Lift
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SV250, SV300, TV380
Cylinder Lift
Tube end width 40 mm (1.6 in)
Rod end width 50 mm (2 in)
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Index
LIFTING - 10.A
Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SR130, SR150
SR175
SR200, TR270
SR220, SR250, TR320
SV250, SV300, TV380
SV185
SV185
Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SV250, SV300, TV380
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TILTING - 20.A

TR270 , TR320 , TV380
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Contents
TILTING - 20.A
TECHNICAL DATA
Cylinder
SR130, SR150
SR175
SR200, TR270
SR220, SR250, TR320
SV185
SV250, SV300, TV380
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TOOL POSITIONING - TILTING

SR130, SR150
Cylinder Bucket
Tube end width 76 mm (3 in)
Tube end port size 9/16-18 UNF-2B SAE O-ring boss
Rod end port size 9/16-18 UNF-2B SAE O-ring boss
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SR175
Cylinder Bucket
Collapsed length 610 mm (24 in)
Supply port size 9/16-18 UNF-2B SAE O-ring boss
Return port size 9/16-18 UNF-2B SAE O-ring boss
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SR200, TR270
Cylinder Bucket Tilt

Tube end width 76.2 mm (3 in)
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SR220, SR250, TR320
Cylinder Tilt
Collapsed length 609.6 mm (24 in)
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SV185
Cylinder Bucket
Rod end width 45.7 mm (1.8 in)
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SV250, SV300, TV380
Cylinder Tilt
Collapsed length 609.6 mm (24 in)
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Index
TILTING - 20.A
SR130, SR150
SR175
SR200, TR270
SR220, SR250, TR320
SV185
SV250, SV300, TV380
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LEVELLING - 30.A

TR270 , TR320 , TV380
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Contents
LEVELLING - 30.A
TECHNICAL DATA
Control valve
General specification of the 60% self level valve on medium and large frame . . . . . . . . . . . . . . . . . . . . . . . 3
SR175, SV250, SV300, TV380
General specification of the 48% self level valve on small frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SR130, SR150
General specification of the 72% self level valve on large frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SR220, SR250, TR320
General specification of the 50% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SR200, TR270
General specification of the 40% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SV185
SERVICE
Command
Remove Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Command valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control valve
Remove Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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TOOL POSITIONING - LEVELLING
Control valve - General specification of the 60% self level valve on

medium and large frame
SR175, SV250, SV300, TV380
Manufacturer Eaton - Part Number 39055-EEG
Proportional Flow Divider Settings: Port D = 60 %

Port B = 40 %
Hydraulic Requirements: Flow = 57 l/min (15 US gpm)

System Pressure = 210 bar (3050 psi)

Self Level Override Solenoid Connection Type: Deutsch DT series.
Proportional Flow Divider Adjustment: Remove plastic cap.

Turn counter clockwise to increase flow to the tilt cylinders.
Turn clockwise to decrease flow to the tilt cylinders.
Port Identification Chart: (A) Lift Cylinder Rod End

(B) CV Work Port B1
(C) Tilt Cylinder Rod End
(D) Tilt Cylinder Base End
Control valve - General specification of the 48% self level valve

on small frame
SR130, SR150
Manufacturer Eaton - Part Number 39055-EEJ

Port B = 52 %



(B) CV Work Port B1
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on large frame
SR220, SR250, TR320
Manufacturer Eaton - Part Number 39055-EEF

Port B = 28 %




(B) CV Work Port B1
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on medium frame
SR200, TR270
Manufacturer Eaton - Part Number 39055-EEH

Port B = 50 %

Intermittent Pressure Spikes = 276 bar (4000 psi)
Maximum Pressure Drop Across Valve = 10 bar (150 psi) @ 57 l/min (15
US gpm)



(B) CV Work Port B1
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on medium frame
SV185
Manufacturer Eaton - Part Number 39055-EEK

Port B = 60 %



(B) CV Work Port B1
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Command - Remove Self Level Valve Solenoid

Prior operation:
1. Locate self level valve solenoid Y-318 (1) on the right

side, middle of the machine.
931001804 1
2. Disconnect connector X-318 (1) from the self level

valve solenoid Y-318 (2).
931001701 2
3. Loosen and remove nut (1). Remove the self level

valve solenoid Y-318 (2).
931001702 3
Next operation:
Command - Install Self Level Valve Solenoid (G.30.A)
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Command - Install Self Level Valve Solenoid

Prior operation:
Command - Remove Self Level Valve Solenoid (G.30.A)
1. Insert the self level valve solenoid Y-318 (1) into the
valve block (2).
931001702 1
2. Thread nut (1) on stud and tighten to standard torque.
931001701 2
3. Reconnect connector X-318 (1) to the self level valve

solenoid Y-318 (2).
931001701 3
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Command valve - Remove

WARNING
Pressurized system!
W1044A
NOTE: Never loosen any hydraulic lines without first relieving all pressure in the system. Refer to PRIMARY HY-
DRAULIC POWER SYSTEM - Depressurising (A.10.A)
1. Label and disconnect electrical connection (1).
931001722 1
2. Label and disconnect bucket hydraulic tubes (1) and

cap open ports.
931001720 2
3. Label and disconnect supply tube (1) and cap open

ports.
931001720 3
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4. Label and disconnect drain hose (1).
931001720 4
931001720 5
6. Remove command valve.
931001721 6
Next operation:
Command - Install (G.30.A)
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Command valve - Install

1. Locate where the command valve (1) is positioned
on the body.
931001720 1
931001720 2
3. Connect valve drain hose (1).
931001720 3
4. Connect valve supply tube (1).
931001720 4
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5. Connect bucket hydraulic tubes (2).
931001720 5
6. Connect electrical connection (1).
931001722 6
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Control valve - Remove Self level valve

Prior operation:
NOTE: Never loosen any hydraulic lines without first relieving all pressure in the system. Refer to PRIMARY HY-
DRAULIC POWER SYSTEM - Depressurising (A.10.A)
1. Locate control valve (1).
931001804 1
2. Disconnect electrical connection (1).
931001701 2
3. Disconnect hydraulic tube (1) and cap open ports.
931001702 3
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4. Disconnect lower tubes (1) and cap ports.
931001981 4
5. Disconnect front tube (1) and cap port.
931001981 5
931001981 6
7. Remove control valve.
931001707 7
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Control valve - Install Self level valve

1. Install control valve (1) onto body in correct location.
931001804 1
931001981 2
3. Connect front tube (1).
931001981 3
4. Connect lower tubes (1).
931001981 4
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5. Connect hydraulic tube (1).
931001702 5
6. Connect electrical connection (1).
931001701 6
Next operation:
Tilt system - Lower (E.34.A)
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Index
LEVELLING - 30.A
Command - Install Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Command - Remove Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Command valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Command valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Control valve - General specification of the 40% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SV185
Control valve - General specification of the 48% self level valve on small frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SR130, SR150
Control valve - General specification of the 50% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SR200, TR270
Control valve - General specification of the 60% self level valve on medium and large frame . . . . . . . . . . . . . . . . . 3
SR175, SV250, SV300, TV380
Control valve - General specification of the 72% self level valve on large frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SR220, SR250, TR320
Control valve - Install Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control valve - Remove Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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SECONDARY FUNCTIONS Hydraulic - 90.C

TR270 , TR320 , TV380
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Contents
FUNCTIONAL DATA
Control valve
Overview High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview Auxiliary Override Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC
Control valve
Testing 2nd Aux Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing 2nd Aux Retract Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testing 2nd Aux Hyd Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing High Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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TOOL POSITIONING - SECONDARY FUNCTIONS Hydraulic
Control valve - Overview High Flow

The Operator can command additional flow to the auxiliary circuit by engaging Auxiliary High flow Function. This will
provide increase flow and pressure to the auxiliary circuit. Of up to 128 l/min (35 US gpm) and up to 215 bar (3050
psi).
High Flow feature is engaged by pressing the On/Off switch mounted on left hand A post. The switch selects Standard
or Enhance High Flow and is illuminated when High Flow or Enhanced High Flow is on. Allows the operator to enable/
disable the function depending on the attachment requirements. The attachment flow is controlled with the switch in
the Left Hand Control Handle.
The External Auxiliary Control can be controlled ONLY if ALL of the following conditions are met
2. Operator Restraint engaged
3. The ignition is in the ON position
4. Hydraulic Enable switch is activated
The Operator can command additional pressure to the auxiliary circuit by engaging the Enhanced Auxiliary High flow
function. This will provide increase pressure to the auxiliary circuit. Flow is 128 l/min (35 US gpm) and pressure up
to 275 bar (4000 psi). The loader control valve standard auxiliary circuit is unaffected when High Flow is disabled.
When Standard or Enhanced High Flow is enabled the loader control valve standard auxiliary circuit is limited to 2nd
Aux circuit flow of 30.3 l/min (8 US gpm). The 275 bar (4000 psi) High Flow setting can only be used with approved
attachments and is controlled by a circuit interlock installed at the multifunction plug with the attachment.
High Flow feature is engaged by pressing the On/Off switch mounted on left hand A post. Allows the operator to
enable/disable the function depending on the attachment requirements.
The Enhanced High Flow Auxiliary Control can be controlled only if all of the following conditions are met
2. Operator Restraint engaged
4. Engine is running
6. Multifunction high pressure interlock plug connected ("HP" mode only)
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Control valve - Overview Auxiliary Override Control

The machine can be used to operate auxiliary attachments which require the operator to exit the cab. The operator can
engage the auxiliary hydraulics such that they will remain on full flow so that the attachment will be provide hydraulic
lines for P and T. The attachment will most likely contain its own control valve.
Operator must press the Auxiliary Hydraulic Interlock Override switch on the instrument cluster. This will override the
seat switch and restraint bar. A lamp will flash indicating that the override is activated and the operator must leave
the seat within 30 seconds otherwise the feature will deactivate.
When the button is pressed (press and release within 10 sec) the following conditions will be set
1. Park brake engaged
2. Loader arm and bucket disabled
3. Engage port locks
4. Loader Pilot interlock unlocked
The operator can put the thumbwheel into the forward detented position, before or after Aux Override is pressed. Any
reverse flow command will be ignored.
If the operator does not leave the seat within 30 seconds, the SSL will go into hydraulics disable state and the operator
must re-enabled hydraulics to regain control of the machine.
When the operator re-enters the SSL AND the seat switch THEN lap bar are down, the machine will enter hydraulics
disable state. Otherwise Aux override will remain active. He will have to meet the Hydraulics Enable Function Enable
Conditions to re-enable hydraulics.
At any time the Aux override or the hydraulics enable button can be pressed to deactivate the feature.
Auxiliary Override is functional with the standard flow and high flow. Not allowed with enhanced high flow option.
The Auxiliary Override Feature can be activated only if all of the following conditions are met
2. Operator Restraint is engaged
Valve Logic Enabled Disabled

Port Lock Locked not controlled
Park Brake Activated not controlled
Ground Drive Interlock Locked not controlled
Loader Interlock Unlocked not controlled
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Control valve - Testing 2nd Aux Extend Solenoid

Disconnect connector X-AUX_EXT Normal resistance. 0 Ω, or greater than 1 K Ω
from the 2ND AUX EXTEND SOLENOID Action Action
Check Go to test 2 The 2ND AUX EXTEND SOLENOID has
for resistance between 2ND AUX failed. Replace the solenoid.
EXTEND SOLENOID pins 1 and 2 (EH)
pins A and B (Mech).
X-AUX_EXT pin 2 (EH) pin B (Mech)
and ground.
ing (A.30.A) to Repair or replace broken wire
Check See the following for further testing 554 (White) (EH) 554/454 (White)
wire condition between X-AUX_EXT • Control valve - Testing (Mech).
pin 1 (EH) pin A (Mech) and connec- 2nd Aux Hyd Switch
tor X-408 (EH) X-407 (Mech) pin 2. (G.90.C)
• Control valve - Test-
ing High Flow Switch
(G.90.C)
• Electrical control - Test-
ing Hydraulic Coupler
Switch and Solenoid
(J.80.C)
• OPTION RELAY in ELEC-
TRICAL POWER SYS-
TEM - Component iden-
tification Relay Index
(A.30.A)
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Control valve - Testing 2nd Aux Retract Solenoid

Disconnect connector X-AUX_RET Normal resistance. 0 Ω, or greater than 1 K Ω
from the 2ND AUX RETRACT Action Action
SOLENOID Go to test 2 The 2ND AUX RETRACT SOLENOID
Check has failed. Replace the solenoid.
for resistance between 2ND AUX
RETRACT SOLENOID pins 1 and 2
(EH) pins A and B (Mech).
X-AUX_RET pin 2 (EH) pin B (Mech)
and ground.
ing (A.30.A) to Repair or replace broken wire 552
Check See the following for further testing (White).
wire condition between X-AUX_RET • Control valve - Testing
pin 1 (EH) pin A (Mech) and connec- 2nd Aux Hyd Switch
tor X-408 (EH) X-407 (Mech) pin 3. (G.90.C)
(G.90.C)
Switch and Solenoid
(J.80.C)
• OPTION RELAY in ELEC-
TRICAL POWER SYS-
TEM - Component iden-
tification Relay Index
(A.30.A)
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Control valve - Testing 2nd Aux Hyd Switch

Remove HIGH FLOW / COUPLER 0Ω Fuse is blown.
FUSE from the ACCESSORY POWER Action Action
DISTRIBUTION. Go to test 2 Replace the fuse with same type and
Check amp rating.
for continuity across HIGH FLOW /
COUPLER FUSE.
on, Action Action
for voltage from ACCESSORY POWER tion system upstream of HIGH FLOW
DISTRIBUTION pin E11 and ground. / COUPLER FUSE.
Disconnect connector X-408 (EH) For each resistance check, 0 Ω in 0 Ω in multiple positions or infinite
X-407 (Mech). one position, infinite resistance in all resistance in all positions.
Check others. Action
Using a multi-meter, check for resis- Action The 2ND AUX HYD SWITCH has failed.
tance between LEFT HAND CONTROL Go to test 4 Replace the LEFT HAND CONTROL
HANDLE HANDLE.
pins 1 and 2
pins 1 and 3
while cycling the 2ND AUX HYD
SWITCH S-033.
Check See the following for further testing wire 558/744 (Orange) or adjacent
wire condition between ACCESSORY • Control valve - Testing wiring.
POWER DISTRIBUTION pin E12 and 2nd Aux Extend Sole-
connector X-408 pin 1. noid (G.90.C)
(G.90.C)
Switch and Solenoid
(J.80.C)
84423866 25/07/2011
G.90.C / 7
Control valve - Testing High Flow Switch


Remove HIGH FLOW / COUPLER 0Ω Fuse is blown.
FUSE from the ACCESSORY POWER Action Action
DISTRIBUTION. Go to test 2 Replace the fuse with same type and
Check amp rating.
for continuity across HIGH FLOW /
COUPLER FUSE.
on, Action Action
for voltage from ACCESSORY POWER tion system upstream of HIGH FLOW
DISTRIBUTION pin E11 and ground. / COUPLER FUSE.
the HIGH FLOW SWITCH. Reconnect Action move jumper.
all other connectors. Connect a The HIGH FLOW SWITCH has failed. Action
jumper between connector X-303 Replace the switch. Go to test 4
pins B and C.
Check
Check See the following for further testing wire 753/744 (Orange) or adjacent
wire condition between ACCESSORY • Control valve - Testing wiring.
POWER DISTRIBUTION pin E12 and 2nd Aux Hyd Switch
connector X-303 pin B. (G.90.C)
• Hydraulic line - Testing
Std High Flow Solenoid
(H.20.B)
84423866 25/07/2011
G.90.C / 8
Index

Control valve - Overview Auxiliary Override Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control valve - Overview High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control valve - Testing 2nd Aux Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control valve - Testing 2nd Aux Hyd Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control valve - Testing 2nd Aux Retract Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control valve - Testing High Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
84423866 25/07/2011
G.90.C / 9
PRINTED IN U.S.A.
84423866 25/07/2011
EN

Case Skid Steer Loader Service Manual Pgs 1192-1566

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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

4. Install the inner gear (1) with the chamfered side of

5. Install the outer gear (1) with chamfered side facing

6. Replace the o-ring (1) on charge pump housing.

7. Install charge pump housing (1) using reference

8. Install the flange (1).

9. Install and tighten the mounting flange bolts (1).

Charge pump - Remove

2. Remove the flange (1).

3. Apply reference mark (1) on pump housing and

4. Remove the charge pump housing (1).

5. Remove o-ring (1) from charge pump housing.

6. Remove the outer gear (1).

7. Remove the inner gear (1).

8. Remove the coupler (1).

9. Apply reference mark (1) on wear plate.

10. Remove the wear plate (1).

Charge pump - Inspect

Charge Pump Inspection

Motor - Remove Drive motor

1. The loader must be raised and supported with the

2. Remove the wheel hardware (1) and pull wheels from

3. Place suitable container under chain tank drain plug

4. Remove the six bolts (2) securing the drive chain

5. Remove front and rear axle housing hardware (4).

6. Remove front and rear axle housings

7. Push the sprocket forward and remove chains from

9. Disconnect shift tube (on 2 speed equipped models).

Use acceptable lifting equipment and remove the

Motor - Install Drive motor

1. Apply a bead of LOCTITE® 598 ULTRA BLACK adhe-

2. Apply a 3 mm (0.1 in) bead around the outside of

4. Install new mounting hardware (1) and torque to 122

5. Connect the hydraulic hoses (1) to hydrostatic drive

7. Connect chains to drive sprocket

8. Install front (1) and rear axle housings.

9. Install front and rear axle housing hardware (1) and

11. Install chain inspection cover (1) and mounting hard-

13. Install wheels (1) and wheel hardware (2)

14. Remove supports and lower skid steer

16. Install bucket refer to Bucket - Install (J.20.B)

Motor - Remove track drive motor

1. Loosen and remove the upper and lower mounting

2. Apply vacuum to the reservoir. Refer to Reservoir -

6. Make a reference mark on the drive motor (2) and the

Motor - Install track drive motor

2. Install the mounting bolts (1) into the main frame.

3. Tighten the mounting bolts to an initial torque of 67

4. Remove the plastic plugs from the motor ports (1).

5. Apply vacuum to the reservoir. Refer to Reservoir -

Motor - Assemble Single speed drive motor

1. If removed, install a new inner bearing cup in the front

2. If removed, install a new outer bearing cup in the front

3. Lubricate a new shaft seal with clean hydraulic oil.

9. Install the split ring onto the shaft.

11. Remove the split ring. Install a shim with a thickness

12. Install the split ring on the shaft.

13. Release the preload from the bearing and remove

14. Check the shaft to make sure it rotates in the front

17. Install the cam on the cylinder block. Be sure to align

19. Lubricate the seals on the distributor with clean hy-

21. Use the marks made during disassembly and install

22. Apply LOCTITE® 243 to the threads and install the

23. Tighten the socket head cap screws alternately from